Heavy Duty Sliding Gate Operator User`s Manual
Contents
1. Heavy Duty Sliding Gate Operator User s Manual Model COS 1B COS 3B Table of Contents Important safety 3 Main feature Screan uestis 3 Technical 4 Operator main structure and its 4 Installation guidelines 2 tae pce riui e Pe ob es ur Pa Dita 5 cutee 9 Maintenance Mem 12 Troubleshooting MN LS 12 Important safety information Carefully read and follow all safety precaution and warnings before attempting to install and use this operator incorrect installation can lead to severe injury death When opening or closing the gate do not attempt to walk or drive through the gate Be careful when in close proximity to moving parts especially the rack and pinion gear where hands or fingers could be pinched Children should not be allowed to play near or operate automatic gates The following two auto reverse functions must be checked during installation to ensure that the gates can auto reverse in the event of obstruction This auto reverse function should be regularly inspected and adjusted if necessary o When photo beam is use2. make sure the wires are plugged into P3 N O mode correctly Replace the thermal breaker device if damaged Remote control not working The indicator light of remote control does not light up battery weaken check the batteries on your remote control and replace it if weaken Remote control not able to synchronize with the receiver Send it to StarGuard for further inspection replace with a new remote control if the device cannot be repaired Broken Receiver Replace the receiver if the hardware cannot be repaired The remote control operating distance is too short Signals are probably shielded by a metal related substance such as the operator metal cover or even the metal gate Move the receiver away from the metal related substance or fix a better antenna on the wall vertically which replaced the old antenna Bad position on the receiver A good practice is to fix it proximity to the control panel box or inside the panel box Best is to fix it on the concrete wall with adequate open space area as shown in figure 3 0 above
3. re calibrate the limit switch plate position to allow the gate open closed fully again The gate stop in mid way or reverse itself before reaching the full limit position Gate is obstructed photo beam sensed the obstruction Remove the obstruction Annoying noise occurred during the opening closing of the gate Noise should be coming from the moving things such as the wheel the rack and the motor pinion gear One of the wheel s bearing might be rotten or over burden due to imbalance floor level Consequently lead to the misalignment of racks which would burden the motor pinion gear The worst case happens when the motor is damaged as the consequences of noise ignorance Regularly check the condition of the gate s wheel Try release the motor clutch and manually move the gate and check the gate should be moving freely If not replace the worn out wheels The motor is running but the gate not The motor clutched is loosen is being released by someone Tighten the motor clutch by turning it clock wise with the used of the L type hex wrench Why is the motor overheated The thermal overload breaker might not be function properly or the wires are loosen at the input jumper P3 Which causing thermal breaker will never cut off the motor when overcurrent incident occurs Check the current setting of the thermal overload breaker it should be set below the motor current spec Also check wire connection
4. ION Oil Bath REMOTE CONTROL REMOTE CONTROL Optional PACKAGING DIMENTIONS 323W x 369L x 538H COATING Weather Resistant Powder Finish one phase is absent will stop the motor to operate Operator main structure and its dimension The motor housing dimension is shown in Figure 1 0 below Both the single or 3 phase motor comes with the same housing and dimension The gearbox as well as the motor internal parts are well lubricated and soak with cooling oil which covers the stator the rotator of the motor the worm gear and the worm This will helps to cool down the motor operating temperature especially during heavy usage Figure 1 0 Motor housing dimension Installation guidelines The gear rack and the gate operator is the main mechanism that moves the sliding gate The gear racks must be welded onto the sliding gate and must be solid The gate operator plays a big role to drive the gear racks and thus moving the gate along The control panel is another important part that controls the opening and closing of the gate It is recommended to install the control panel on the wall or inside the security guard house If flood is a concern try installing the control panel box above the flood level Also photo beam provides extra safety feature and must be tested and installed properly Another important part is the wiring must be enclosed with the PVC conduit and they should be hiding in the ground or install o
5. PPED THIS CAN BLACK NEUTRAL BE CONNECTED TO LAMP EARTH 8 BLACK us m 8 4 LIMIT SWITCH 3 NC ONLY 4 1 Re H 9 1 N 3 PHASE I e lt 2 V MOTOR THERMAL OVERLOAD E uin morem mi 1 OTHER FUNCTIONS 1 LIMIT SWITCHES MUST NC TYPE TRIP PIN PRESS DOWN RESET 2 FOR TESTING USING SINGLE PHASE MAINS SET Pl IPH WHEN IN USE IT MUST BE SET TO FOR MOTOR PROTECTION WHEN ANY PHASE POWER NOT PRESENTS THE MOTOR DRIVE WILL STOP 3 FOR SAFETY PHOTOBEAM DEVICE MUST BE CONNECTED TO PHOTOBEAM TERMINAL TO PREVENT INJURY OR DAMAGES WHEN BEAM IS CUT DURING GATE CLOSING THE MOTOR WILL BE REVERSED TO OPEN DURING GATE OPENNING BLOCKING OF THE BEAM HAS NO EFFECT AND GATE WILL REMAIN OPENNING 4 THERMAL OVERLOAD CTH 22 MUST BE SET AS SHOWN ABOVE CURRENT IS SET TO ABOUT AND TRIP MODE SET TO WHEN OVERLOAD OCCURS THE GATE WILL BE AUTO REVERSED FOR SHORT DISTANCE AND STOP REMOVE OBSTRUCTION AND RESET BY PRESSING THE TRIP PIN DOWN WARNING TO PREVENT RISK OF INJURY OR DEATH NO ONE SHOULD CROSS THE PATH OF THE MOVING GATE OR STAND NEARBY Maintenance Regularly check any noise came from the wheels or the gear racks Alignment adjustment and calibration needed when abnormal noise is found Regularly grease the wheels and axles to ensure the gate moves smoothly Ensure the ope
6. ar rack installation guides Motor Clutch Release function In case of power failure you can release the motor clutch by turning it counter clock wise with the using of the provided L Type hex wrench You would able to move the gate manually once the clutch is released Figure 5 0 below shows the motor release point Figure 5 0 motor release point Limit switch plate installation Install the limit switch plate as shown in Figure 6 0 onto the gear rack The limit switch plate is used to trigger the operator s limit switches After the limit switch plate is installed power up the control panel but release the gear clutch and push the sliding gate manually to pre determine the gate position When the switch is triggered the controller will indicate the gate opening closing position Hook on the limit switch plate onto the rack as shown in the picture and then tighten it with the provided screws and nuts Depends on the closing gate direction assume the gate fully closing to the left side and the red LED should light up which indicate a closed position is detected If the door is not closed perfectly or the red LED is not light up calibrate and adjust the limit switch plate to the proper position manually until it is perfectly tuned and the red LED light up There are two LEDs indicators one is for closing door red and the other one is for opening door green If a wrong LED is light up then you need t
7. d the gate will auto reverse fully when obstruction occurs o The gate will auto reverse by 2ft and motor drive is cut off whenever the gate is crashed jammed for the duration of 15secs to prevent overheating At this point it is important to call the qualified contractor to release the safety crutch breaker and to re calibrate the gate before letting the motor running as normal again Another important safety feature to prevent overheating when using a 3phase motor the controller will cease operate the motor operation if any single phase power source is missing The motor controller is protected by anti thunder fuse The fuse should blow off when thunder strike and must be replaced with a new one to operate as normal again It must be reminded that the motor is supplied by 415Vac for 3phase system and 240Vac for a single phase system The operator should be switched off before repairing it Be careful not to touch the high watt resistors as they may get very hot during heavy usage The gate operator should be installed by a qualified technician otherwise serious personal Injury death or property damage may occur Install the gate operator on the inside of the property DO NOT install it on the outside of the property where the public has access to it Do not allow the control panel to be placed at the reachable place to prevent any stranger to access them by reaching through the gate In the event of power failure an emergency release key allows yo
8. d safety feature Prevent motor overheating cut off motor drive if a motor is jammed for the duration of 15secs Safety photo beam function auto reverse amp auto Stop during obstruction Motor operating in one speed only courtesy with soft start soft stop feature Pillar lamp lighting AC fan usage programmed with 3 minutes operations only Limit switch NO NC settings jumper selectable Motor clutch release key Function descriptions photo beam input CON1 12Vdc output CON2 Limit switches In btw CON1 amp CON2 3Phase light bulbs L1 L2 L3 Push buttons CON3 Open push button Close push button Stop push button Photo beam device must be connected to photo beam terminal CONI mode as this feature can prevent unnecessary injury or damage When the photo beam detected any obstruction during gate closing the motor will be reversed to open On the other hand during the gate opening blocking of the photo beam has no effect and gate will remain opening Leave it disconnected if not used Auxiliary DC output voltage can be used for photo beam supply etc It must be N C type These limit switches are programmed for N C mode Depends on the gate opening closing direction assume the gate is open to the right and close tp the left Connect the left limit switch to the open terminal point and connect the right limit switch to the close terminal point L1 blue L2 RED and L3 Yellow indicate the p
9. d to add some height with the washer if any one side is still not balance Use the balancer ruler for measurement until the alignment is matching properly The diagram below shows the instruction C Figure 3 0 Operator and its base plate installation guides Installation of Rack and pinion A standard metal rack should come with size of 100cm per pieces length Thus if you have a 400cm gate in length you need 4 pieces of racks Fix the three gear rack s bolts provided in the same package with rack onto the racks Lay the first piece of rack on the gear and weld the first bolt on the gate One tip is to always lay the centre of the rack onto the gear to get hold on the centre point and you can allow the edge of the rack align to it with the use of balancer Then it is recommended to weld the two pieces of bolts at both edges each and follow by the centre one as shown in figure 4 0 below Move the gate manually checking if the rack is resting on the pinion gear Repeat the above steps for the rest of the racks while moving the gate manually When the rack has been installed thoroughly moving the gate by hand to ensure it meshes correctly with the pinion gear e In order to let the motor output pinion gear meshes well with the gear rack it is a good practice to ensure the gap between them is 0 5mm throughout the racks to maintain a stress free operation Figure 4 0 Ge
10. n the floor layer The figure 2 0 below shows a big picture of how a typical automatic gate system is installed Gate Operator ae Gear rack Use Underground PVC conduit via the concrete layer Control panel box Figure 2 0 A complete sliding gate system PVC Conduit In order to protect the wires conduit must be pre set into the concrete before it gets harden Make sure no sharp or rough elements obstruct the wires along the conduit path to prevent any unnecessary wire damage in the future The concrete foundation and the mounting of operator base plate The base unit of the gate operator requires a concrete pad in order to maintain proper stability The recommended concrete pad should be approximately 400W x 400L with 200mm deep enough to produce a solid binding with the underground As shown in the figure 3 0 below you can make use of the nuts anchor bolts or J type anchor bolts to be permanently set into the concrete before it is harden Next you can place the base plate onto the concrete surface layer while ensuring the cables is being pulled out from the underground conduit through the cable via hole Leave the concrete dry itself completely before mounting the gate operator onto the base plate concrete Then you can mount the gate operator onto the base plate and use the nuts and washers to tighten it It is also important to verify the alignment of the operator should be parallel to the floor It is recommende
11. o swap the motor mains wire between the Red and the yellow wire refer to connection diagram at CONx Repeat the manual calibration mentioned above until the red LED as well as the gate closing function is working perfectly Finally apply the same test procedure above to test the gate opening Calibrate the limit switch plate until the green LED is tuned perfectly to the gate maximum opening position The gear rack clipping mechanism PE roller is located above the operator output gear PE roller usage is to prevent a robust factory gate Example the h gate to lift up which also helps to reduce the crashing noise generated by the output gear that meshes with the out of aligned gear rack SECTION A A Figure 6 0 Limit switch plate installation guides Electrical COS 3R Sliding Gate Controller 3phase AC motor Operating instructions COS 3R control panel is used in 3 phase power applications and it is designed with phase missing detection to prevent motor by overheated Although it can also be used on a single phase motor application it is most suited to be used for a 3 phase application Two external contactors are needed for 3 phase application The panel also incorporated with additional safety feature such as a high amp sensor cut off device whereby if a high amp situation is sensed the 3 phase motor will be stopped e It utilizes 3 push buttons for open close and stop control e Remote control feature e Motor overheate
12. ommon is plugged in CON correctly If all above is not the cause then it should be the on board components faulty Send it to StarGuard for further inspection the PCB board is either repairable or need to be replaced The gate will not open or close Wires loosen at the connector output terminal block CON3 Check wire connection make sure all open close stop wires are plugged in correctly Wire loosens at the limit switch terminal block CON Check wire connection make sure all open close and common is plugged in CON correctly The power switch of the control panel might be OFF One quick check to see whether the power is ON is to look at whether the on board LEDs have red green lights ON If the LEDs not working try switch ON the on board power switch If all above is not the cause then it should be the on board components faulty Send it to StarGuard for further inspection the PCB board is either repairable or need to be replaced The Soft start is not function as usual anymore wire loosen at the output terminal block CON8 Check wire connection make sure both L amp wires are plugged CONS correctly The high watt resistor are broken Replace the high watt resistors The gate couldn t open close fully as usual anymore Either the limit switch plate or the limit switch itself is out of tune loosen Tighten the limit switch and
13. rator is well earthed and correctly terminated Keep operator dry and clean at all times Sand particles can damage the wheel bearings Keep the gate area clean from sand build up Ensure the operator is covered properly Ensure good ventilation inside the operator cover A good practice is to install extra fan in it Keep any crawling insects ants cockroach etc away from laying eggs within the operator cover A good practice is to apply bugs killer powder on any holes or entry points If flood incident happens power off the operator and do not power on until the flood receded and ensure the control panel is dry If thunder strikes your operator the anti thunder fuse of the control panel will blow off and the MCB inside your house might trip off Contact the contractor to replace the fuse e Regularly change the motor oil Depends on how heavy the motor operates plan to change the motor oil one or twice times per year Troubleshoot TROUBLE POSSIBLE CAUSE SOLUTIONS Motor only runs in one direction Wire loosen at one of the output terminal block 5 Check wire connection make sure all Yellow Red and Neutral wires are plugged in CONS correctly wire loosen at one of the contactor input terminal Check the contactors input wire connection make sure it is plugged in A1 correctly Wire loosens at one of the limit switch terminal block CON Check wire connection make sure all open close and c
14. resent absent of the 3 phase power sources Connected to push button or wireless receiver s output N O mode trigger the gate opening closing stopping For open only control N O mode The button cannot be triggered by other buttons loop detector For close only control N O mode The button cannot be triggered by other buttons or loop detector For stop only control N O mode The button cannot be triggered by other buttons of AC AC pillar Lamp output CON4 Motor contactors output CON5 CON6 24Vac power supply CON7 Soft start Soft stop switch CON8 1 Phase 3 Phase selection P1 Overload sensing input P3 Anti thunder fuse C16 C17 Input power switch SW1 loop detector AC power point for AC Fan AC pillar lamp usage It gives 240V output whenever motor is ON and with a 3 minutes delay OFF after motor has stopped Connect each Red Yellow wires to terminal Al of contactor A and contactor respectively and connect the Neutral wire to terminal 32 of both contactors N C mode Follow the wiring diagram in figure 7 0 24V Auxiliary AC power supply for vehicle loop detector Connect the L amp N wires to the high watts resistors provided to enable the soft start soft stop effect Leave it opens if not used It is advice to use single phase mains for testing the motor controller you can always set P jumper to 1PH for this purpose Howe
15. u to operate the gate manually Main features One speed only courtesy with a soft start feature to cut down the high torque motor start up Anti jam mechanism The operator is installed with a PE roller to prevent the gear rack the gate by lifting up This will prevent damaged to the teeth of the gear rack or the output gear and reduce the friction noises Safety Photo beam function Infrared terminal NC for 3 phase system and NO for single phase system The operator will stop and reverse if it was obstructed on closing and stop when it was obstructed on opening Manual clutch release design for emergency purposes Prevent motor overheating Cut off motor drive after a continuous false operation 15secs Optional 240V output terminal for used with AC lamp usage it is programmed with 3 minutes delay to cut off the output after motor has stopped Heavy duty Gate drive up to 4000kg gate Technical parameters Specification MODEL COS 1B COS 3B POWER SUPPLY 240v AC Single Phase 415v AC 3 Phase MOTOR POWER 2 0 HP 2 5 HP MOTOR SPEED 3000rpm 3000rpm LINEAR GATE SPEED 1ft s 3m 10s 1ft s 3 105 3 phase protection NA 3 phase monitoring LIMIT SWITCH Industrial Switch jumper settings NO NC MOTOR DRIVER 6 Pin Lock OVERLOAD SENSING Adjustable High Amp Cut off MAX GATE WEIGHT MAX GATE WEIGHT 4000kg IR SAFETY BEAM Optional IR SAFETY BEAM Optional Motor GEAR TYPE LUBRICAT
16. ver it must be set the jumper back to 3PH for motor normal operation as well as motor phase missing protection This is the input for the thermal overload breaker N O mode It is advice to set the current overload tripping to 3A or below the motor current spec and the trip mode should set it to H When current is overloaded the gate will be auto reversed for 2 feet and stop Remove obstruction prior to reset the device by pressing the trip pin down in order to allow the operator to work as usual again These two fuses are used to protect the components and circuitry of the control panel The fuses break when the thunder strikes it The fuses must be replaced to allow the control panel works as usual again Main power switch for the control panel It is supplied by a single phase power blue mains 3 PHASE CONNECTION DIAGRAM GLIKON MODEL COS 3R a eL ELE PB COS 3R GLIKON 0 E x 38z 22 aoe la 4 CO se E zz TF DANGER Sb TS eon S 3 t7 COS 3R PUSH BUTTON 0 Bu amp 5 3 PHASE 5 Tu ei AC MOTOR z CONTROLLER OPEN CLOSE STOP OR CONNECT TO WIRELESS RECEIVERS RELAY HIGH VOLTAGE d N N 6 813 YL2 DB LLN 3 IN COMING SUPPLY GIVES 230VAC OUTPUT WHENEVER MOTOR IS ON GREEN AND WITH A 3 MINUTES HAS STO
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