User Manual
Contents
1. Salvo User Manual www castell com Contents N Castell Section 1 Couplings DAO S US ee 4 Salvo al laa Hand COOK ee a ee 6 AVO TDS EE OE EE N EE 8 SANO OMD V 10 SANO see 12 Section 2 Powered Doors Salvo SCP Salvo Control Panel 15 Salvo Safety Proximity Sensor for Sectional Doors anne 24 Salvo Safety Limit Switch for Roller Shutter 26 SAVO HEAR SIOEN causa E E TERT 28 Salvo Power Supply amp Beacon SPSB aassassa eee nra annu saamaa ana aa c cc nc 29 Section 3 Manual Doors SMDL AIS SMDB SDMC Manual Door 2 32 SMDL AI SMDB SDMC Manual Door 35 SADL SMDB SDMC Automatic Door Lock nra nanny na ire c iani ia cns 38 Section 4 Loading Bay Barriers 42 Section 5 Peripherals SAVO dels EE ER 45 SAVO ENECO SUS E 46 siecle 47 Section 6 Safety Critical Information Safety Critical Ier ea 49 U Salvo 2013 E Issue 1 a p Castell Section 1 Couplings U Salvo 2013 E Issue 1 Salvo Susie User Guide Castell The Salvo Susie lock is a key o2. U Salvo 2013 E Issue 1 Salvo Power Supply amp Beacon SPSB User Guide Castell Specifications Material RAL 7035 Grey Polycarbonate IEC 60695 1 2 Dimensions 205mm W 220mm H 140mm D Mounting Details 94mm W 90mm H M5 Operating Temperature 25 C to 115 C Shock Resistance 20 Joules IK10 Ingress Protection IP65 Beacon Material White Polycarbonate Dimensions 85mm x 81mm H Voltage 11 35VDC Current 50mA Operating Temperature 20 C to 70 C Ingress Protection IP65 Cable Entry Size M20 x 2 Precautions WARNING Disconnect Electrical Supply Before Opening Unit Means of Isolation should be located adjacent to the device and should be clearly marked and easily accessible Installation of this eguipment other than for its specified use may impair the operation and safety integrity of this product Installation should be carried out by a competent and qualified person who has read and understood these instructions Any electrical installation must comply with standard BS7671 Requirements for Electrical Installations commonly referred to as the IEE Wiring Regulations or any particular regulations and practices specified by the local electricity supply company at the time of installation Installation must be carried out by competent personnel gualified to IEE 17th Edition or any eguivalent regulations in force at th
3. 6A 1 5mm Beacon N O contacts to control beacon 24VDC 6A 1 5mm Aux 1 Change over contacts to control other peripherals 6A 1 5mm 21 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Castell iagram D iring W zr 12 Et Al FI at si 1 EN et Li or 6 Di aL PEM ODL TER LL VIE Loe Di TLL OI du Fri CI Tg m 1 T kale Hu 5 gl TE DIARI LIG LEI ER Te k MY oa LH YHDY SE We E E UFMDMHSLOIGCS TiB H CISY5e tum nas TH EEE N 1 u E ay jm si pE he es STI RH me Oie Je Dd UT MY TTA Qao ea B 4000 a OTTAA KOS O A bele TE HLA RE mi T eH Du N j i i vr ie 11814 i 51 T 0 3 N I E E EE ia g ime 4 ak et Bru rk E 8 71 i In LUE EF 2 EHH La i Wit N Dem A Lie D ELE Li 1 re Ge BANE 353313 AEN TOS OLO YLKOO Ad KAILMOI HIT ATI gone IMEEM SMS LL N CN Lr 7 i mj 1 L Had 1085 E verl mal 70YS OITTWwWWI INWDO IO
4. European Community Registered Design 000321161 0001 Specifications 268mm h x 140mm w x 50mm d IP680 IEC 60529 EN 60 529 Components fully potted 89 336 EEC CENELEC EN EMC immunity Light Industrial 50082 1 89 336 EEC CENELEC EN Emissions Not applicable EMC benign 50081 73 23 EEC Not applicable Extra low voltage 2002 96 EC Not applicable Voluntary good practice Precautions Installation should be carried out by a qualified electrician Please retain this document A seperate control system is required Do not wash with pressure jet Wiring ______ Refer to SCP wiring schematic diagram on page 24 Order Information Y Information Please advise correct part number when ordering mandatory information Part Number 006538 47 of 51 U Salvo 2013 E Issue 1 a p Castell Section 6 Safety Critical Information Safety Critical Information MT User Guide Castell The system must be designed to meet the reduirements of the Health and Safety Executive and all current legislation Attention is also drawn to the relevant codes of practice 1 General Instructions General guidance for the installation of all Castell products a Fixing of locks should be secure to prevent tampering or unauthorised removal It is recommended that tamper resistant screws and nuts are used or that they are sealed after tightening b Fixing scre
5. SGL is on the connecter can the key be rotated anti clockwise and removed Removal of the SGL lock is the reverse of the above procedure When operation is complete please return to its normal storage location or issuer Precautions AN Salvo SGL is heavy During the course of normal use it may become dirty greasy and slippery If you drop it on your foot you may sustain serious injury Handle with care Wear appropriate personal protective clothing Maintenance A lubrication point is provided adjacent to the key entry aperture and trigger mechanism The recommended lubricant is Armna G4789 or equivalent The recommended lubrication interval is 6 12 months as required Keeping the Salvo SGL clean will ensu re long and reliable service 6 of 51 U Salvo 2013 E Issue 1 Salvo SGL lt User Guide Castell Technical Data Data Working Temperature Min 25 C ice free Max 55 C Weight 2 0 kg Housing Material Light alloy Stainless steel Lock Material Stainless Steel Conforms with Standards EU ISO 1728 1980 Palm Type Coupling USA SAE J318 Glad Hand Connector EER Dimensions in mm 252 6 SALVO SGL 106 2 Order Information Y Information Please advise part number symbol and dog tag when ordering mandatory information Part Number Symbol Dog Tag 7 of 51 U Salvo 2013 E Issue 1 Salvo Type 1 User Guide The Salvo
6. Type 1 lock is a key operated mechanical locking device designed to fit on to all Australian Type 1 emergency brake line connectors Its purpose is to prevent re connection of the air brake hose thereby immobilising the trailer When fitted the Salvo Type 1 can only be removed with the permit key Salvo Type 1 Operation Rotate the key anti clockwise Disconnect the air line from the 2 Slide the Type1 lock over the 8 and remove the key Trailer Type1 air line connector exposed air line connector To remove the Type1 lock from the trailer insert and rotate the key clock wise Pull the lock off the Type1 air line connector When the operation is complete the unit should be returned to either the storage enclosure or to the issuer Precautions Salvo Type 1 is heavy During the course of normal use it may become dirty greasy and slippery If you drop it on your foot you may sustain serious injury Handle with care Wear appropriate personal protective clothing Maintenance Apply lubrication to the inner plungers The recommended lubricant is Armna G4789 or equivalent The recommended lubrication interval is 6 12 months as reguired Keeping the Type 1 lock clean will ensure long and reliable service 8 of 51 U Salvo 2013 E Issue 1 Salvo Type 1 lt 7 User Guide Castell Technical Data Data Working Temperature Min 25 C ice free Max 55 C Weight 0 5 kg Housin
7. bolt and open the door A Installation should be carried out by a competent and qualified person who has read and understood these instructions 32 of 51 U Salvo 2013 E Issue 1 SMDL AIS SMDB SDMC User Guide Castell Step 01 First ensure the door is fully closed Determine the position of the locking bolt to ensure that either parts do not clash with existing door fixings Suggested height between 1 5m and 2m from floor level Step 04 Determine the position of the lock body ensuring that the bolt entry hole aligns with the already secured locking bolt Step 07 Fix the lock and bracket in place with the screws provided Step 02 Mark the position of the bolt clearance hole on the inside of the door running guide Check that the lock and bolt do not clash with bay controls Step 05 Use the hole in the door running guide to align the lock Step 03 Drill the clearence hole in the running guide using a25mm tank cutter la Step 06 Mark and drill the positions of the mounting bracket holes Step 08 With the door fully closed engage the bolt into the lock body through the previously drilled hole in the door running guide Mark the positions of the fixing holes in the door 33 of 51 Step 09 Drill positions Check that the bolt rotates freely then drill remaining holes and pop rivet in place and pop rivet two U Salvo 2013 E Issue 1 SMDL A
8. enclosure can be mounted at a location most suitable to site operations For example on the warehouse exterior wall adjacent to the loading bay door or on a pedestal between each loading bay Salvo Enclosure Specifications N Surface Finish Stainless Steel 200mm w x 300mm 8 x 131mm d A To maintain high visibility periodically clean the enclosure From time to time check that all fixing screws remain tight Installation N Hold the enclosure against the wall to Drill the holes using an 6mm Dia drill If required insert wall fixing plugs mark the position of the fixing holes bit into the holes Order Information Information Please advise correct part number when ordering mandatory information Part Number 006482 46 of 51 U Salvo 2013 E Issue 1 Salvo Traffic Light LA User Guide Castell Salvo Traffic Lights are a means of communicating the status of the loading bay door The lights can be mounted inside outside or on both sides of the loading bay When mounted inside a red light indicates that the bay door cannot be opened A green light indicates that the door can be opened and loading or unloading commenced When mounted outside a red light indicates that the door is open the the vehicle must not drive away A green light indicates that the door is closed and the vehicle can depart Salvo Traffic Light MRG Twin Series Copyright October 2004 EC
9. the Salvo range Salvo Chock relies on sehe Castell s time proven trapped key technology Before Use Use When the chock is received it will 2 The Lock Support Arm must be 3 To complete the assembly the cover be configured for transit To make raised to the vertical position and should be fitted with the fixings the Chock ready for use the Lock the Securing Plates A fitted to provided in 6 positions The Chock Support Arm must be secured in prevent any movement of the arm is then ready for use the operational position The Retention Sleeve B should be slid into position around the joint in the spigot Operation X The Salvo Chock is designed as a part of a safety system to prevent accidental drive aways The Salvo Chock ensures the vehicle is locked in position before the loading bay door can be opened Salvo Chock assembly is fitted Press the pedal until the two chocks 3 Remove the untrapped key The loosely around drivers side front contact the tyre Continue until lock chock is now secured in place wheel Rotate the catch anti springs into place clockwise to the up position as shown Precautions N Salvo Chock is designed to fit any size or type of rigid vehicle from 3 to 26 tonnes with tyre outside diameter from 27 5 to 42 inches 700 to 1070 mm To prevent the risk of manual handling injury only move the chock around using the mobility handle see photos under Operating Instructions Handle wit
10. the use and storage of such keys This is part of our ISO 9001 procedures and reflects our concern on this issue Castell advise that extreme caution must be exercised when storing or using these products Their use and security must be fully and adequately controlled using a permit to work system Using spare master keys or spare bolts tongues will result in the defeat of the interlock system Conseguently this could lead to serious injury fatality damage to plant machinery or damage to the product e Master keys are almost always unnecessary Keys of the correct symbol should be used e Castell have an express order system for the rapid replacement of broken keys 3 Verification After installation it is essential to carry out a commissioning procedure to ensure that the interlock system performs the reguirements for which it was designed The procedures will vary considerably according to the application 4 Training Suitable training regarding the use and operation of the interlock system should be given to a all relevant people Castell can offer training if required 49 U Salvo 2013 E Issue 1 Safety Critical Information User Guide 5 Safe Installation of Castell Electrical Products Note A SECURE EARTH CONNECTION TO ALL LOCKS IS MANDATORY It is a reguirement of the IEE regulations and other standards that the exposed and accessible metal parts of an electrical assembly are adequately earthed This reguire
11. 2013 E Issue 1 a p Castell Section 5 Peripherals U Salvo 2013 E Issue 1 Salvo Pedestal User Guide The Salvo Pedestal is bolted to the floor of the yard and is used primarily for installations that have a narrow bay pitch and limited wall access and fixing space The pedestal is used in conjunction with Salvo Control Panel and Salvo Enclosure double box Salvo Pedestal Specifications N Powder Coated Carbon Steel Er Precautions A To maintain high visibility periodically clean the pedestal From time to time check that all fixing screws remain tight Maintenance Installation The location of the Pedestal is affected by the position of the existing bay canopy and or curtains Consideration must also be given to the accidental opening of the trailer doors during movement of the trailer Ensure that the trailer doors cannot strike the pedestal Additional steelwork uni strut should be used to connect the pedestal to the bay wall thereby providing greater stability The SCP cable can be tied to the steel work for protection and support Order Information Please advise correct part number when ordering mandatory information Part Number 006480 45 of 51 U Salvo 2013 E Issue 1 Salvo Enclosure lt gt User Guide Castell Salvo Enclosures are used for the safe and dry storage of the Susie and or Palm Glad Hand locks The
12. IS SMDB SDMC gt User Guide Castell Specifications Termination PG11 Approvals VDE UL CSA Mechanical Life 200 000 Cycles Operating Temperature Range 30 C to 80 C 22 F to 176 F Ingress Protection IP65 Maintenance Instructions Instructions Under normal operating conditions very little maintenance is reguired If used in dusty conditions blowing out with compressed air will prevent a build up of sediment in the locks The use of powdered graphite is recommended if necessary Under no circumstances however should the locks be oiled or greased as this causes the locks to clog and malfunction All locking systems should be checked regularly for correct operation security of fixings and condition of keys IC D The function of all keys that should be trapped must be checked under operating conditions as should the ease of removal of released keys In the event of malfunction evident wear or damage parts should be replaced or returned to Castell for repair if appropriate Users of interlock systems have a duty under Section 2 of the Health and Safety at Work etc Act 1974 to ensure that the systems are correctly installed and maintained in a satisfactory condition Order Information Information Please advise correct part number and symbol when ordering mandatory information i Part Number Description Symbol 006508 Hand 1 With Bolt please advise 007044 Hand 1 With Chain
13. Kit please advise 006509 Hand 2 With Bolt 007045 Hand 2 With Chain Kit please advise U Salvo 2013 E Issue 1 SMDL AI SMDB SDMC User Guide The SMDL AI Salvo Manual Door Lock is a mechanical interlock used to positively bolt loading bay doors in the closed position The unit incorporates a locking bolt which Passes through the door running rail and into the lock body Only when the key is inserted and turned can the locking bolt be disengaged allowing the door to be opened SMDL AI SMDB Operation When correctly installed the loading bay door is locked in the down position and the key is removed To operate first insert the key and rotate clock wise The locking bolt can now be rotated on its axis and released The loading bay door can now be opened With the door open the key is retained in the lock The dock leveller can now be operated as normal Insert the key 2 Rotate the key into the lock clockwise Rotate the Release the locking bolt locking bolt and open the door Precautions A Installation should be carried out by a competent and qualified person who has read and understood these instructions 35 of 51 U Salvo 2013 E Issue 1 SMDL AI SMDB SDMC User Guide Castell Step 01 First ensure the door is fully Step 02 Mark the position of the bolt closed Determine the position of the clearance hole on the inside of the door locking bolt to ensure th
14. Panel ensures that the loading bay door cannot be opened before the vehicle airline is disconnected via the Salvo Susie coupling and the key has been transferred from the coupling to the SCP SCP with bay controls 2 Insert key and turn clockwise SCP with bay controls Isolated ready to receive key energised ready to open door and deploy dock leveller Specifications Y Temperature Operating Min 25 C Max 55 C Size 300mm H x 220mm W x 157mm D 172mm with Mounting Mounting Hol Tei ir mse Nr Material Enclosure Mild Steel to BS 1449 HR4 Lock Portion Stainless Steel 304 316 Weight 5 5 kg Cable Entry Size M20 x 2 Switch Approvals IEC947 1 3 IEC947 5 BS EN60947 VDE 0660 UL Listed TBA Ingress Protection IP55 Enclosure Switch Rating Continuous unattended remote Power Supply Required 24VDC Max Power Consumption 20VA 20W Power Frequency 50 60Hz Relay Specification Max switching voltage 240VAC 6A Max switching current 6A 15 U Salvo 2013 E Issue 1 Salvo Control Panel SCP lt lt User Guide Castell Component Inputs Y Inputs e SPSB Salvo Power Supply Beacon e SADL Salvo Automatic Door Lock e SBDS Salvo Bay Door Sensor Component Outputs Outputs Traffic Light Door Control Dock Leveller Control Amber Beacon Precautions D Lockout Tagout A Before installing and using your SCP unit a proper lockout tago
15. TNNOJ iA I TOYS OE CRS EO FORTE DEI Merk us Di ETRE al EEO LOO BET N E DL AL DXMCIT LIK MM CC Bi MIK TED mi bee MI L PL Ke Nubes LEE TUR k 31888 FIS ee UIEN AE ALIRIE Hd EH ETK AAA ME MAN A dI EIT AE CCI LAN Pi hef Ri HOM H d MEE Uu TA b H R NES Uit TA 222 maar una WEA i i apua LOCH UM papi a SULAA ecke poan BO O exe tg as m sss i KKO 01 ORS ae uuibssz JE H OE MM OE ME Y OO O 1 ay Di Bus my OOOOOOOOOOOOODOOO arc MED 7 05 0 0 9 0 9 9 dk 0 0 LN MI u poo B IM JO ia nuc mo jo XX X XXX PERVO NSK PEGI 1000 ds UA Su ul Par de M x M M M M M M X M M X M X Xj 090200 SASSI suc OJEPURJA N i a R TUT Ld f BD HOKKI AA OL LM K MN KOMMA MMX MX HAM P J4 Y amp MM NO 00205 aug JO 10247 pua HIE BUI os 2 T d i M m LN i TE LAXE M MOM OM MOM ME MM N JEN 1900900 SIGG USMS UU Ajages AGE PIE C X X X CX X XN Br
16. ad understood these instructions A Do not use this product as a safety or emergency stop device or in any other application where failure of the product could result in personal injury Handle with Care Beware of Pinch points where the two halves slide telescope together Castell Safety recommends that this switch is wired in series with the door down limit switch see Installation Wiring Diagram IMS08992 Maintenance N From time to time check that all fixing screws remain tight 26 of 51 U Salvo 2013 E Issue 1 Salvo Safety Limit Switch gt User Guide Castell installation N Plan View Side Elevation O The limit switch mounting bracket should be positioned approximately 3m above floor height 2 Align the bracket on the bay door rail and mark the position of the holes 3 Drill the holes secure the bracket place using the fixings provided 4 Position the door bracket to ensure that the switch roller is actuated when the door is fully closed Order Information Y Information Please advise part number when ordering mandatory information Part Number 005606 27 of 51 U Salvo 2013 E Issue 1 Salvo Transformer User Guide Salvo Transformer is used to convert power supplies of 415VAC down to 230VAC It is only required on sites where 230VAC is not available It is supplied as mounted in a polycarbonate enclosure Salv
17. als 1 2 amp 3 SCP 1 Connect to V terminal of PSU 2 Connect to V terminal of PSU 3 Connect to Earth terminal of PSU Connector 8 Terminals 5 amp 6 SCP 5 Connect to terminal of Beacon connector block 6 Connect to terminal of Beacon connector block 18 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Castell Our standard 24V door locks are to be used re SADL Connect to terminal 1 2 amp 4 of Connector 2 and terminal 10 of Connector 8 Connector 2 terminal 1 connect to terminal 2 of SADL Door Lock Connector 2 terminal 2 connect to terminal 14 of SADL Door Lock Connector 2 terminal 3 connect to terminal 4 of SADL Door Lock Connector 8 terminal 4 connect to terminal 3 of SADL Door Lock Connector 8 terminal 10 connect to terminal 1 of SADL Door Lock N ET b i If locating the SCP outside find a suitable route for Typical SCP installation location outside warehouse the cable through the building wall and drill cable hole as shown Typical SCP installation location using mounting Typical SCP installation location outside warehouse plate on pedestal 19 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Installation 4 4 N 4 4 5 2 Connect Door Close Limit Interface In the case of an automatic door there is not a reguirement for the SADL however there is a reguirement for a signal from the door control panel to indi
18. at either parts running guide Check that the lock and do not clash with existing door fixings bolt do not clash with bay controls Suggested height between 1 5m and 2m from floor level Step 03 Drill the clearence hole in the running guide using a 25mm tank cutter u Step 04 Determine the position of the Step 05 Use the hole in the door lock body ensuring that the bolt entry running guide to align the lock hole aligns with the already secured locking bolt Step 06 Mark and drill the positions of the mounting bracket holes Step 07 Fix the lock and bracket Step 08 With the door fully closed place with the screws provided engage the bolt into the lock body through the previously drilled hole in the door running guide Mark the positions of the fixing holes in the door 36 of 51 Step 09 Drill and pop rivet two posi tions Check that the bolt rotates freely then drill remaining holes and pop rivet in place U Salvo 2013 E Issue 1 SMDL AI SMDB SDMC gt User Guide Castell Specifications Weight 1 1 kg Bolt Material Stainless steel Housing Material Stainless Steel Lock Material Stainless Steel Operating Temperature Range 40 C to 140 C 40 F to 284 F Maintenance Instructions Instructions Under normal operating conditions very little maintenance is reguired If used in dusty conditions blowing out with compressed air will prevent a build up of sedi
19. cate the bottom limit Connector 2 terminal 1 amp 2 connected to bottom limit volt free contacts of the Door control panel 6 Auto Door Control Interface It is the case of an automatic door it is necessary to prevent opening of the door when the Castell Key is in the free position Connect to Connector 2 terminal 7 amp 8 The 7 amp 8 terminals to be connected in series with the Door up push button wiring OR The 7 amp 8 terminals to be connected across the door inhibit terminal of the Door control panel Please note that the SCP is a failsafe device therefore if there is a failure then the door cannot be opened 7 Connect Dock Leveller Control Interface It may be necessary to prevent activation of the dock leveler when the door is closed Connect to terminal 5 amp 6 Connector 2 The 9 amp 10 terminals to be connected in series with the Dock leveler raise push button wiring Please note that if there is a power failure then the dock leveller cannot be raised 8 Power Supply Input Connect 230 110VAC supply to SPSB supply to be fused at 3A Connect Live to L AC terminal of PSU Connect Neutral to N AC terminal of PSU Connect Earth to Earth terminal of PSU Means of Isolation should be located adjacent to the device and should be clearly marked and easily accessible 9 Check Functions Check all Functions 10 Fuse Replacement The SCP internal fuse is located above the PCB adjacent to co
20. cts EC Declaration We the manufacturers declare that the components detailed herein and placed on the market comply with all the essential health and safety reguirements applying to them Empowered signatory Mr T C Whelan Managing Director 50 U Salvo 2013 E Issue 1 U Salvo 2013 E Issue 1 9 SS Castel The Future of Safety is Here Castell Safety International Castell Safety International Castell Interlocks Castell Safety International The Castell Building Oskar J ger StraBe 137 150 N Michigan Avenue Building 1 No 123 217 Kingsbury Road 50825 K ln suite 800 Lane 1165 Jindu Rd London NW9 9PQ Germany Chicago IL 60601 Shanghai 201108 UK USA China t 44 0 20 8200 1200 t 49 0 221 169 47 94 t 1 312 360 1516 t 86 0 21 6151 9028 f 44 0 20 8205 0055 f 49 0 221 169 47 95 f 1 312 268 5174 f 86 0 21 6151 9030 uksales amp castell com vertrieb castell com ussales castell com chinasales castell com www castell com www castell com www castell com www castell com A HALMA COMPANY Castell i d A member of the UVDB Verify W EN BRITISK SAFETY ISO 9001 COUNCIL Q 10297
21. d at the opposite end of the key entry aperture The recommended lubricant is Armna G4789 or equivalent The recommended lubrication interval is 6 12 months as required Keeping the Salvo Susie lock clean will ensure long and reliable service A of 51 U Salvo 2013 E Issue 1 Salvo Susie LA User Guide Castell TechnicalData N Data Working Temperature Min 25 C ice free Max 55 C Weight 1 0 kg Material Stainless steel lock complete with TPE Thermoplastic Elastomer sleeve Standards UK BS AU138b C type coupling Dimensions in mm SALVO SUSIE Order Information Information Please advise part number symbol and dog tag when ordering mandatory information Part Number Symbol Dog Tag 5 of 51 U Salvo 2013 E Issue 1 Salvo SGL User Guide Castell The Salvo Glad Hand Lock SGL is a key operated mechanical locking device designed to fit on to all European and US trailer emergency brake line connectors Its purpose is to prevent re connection of the air brake hose thereby immobilising the trailer When fitted the SGL can only be removed with the permit key Salvo SGL Operation Disconnect the 2 airline from the trailer connector then engage the centre peg of the SGL on to the air line connector on the trailer Rotate SGL downwards Slide the SGL lock portion towards the air line connector Only when the Salvo
22. e time of installation Order Information Y Please advise correct part number when ordering mandatory information gt P PP Part Number 007008 30 U Salvo 2013 E Issue 1 IS PS Castell Section 3 Manual Doors U Salvo 2013 E Issue 1 SMDL AIS SMDB SMDC User Guide Castell The SMDL AIS Salvo Manual Door Lock Is a mechanical interlock used to positively bolt loading bay doors in the closed position The switch contacts can be used for controlling power to the dock leveller or other ancillary electrical devises e g traffic lights The unit incorporates a locking bolt which passes through the door running rail and into the lock body Only when the key is inserted and turned can the locking bolt be disengaged allowing the door to be opened The turning of the key closes the switch contacts SMDL AIS SMDB Operation N When correctly installed the loading bay door is locked in the down position and the key is removed With the key removed the switch contacts are open and the dock leveller is disabled To operate first insert the key and rotate clock wise The locking bolt can now be rotated on its axis and released The loading bay door can now be opened With the door open the key is retained in the lock The dock leveller can now be operated as normal Insert the key 2 Rotate the key into the lock clockwise Rotate the Release the locking bolt locking
23. ent wear or damage parts should be replaced or returned to Castell for repair if appropriate Users of interlock systems have a duty under Section 2 of the Health and Safety at Work etc Act 1974 to ensure that the systems are correctly installed and maintained in a satisfactory condition Order Information Information Please advise correct part number when ordering mandatory information Part Number Description 006479 With Bolt 007051 With Chain Kit 40 U Salvo 2013 E Issue 1 IS PS Castell Section 4 Loading Bay Barriers U Salvo 2013 E Issue 1 Salvo Bollard User Guide The Salvo Barrier comprises a pair of bollards a chain kit and a choice of interlock see table below Each bollard is bolted to the warehouse floor either side of the loading bay door Salvo Bollard Operation The SADL is a keyless solenoid controlled lock that locks and unlocks dependant on the signal received from the SCP unit When the SGL is fitted to a truck the key is released and is then taken to be inserted into the SCP Once inserted and turned it will send a signal to the SADL illuminating the green LED and electromechanically allowing the removal of the bolt this there fore allows the opening of the dock door or a chain barrier When the bolt is removed a yellow light illuminates indicating that access has been granted and will also send a signal back to the SCP locking the key in its panel this pre
24. es together for a system configuration it is best to ensure the correct operation of each device independently before starting to help reduce troubleshooting time later in the event of discrepancy Prior to installation when applying eguipment on a new supply circuit always ensure the correct line voltage exists and is stable Remember to shut the power off after this is checked and before performing any wiring of the system 16 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Installation 1 4 Steps for installing the SCP Step 1 Specify location of SADL inside outside Step 2 Mount SCP Step 3 Install multi core cable Step 4 1 Install Traffic Lights Step 4 2 Install SPSB Step 5 1 Install SADL Step 5 2 Connect Door Close Limit Interface Step 6 Connect Auto Door Control Interface Step 7 Connect Dock Leveller Control Interface Step 8 Connect power 24VDC 1 Specify Location of SCP Before carrying out installation it is extremely important to determine the location of the SCP This would depend on the specific site reguirement The options being e Mounted inside the Warehouse where the warehouse staff controls the Salvo coupling e Mounted Outside the Warehouse where the shunters drivers control the Salvo coupling e Ifin any doubt contact the site project manager or the Castell Product Manager 2 Mount SCP Depending on site conditions Ideally the SCP s
25. g Material Stainless steel Lock Material Stainless Steel Standards Conforms with AS4945 2000 Dimensions in mm SALVO TYPE 1 49 63 2 Order Information Please advise part number symbol and dog tag when ordering mandatory information Part Number Symbol Dog Tag 9 of 51 U Salvo 2013 E Issue 1 Salvo Club lt gt User Guide Castell The Salvo Club helps ensure loading dock safety The Salvo Club brings added safety to loading dock procedures by locking a vehicle s steering wheel The Salvo Club can be attached to vehicle steering wheels of varying sizes and will remain locked in place once the Castell key is removed When loading unloading procedures are complete the Castell key may be replaced and the Salvo Club can be removed allowing the vehicle driver to depart from the loading bay Salvo Club Operation N O Slide the two halves of the Salvo Club apart engaging the hooks inside the wheel Begin by fully 2 closing the two halves of the Salvo Club Then place the Salvo Club in position over the steering wheel The Salvo Club Is now locked in place restricting rotations of the steering wheel Rotate and remove the key Precautions A Salvo Club will not prevent a vehicle drive away It s purpose is to provide a warning that loading unloading activity may still be ongoing Handle with Care Beware of pinch poin
26. h Care Beware of pinch points where the two halves slide telescope together 12 of 51 U Salvo 2013 E Issue 1 Salvo Chock LA User Guide Castell Maintenance Periodic visual checks should be carried out by the site manager safety officer Do not lubricate lock barrel with oil or grease use CK Dry Powder Graphite if necessary The recommended grease to lubricate sliding parts is Armna G4789 or equivalent Technical Data Data Material Powder coated carbon steel and aluminium Weight 26kg Colour Safety yellow graphite grey Dimensions in mm SALVO CHOCK 965 to1318 Order Information Information Please advise part number and symbol when ordering mandatory information Part Number Symbol 13 of 51 U Salvo 2013 E Issue 1 IS PS Castell Section 2 Powered Doors U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Castell The Salvo Control Panel Plus SCP is the main interface between the Salvo couplings and associated bay door controls The SCP comprises of a wall mounted panel with easy to use Castell interlock key switch to allow operation of the bay There is also panel indication of status and operation Installation is via plug in terminals on the internally mounted PCB SCP Operation The Salvo Control Panel is designed as part of a safety system to prevent accidental drive aways The Salvo Control
27. h the door down limit switch Where this is not possible two switches should be used see Installation Wiring Diagram IMS08992 Maintenance From time to time check that all fixing screws remain tight 24 of 51 U Salvo 2013 E Issue 1 Salvo Safety Proximity Sensor LA User Guide Castell installation N Operating Distance 15mm Minimum O The magnet should be mounted low enough on the door to ensure it does not reach the point where the door begins to be rolled when the door is fully opened Align the Switch bracket with the Magnet mark and drill holes and fix to the frame O Ensure the Switch and Magnet align when the door is fully closed 4 Adjust the Switch and Magnet to meet the acceptable operating distance Order Information Information Please advise part number when ordering mandatory information Part Number 007050 25 of 51 U Salvo 2013 E Issue 1 Salvo Safety Limit Switch lt gt User Guide Castell The Salvo Safety Limit Switch comprises a mechanical roller switch and bracket set It is mounted so that the roller is actuated by the opening and closing of the loading bay door It should be mounted in accordance with these instructions in a raised position to prevent accidental damage Salvo Safety Limit Switch Specifications N Installation should be carried out by a competent and gualified person who has re
28. hould be mounted 1 5m above floor level If mounted outside the building it should be mounted beneath the traffic lights If mounted inside the building it should be located adjacent to the dock controls 3 Install Multi core Cable Consideration should be taken on how the cables are going to run to the various peripherals An assessment of site conditions needs to be taken to determine the type of cable used Armoured cable is suggested for areas of low level of protection against damage by vehicles CY or SY cable to be used where there is a good level of protection The more peripherals and interface connections need the more cores are required Consult the wiring diagram to determine the number of cores needed It is suggested the power cabling is run separately where practicable Care should be taken to route and secure all wiring to the Control PCB to avoid interference with the enclosure locking mechanism 17 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Installation 2 4 4 1 Install traffic Lights Our standard 24VDC traffic lights are to be used re SETL Connect to Connector 8 Term 7 8 9 10 9 connect to ve terminal of red traffic light 7 connect to ve terminal of green traffic light 10 amp 8 connect to ve terminal of both red and green traffic light 4 2 Install SPSB Mounting Holes 90mm H x 94mm W SPSB M5 Fixings Connections Connector 1 Termin
29. ment in the locks The use of powdered graphite is recommended if necessary Under no circumstances however should the locks be oiled or greased as this causes the locks to clog and malfunction All locking systems should be checked regularly for correct operation security of fixings and condition of keys etc The function of all keys that should be trapped must be checked under operating conditions as should the ease of removal of released keys In the event of malfunction evident wear or damage parts should be replaced or returned to Castell for repair if appropriate Users of interlock systems have a duty under Section 2 of the Health and Safety at Work etc Act 1974 to ensure that the systems are correctly installed and maintained in a satisfactory condition Order Information Please advise correct part number and symbol when ordering mandatory information Part Number Description Symbol 006510 Hand 1 With Bolt 007041 Hand 1 With Chain Kit MANGA Hand 2 With Bolt 007043 Hand 2 With Chain Kit U Salvo 2013 E Issue 1 SADL SMDB SDMC lt gt User Guide Castell The SADL is a keyless solenoid controlled Lock that locks and unlocks dependent upon the signal received from the Salvo Control Panel SCP The unit incorporates a locking bolt which passes through the door running rail and into the lock body Only when the signal is received fr
30. ment is particularly critical in the case of key actuated locks since the key is conductive and is deliberately grasped by operators Castell electrical products can be grouped into two categories those that are self contained for front of board mounting and those that are supplied un mounted for back of board installation by the customer The products that are mounted in boxes or housings are Class 1 eguipment are provided with earthing tags which MUST be bonded by the earthing conductor to earth TNS System The lock portions and metal structure of products for back of board mounting MUST either be a Connected directly to earth via an earthing tag on the mounting screws OR b Bonded with a sound electrical connection onto a conductive structure which in turn is connected to earth ensuring the correct earth fault loop impedance Installation of electrical equipment must be carried out by a qualified electrician using E E recommended practice In particular the correct rating of products and the earthing of attached locks and metal structures as described above is imperative Installation should be carried out by a competent and qualified person who has read and understood these instructions Any electrical installation must comply with standard BS7671 Requirements for Electrical Installations commonly referred to as the IEE Wiring Regulations or any particular regulations and practices specified by the local electricity s
31. nnector TB4 marked F Panel Fuse Fuse Rating GSL003 5 x 20mm Time Lag Glass Tube Fuse RS668 6007 20 U Salvo 2013 E Issue 1 Salvo Control Panel SCP lt gt User Guide Castell Function Condition Door de activated SADL de energized Traffic light green Key Free Orange beacon OFF Dock leveler de activated Vehicle restraint de activated SCP lights Green if ext Red if int Door activated but not yet opened SADL energized but not yet opened Traffic light green Key Trapped Door Closed Orange beacon ON Dock leveler de activated Vehicle restraint activated SCP lights Green if ext Red if int Door activated and opened SADL energized and unbolted Traffic light red Key Trapped Door Open Orange beacon ON Dock leveler activated Vehicle restraint activated SCP lights Red if ext Green if int 0 0 0 Connect ID Description Power Rating Cable Size 24VDC 24VDC power connections Connector 1 Term 1 amp 2 20w 1 5mm Connect ID Description Cable Size SADL Door Closed Solenoid controlled door lock or the door closed contact in the door control panel 1 5mm Connect ID Description Power Rating Cable Size Auto Door N O contacts to interlock with the door 6A 1 5mm Dock Leveller N O contacts to interlock with the Dock leveller 6A 1 5mm Traffic Light Change over contacts to control the traffic lights 24VDC
32. o Transformer Specifications N Enclosure Polycarbonate 180mm h x 182mm w x 111mm d Cable Entry 2 x M20 Glands 63VA Transformer Input 0 230V 400V Output 2 x 0 115V Installation should be carried out by a competent and qualified person who has read and understood these Instructions Order Information Information Please advise part number when ordering mandatory information Part Number 007264 28 of 51 U Salvo 2013 E Issue 1 Salvo Power Supply amp Beacon SPSB User Guide The Salvo Power Supply converts 110 240V to 24VDC to power the SCP providing a safer power level at the user interface The SPSB is mounted to the interior wall of the warehouse adjacent to the Loading Bay and is combined with an Amber Beacon to provide notification that the Loading Bay has been activated and it is safe to open the bay door and commence loading or unloading Salvo Power Supply amp Beacon Specifications Power Supply Input Voltage 100 240VAC 88V 264VAC Full Range Frequency 47 63Hz Current lt 2A0115V and 1 2A 230V AC input full load Inrush Current 40AQ230VAC input Cold Start at 25 C ambient Leakage Current 2 0mAQ240VAC input Output Voltage 24V Rated Load OA Range Load 3 2A Output Tolerance 1 Line Regulation 0 5 Load Regulation 0 5 Ripple Noise MAX 120mV Efficiency Typ 8596 Power 76 8W 29
33. om the SCP can the locking bolt be disengaged allowing the door to be opened SMDL AI SMDB Operation The SADL is a keyless solenoid controlled lock that locks and unlocks dependant on the signal received from the SCP unit When the SGL is fitted to a truck the key is released and is then taken to be inserted into the SCP Once inserted and turned it will send a signal to the SADL illuminating the green LED and electromechanically allowing the removal of the bolt this therefore allows the opening of the dock door or a chain barrier When the bolt is removed a yellow light illuminates indicat ing that access has been granted and will also send a signal back to the SCP locking the key in its panel this prevents the removal of the permit key while loading is granted Precautions A Installation should be carried out by a qualified electrician Please retain this document Electrical Connection Refer to Salvo Control Panel Wiring Diagram 38 of 51 U Salvo 2013 E Issue 1 SADL SMDB SDMC User Guide Castell Step 01 First ensure the door is fully Step 02 Mark the position of the bolt Step 03 Drill the clearence hole in the closed Determine the position of the clearance hole on the inside of the door running guide using a25mm tank cutter locking bolt to ensure that either parts running guide Check that the lock and do not clash with existing door fixings bolt do not clash with bay controls Sugge
34. ou Auges 1004 aug KOJ eng epson 3 D LEER a AN CX M XJ ag eR 9 uone e1su 800 00 GSdS uodesg Nsd OMES 100 00 dOS Iau amp d 04ju02 h H 22 U Salvo 2013 E Issue 1 Salvo Control Panel SCP User Guide Castell Order Information Y Information Please advise part number and symbol when ordering mandatory information Part Number Symbol U Salvo 2013 E Issue 1 Salvo Safety Proximity Sensor User Guide Castell The Salvo Safety Proximity Sensor is designed for use with Roller Shutter Doors where mechanical Roller Switches cannot be used It should be mounted in accordance with these instructions as close to the door frame as possible to prevent accidental damage Salvo Safety Limit Switch Specifications Proximity Switch 120 WNA Max Brass Nickel Plated 2 x 0 5mm PVC covered Black insulated Brown Blue Metal Threaded Magnet Brass Nickel Plated Precautions Installation should be carried out by a competent and qualified person who has read and understood these instructions A Do not use this product as a safety or emergency stop device or in any other application where failure of the product could result in personal injury Handle with Care Beware of Pinch points where the two halves align Castell Safety recommends that this switch is wired in series wit
35. perated mechanical locking device designed to fit on to all UK trailer emergency brake line connectors It s purpose is to prevent re connection of the air brake hose thereby immobilising the trailer When fitted the Salvo Susie can only be removed with the permit key The Salvo Susie has an ergonomically designed grip This enables the lock to be fitted and removed efficiently in wet and cold weather The grip design provides protection to oil and grease making it ideal for harsh environments Salvo Susie Operation The Salvo Susie lock is designed as a part of a safety system to prevent accidental drive aways The Salvo Susie interlock ensures the vehicle air line is disconnected before the loading bay door can be opened O Disconnect the airline from the 2 Slide the Salvo Susie lock over the 8 Rotate the key anti clockwise and remove the key trailer Susie air line connector exposed air line connector To remove the Susie lock from the trailer insert and rotate the key clock wise Pull the lock off the Susie air line connector When the operation is complete the unit should be returned to either the storage enclosure or to the issuer Precautions A Salvo Susie is heavy During the course of normal use it may become dirty greasy and slippery If you drop it on your foot you may sustain serious injury Handle with care Wear appropriate personal protective clothing Maintenance A lubrication point is provide
36. sted height between 1 5m and 2m from floor level Step 04 Determine the position of the Step 05 Mark and drill the positions of Step 06 Fix the lock and bracket in lock body ensuring that the bolt entry the mounting bracket holes place with the screws provided hole aligns Use the hole in the door running guide to align the lock Step 07 With the door fully closed Step 08 Drill and pop rivet two engage the bolt into the lock body positions Check that the bolt rotates through the previously drilled hole in the freely then drill remaining holes and pop door running guide Mark the positions rivet in place of the fixing holes in the door 39 of 51 U Salvo 2013 E Issue 1 SADL SMDB SDMC gt User Guide Castell Specifications 5 C to 40 C Mean over 24 hours 35 C Maintenance Instructions Instructions Under normal operating conditions very little maintenance is reguired If used in dusty conditions blowing out with compressed air will prevent a build up of sediment in the locks Under no circumstances however should the locks be oiled or greased as this causes the locks to clog and malfunction All locking systems should be checked regularly for correct operation security of fixings and condition of keys etc The function of all keys that should be trapped must be checked under operating conditions as should the ease of removal of released keys In the event of malfunction evid
37. ts where the two halves slide telescope together Maintenance Apply lubrication to the inner plungers The recommended lubricant is Armna G4789 or equivalent The recommended lubrication interval is 6 12 months as reguired Keeping the Salvo Club lock clean will ensure long and reliable service 10 of 51 U Salvo 2013 E Issue 1 Salvo Club lt gt User Guide Castell Technical Data Working Temperature NA Weight 1 5kg Housing Material Steel Cro moly Steel Construction with heat treated steel hook Lock Material Stainless Steel Brass Steering Wheel Size Min 22cm Internal Diameter Max 48cm Internal Diameter Dimensions in mm SALVO CLUB 610 840 Order Information Please advise part number and symbol when ordering mandatory information Part Number Symbol 11 of 51 U Salvo 2013 E Issue 1 Salvo Chock User Guide Castell Salvo Chock is a device designed to immobilise nonarticulated goods vehicles whilst they are being loaded and unloaded When used in conjunction with other Salvo products it can prevent inadvertent or unauthorised drive aways It is designed to be deployed on the drivers side front wheel of the vehicle Salvo Chock introduces discipline into the chocking procedure by interlocking the chock and the loading bay If the chock is not correctly fitted the bay door cannot be opened Like all of the existing products in
38. upply company at the time of installation Installation must be carried out by competent personnel qualified to current IEE or any equivalent regulations in force at the time of installation Castell offer an installation and maintenance service for its products and will be pleased to offer advice 6 Maintenance of Castell Interlocks A WARNING Disconnect Electrical Supply Before Opening Unit Under normal operating conditions very little maintenance is reguired If used in dusty conditions blowing out with compressed air will prevent a build up of sediment in the locks The use of powdered graphite is recommended if necessary Under no circumstances however should the locks be oiled or greased as this causes the locks to clog and malfunction All locking systems should be checked regularly for correct operation security of fixings and condition of keys etc The entrapment of all keys that should be trapped must be checked under operating conditions as should the ease of removal of liberated keys In the event of malfunction evident wear or damage parts should be replaced or returned to Castell for repair if appropriate Users of interlock systems have a duty under section 2 of the Health and Safety at Work Act 1974 to ensure that the systems are not only correctly installed but are maintained in a satisfactory condition We are here to help Castell offer an installation and maintenance service as well as advice on the selection of produ
39. ut procedure should be developed for this unit and related energy sources Training Only those trained in the proper use of this eguipment should be allowed to install use and maintain it Installation Proper installation will ensure safe operation and long life of this product Never use this product for anything other than its intended purpose It is recommended to route cabling via the cable gland access provided at the base of the unit Remove knock outs and fit cable glands provided Always make connections to this device in accordance with instructions set forth in this manual and any applicable electrical codes for your area A lockable local disconnect is recommended to properly isolate this unit Constantly be aware of vehicle traffic on or near the loading bays ESD electrostatic discharge circuit boards are vulnerable to damage by electrostatic discharge Before handling any boards ensure you dissipate your body s charge Operation Maintenance A WARNING Disconnect Electrical Supply Before Opening Unit Never operate this unit with the access door open Never place any body parts near exposed electrical components Avoid poking prodding into unit with tools that can conduct electrical current Never force the electrical contacts or key solenoid to manually operate this unit Failure to follow this instruction could void the manufacturer s warranty Preinstallation Check When preparing to wire multiple devic
40. vents the removal of the permit key while loading is granted Precautions To maintain high visibility periodically clean the bollard From time to time check that all fixing screws remain tight Maintenance N To maintain high visibility periodically clean the bollard From time to time check that all fixing screws remain tight Specifications N Post Material Powder coated carbon steel Cap Material UV resistant ABS black Dimensions 1 016mm x 100mm x 150mm Weight 16kg Colour Safety yellow Mounting Hardware Supplied 42 of 51 U Salvo 2013 E Issue 1 Salvo Bollard User Guide Castell Installation X Fixing Instructions Installation begins with bolting the footplate to the floor of the warehouse Mark the position of the fixing Bolt the footplate to the floor 3 Lower the Bollard into place holes on the warehouse floor and using the fixings provided over the footplate drill with a suitable masonary drill 2 Secure the Bollard to the footplate with the bolts provided Order Information Information Please advise correct part number when ordering mandatory information Part Number Description System Components 006513 SCB SMDL AIS 1 c w Chain Kit amp Bollard 006514 SCB SMDL AIS 2 c w Chain Kit amp Bollard SCB SMDL AI 1 c w Chain Kit amp Bollard 006516 SCB SMDL AI 2 c w Chain Kit amp Bollard 006517 SCB SADL c w Chain Kit amp Bollard 43 of 51 U Salvo
41. ws and brackets should be corrosion resistant and the appropriate tightening tongues and anti vibration washers should be used c Locks should not be used in ambient temperatures above 75 degrees Centigrade 167 degrees Fahrenheit for brass figure and O locks and 100 degrees Centigrade d Locks and switches must be protected from the ingress of water and dust and products of suitable IP rating must be selected Protective caps are available and locks can be selected with protective enclosures The ingress of water and dust should be reduced by mounting the locks vertically rather than face up where possible e Chemical corrosion of locks can be avoided with the various finishes for locks and keys that are available Alternatively most products are available in 100 stainless steel f In general the installation of Castell locks must not result in a torque in excess of 5 5 Nm 4 Lbs ft being transmitted through the lock centre via the key This is a typical hand operating torgue and additional leverage through the key using tools of any kind should be avoided 2 Spare Keys Master Keys Spare Access Locks Actuation Bolts Tongues Castell will only supply spare keys and spare access lock bolts tongues when a signed order with order number is received on the customers headed paper This is also reguired for figure lock master keys in addition to which the customer is required to sign a document accepting responsibility for
Download Pdf Manuals
Related Search