Installation and operating instructions Barriers KOLOSS 60 – 120
Contents
1. KO 2 1 7 Met Nd i gt Drawing 33 Pos Qty Part name 1 1 Base frame 2 1 Main shaft 3 1 Motor Gearbox KOLOSS 120 4 1 Mounting plate 5 1 Spring assembly KOLOSS 120 6 1 Cover frame right 7 1 Cover frame left 8 1 Hood 9 2 Boom holder support 10 1 Cover with door 11 1 Cover with door Table 14 49 KOLOSS 60 120 ke Drawing 34 Pos Qty Part name 1 1 KOLOSS 120 2 1 Boom 12m 3 1 Packing 4 1 Accessories KOLOSS 120 Table 15 502. After the installation an EG declaration of conformity according to EC machinery directive 2006 42 EG for the complete system has to be issued by the person responsible for the integration according to product standard DIN EN 13241 1 Name plate The name plate of the barrier is attached at the inside front of the barrier housing KOLOSS 60 120 Function description Barriers serve as passage control of vehicle paths By raising and lowering of the barrier boom the passage is granted or obstructed For a boom length of 6 000mm and longer we recommend the use of a fixed or swinging support for a boom length of 9 000mm and longer the use fixed or swinging support is mandatory The controller offers the possibility to activate the barrier by radio remote control The controller is able to observe the max permitted force which was set before in the learning sequence If during the closing movement more force is needed the barrier reverses Additionally several different safety features e g photoelectric barriers can be connected ATTENTION In order to reduce the risk potential related to the movement of the barrier boom additional optical and or acoustical warning devices should be installed 10 KOLOSS 60 120 Technical Data KOLOSS 60 120 Operative range Application for Drive pulse from Table 1 General data Mains supply Max current Duty cycle Temperature range Controller Measu
3. Attention You may use the service device ZS701 to read the error memory of the controller 38 12 KOLOSS 60 120 Examples for use of loop detectors B3 2 This loop may be used for opening or for detecting that a vehicle is present connected to socket B3 by contacts X1 24 top und X1 24 bottom B3 1 This loop is for the safety only and is placed under the barrier boom connected to socket B3 by contacts X1 23 top und X1 23 bottom B2 This loop is for opening only connected directly to socket B2 contacts 7 and 8 Push button key switch card reader coin selector etc Photo cell Example 1 for 1 channel loop detector on socket B3 Entrance and Exit opening with push button Safety and closing with loop detector on socket B3 1 all jumpers at default settings Remove red jumper of socket B3 and jumper between the terminals 27 bottom and 6 bottom Drawing 21 Example 2 for 2 channel loop detector on socket B3 Entrance opening with a key switch Safety and closing with both loops B3 1 and B3 2 Exit opening with loop B3 2 Safety and closing with both loops all jumpers at default settings Remove red jumper of socket B3 and jumper between the terminals 25 top and 25 bottom DIP S8 min 1000mm max 1500mm gt Drawing 22 Example 3 for 1 channel loop detector on socket B3 Entrance and Exit opening with a coin selector Safety with photo cells and loop B3 1
4. Automatic closure by photo cell is not activated The closing function by loop B3 2 is not applicable S8 on When an obstacle is not longer present the barrier closes Photo cell test LSTST Before each closing of the barrier the photo cells may be tested S9 off Photo cell test is not activated 29 8 5 8 6 KOLOSS 60 120 S9 on A photo cell test occurs before each closing Attention The photo cell test has to be learnt when programming the controller Photo cell test Before the closing of the barrier the photo cells may be tested The photo cell test consists of two parts Part one The transmitter is taken off the power supply and then the receiver has to report an obstacle within max 2 5 seconds Part two The transmitter is connected to the power supply again and then the receiver has to report that no obstacle is present If during part one the receiver does not report an obstacle the photo cell is faulty and an error code is shown on the Diag LED flashes 6 times If during part two the obstacle is still being reported the controller assumes a real obstacle being present the barrier will not close No error code is shown Max 6 photo cells can be connected to the controller MO63 and be tested For the testing of more than one photo cell the relay connections of the receivers have to be connected in series Parallel to the relay connections a resistor of 1kOhm each has to be connected X1 26
5. Automatic closure when the time to stay open has elapsed Remove the jumper between 9 top and 9 bottom and connect the safety contact of the photo cells to them all jumpers at default settings Remove red jumper of socket B3 and jumper between the terminals 27 bottom and 6 bottom 39 KOLOSS 60 120 Drawing 23 Example 4 for 2 channel loop detector on socket B3 Entrance and Exit with card reader The loop B3 2 allows use of the card reader only when a vehicle is on the loop The loop B3 1 is for safety and closing when a vehicle leaves the loop The jumpers are at the default settings Remove the jumper between terminals 6 bottom and 27 bottom and connect the contact from the card reader here Remove the red jumper of socket B3 between terminals 6 and 10 min 1000mm max 1500mm min 1000mm max 1500mm B3 2 Drawing 24 Example 5 for 1 channel loop detector on socket B2 and 2 channel loop detector on socket B3 Entrance with card reader The loop B3 2 allows use of the card reader only when a vehicle is on the loop Remove the jumper between terminals 6 bottom and 27 bottom and connect the contact from the card reader here Safety with loop B3 1 opening with loop B2 closing with B3 1 or B2 Remove the red jumper of socket and set DIP switch S8 on Drawing 25 Example 6 for 2 x 1 channel loop detector on socket B2 and socket B3 Entrance opening with key switch Safety with lo
6. X1 11b X1 20 X1 22 X1 13t X1 14t X1 15t X1 14b X1 17b X1 19b KOLOSS 60 120 Ground for photo cell transmitter OV only for photo cell test 24Vdc stabilised for external equipment max 500mA 12Vdc stabilised for external equipment max 500mA Ground for external equipment Display barrier open The contact V15 12 is connected with the contact V15 14 when the barrier is open The contact will be closed when the green light is lit Maximum permissable 24V 1A Display barrier closed The contact V15 13 is connected with the contact V15 14 when the barrier is open The contact will be closed when the red light is lit Maximal admissible 24V 1 Common terminal for display barrier open and barrier closed Motor OPEN Motor CLOSE The red traffic light is on when the barrier is closed The red traffic light is also on during the time warning prior to opening max 230V 120W The contact for the Amber or the flashing light is closed when the barrier is moving and during the time warning prior movement max 230V 120W The green traffic light is on when the barrier is open During the time warning before closing the green traffic light is out max 230V 120W N L1 power supply 230V 50Hz N power supply 230V 50Hz 27 8 4 1 8 4 2 8 4 3 KOLOSS 60 120 Visual indication the radio remote control receives a signal BTZ2
7. allowed All alterations or extensions to the appliance must be carried out with parts which ELKA Torantriebe GmbH u Co Betriebs KG have defined as suitable for such alterations and be carried out by qualified personnel Please note that with any alteration of the product no matter whether mechanical or electrical the warranty expires and the conformity is revoked Only the use of ELKA accessories and original ELKA spare parts is allowed In case of any contravention ELKA disclaims liability of any kind INFORMATION The operation of the system within CEN countries must also be conformant with the European safety relevant directives and standards We reserve the right to make technical improvements without prior notice 1 1 1 2 1 3 KOLOSS 60 120 Symbol explanation Remarks regarding the safety of persons and the gate opener itself are marked by special symbols These remarks have to be absolutely observed in order to avoid accidents and material damage DANGER points to an imminent dangerous situation which can cause death serious injuries if it is not avoided WARNING points to a potentially dangerous situation which can cause death serious injuries if it is not avoided ATTENTION points to a potentially dangerous situation which can cause minor or slight injuries if it is not avoided ATTENTION points to a potentially dangerous situation which can cause property da
8. closes automatically and learns the running time for closing and the torque power for the reversing on obstruction The learnt values are stored even if power failure occurs and the Diag LED turns off Personal code for radio remote Setting personal code for radio remote Push the learn button approx 3 seconds the red Diag LED starts flashing Push the corresponding button on your transmitter The controller learns the code the red Diag LED is lit while a signal is received Release the button The code is stored even if power failure occurs and the Diag LED turns off Cancel personal code Push the learn button approx 3 seconds the red Diag LED starts flashing Keep the learn button pushed for approx 10 seconds The red Diag LED lights for 2 seconds the personal code is erased and the learning is finished 31 KOLOSS 60 120 External connections For the power supply of the external equipment e g photo cells induction loops the controller provides stabilised 24Vdc and 12Vdc Max 500mA can be drawn from the 12V source and the 24V source but together max 700 The supply of the photo cell transmitter during photo cell test comes from the 24V source and has to be considered Barrier closed red light 29 9 Barrier moving or about to move amber or flashing light Photo cell 9t 19b 8t 8b 69 9 Barrier open green light No boom option Baum obe
9. end positions should be checked and if necessary be adjusted For adjusting loosen slightly the front counter nut of the corresponding limit switch Make sure that the limit switch does not turn Move the limit switch into the desired direction Tighten the counter nut Check the new adjustment in a test run If necessary repeat the adjustment ATTENTION Now again check during operation that the rotating direction is correct gt Ifthe drive lever moves in direction to the road then swap the motor connector cable X1 19 and X1 21 22 7 2 KOLOSS 60 120 Emergency release Friction clutch The vandalism protection for the barriers KOLOSS 60 90 120 consists of an internal friction clutch which can be operated by a rating nut accessible from the outside Is the barrier boom forced upwards the clutch slides through when a certain force is applied The barrier boom is still connected mechanically with the motor gearbox unit After the vandalism protection was activated no parts of the barrier need to be exchanged The gearbox suffers no damage Adjusting the friction clutch Releasing Loosen the rating nut of the friction clutch located behind the emergency release cover anti clockwise direction a using the supplied key SW 27 32 not remove the rating nut completely The barrier opens through the spring tension to approx 30 45 when the rating nut was loosened sufficiently Engaging Tighten the rating nut
10. of the friction clutch located behind the emergency release cover clockwise direction b see Table 4 Drawing 16 1 Emergency release cover 2 Rating nut a direction a releasing b direction b engaging The friction clutch is factory adjusted to the correct torque During setting up of the barrier it is absolutely necessary to release the clutch When engaging make sure the same torque is adjusted again since otherwise problems during operation could arise Tighten the friction clutch with the nut manually then retighten the nut using the number of revolutions Nm as specified in the table 4 23 KOLOSS 60 120 Spring assembly The spring assembly has to be adjusted according to the length of the boom and the mounted accessories as shown in Table 5 Boom length Accessories mm kg m EL 000 movements Table 5 HG75 Hanging skirt 75 7 approved up to 9 000mm HG150 Hanging skirt 150 approved up to 6 000mm SG150 Top and bottom approved up to 6 000mm skirt REMARK During installing replacement of the springs make sure they are aligned as much as possible symmetrically within the assembly REMARK The boom must be levelled off between 30 45 otherwise the initial tension of the spring assembly has to be changed using the spanner 24 KOLOSS 60 120 Controller 63 LERN 0 3 1024002 ope o 0 0 0 0 0 0 0 0 0 0 o LEE NIA NG apo
11. on Torque setting is wrong Adjust it closing The boom isn t vertical when the barrier is open The green LED SEA is Limit switch open Re adjust it and the out maladjusted but still corresponding switches mechanical stopper The green LED SEA is Faulty limit switch Replace it lit The red diagnostic open LED flashes twice then a break The limit switch Re adjust it and the open is corresponding maladjusted and mechanical stopper doesn t switch The boom isn t horizontal when the barrier is closed The green LED SEZ is Limit switch closed Re adjust it and the out maladjusted but still corresponding switches mechanical stopper The green LED SEZ is Faulty limit switch Replace the limit switch lit The red diagnostic closed LED flashes three times then a break The limit switch Re adjust the limit closed is switch and the maladjusted and corresponding doesn t switch mechanical stopper Table 8 37 11 4 KOLOSS 60 120 Error code The red Diag LED serves as a status indicator During regular fault free operation the LED is only lit when a radio remote signal is received An error code is given when the controller detects a fault the Diag LED flashes max 12 times then a break then repeats the flashing code error Cause solution code Limit switch OPEN did not open after the learnt running time flashing The limit switch has a
12. short circuit Limit switch CLOSE did not open after the learnt running time flashing The limit switch has a short circuit Both limit switches signal at the same time While SEA and SEZ flashing signal at the same time the controller is blocked The power supply limit for the external equipment 12V and or 24V flashing has been reached The power source load is too high The controller is blocked Check the connected equipment gt Photo cell error The following error occurred during the photo cell flashing test The transmitter is inactive but the receiver does not signal an obstacle N An error occurred during learning of the torque power for the flashing reversing on obstacle Either the controller the motor or the capacitor of the motor are faulty Check the above and repeat the learning of the running time If the error still exists the controller is faulty The EEPROM has lost the data Repeat the learning of the flashing running time If the error still exists the controller is faulty The EEPROM is faulty flashing The controller has detected a fault in the redundant detection of flashing the stop contact The controller is faulty gt o 11x One of the motor relays has not switched off The controller is flashing faulty 12x The controller detects that the Triac has not switched off The flashing controller is faulty Table 9
13. the product and serves to control the barrier Any use above and beyond the above mentioned use is prohibited and constitutes improper use KOLOSS 60 120 Danger which could emanate from the site of operation The barriers KOLOSS 60 120 operate with moving parts WARNING Rotating and or linear movable components can cause serious injuries Do not reach into moving parts or handle any moving components during operation 5 Turn the appliance off before any maintenance work repair work or other work and secure it against unintentional restarting 3 2 H H KOLOSS 60 120 Transportation and storing Transportation inspection The shipment has to be inspected for transportation damage immediately after receipt In case of any damage record the type and extent on the delivery receipt or refuse acceptance Inform ELKA Torantriebe immediately in the event of damage In case the above points are not observed claims will be denied due to insurance regulations Storing The barrier has to be stored as follows Do not expose the barrier to aggressive substances Do not expose the barrier to heat sources Storage temperature 20 C to 70 C Lifting heavy loads WARNING Risk of injury by lifting heavy loads Lifting heavy loads may cause serious injuries gt Tolift the barrier use a suitable lifting device 5 Wear suitable safety shoes KOLOSS 60 120 Declaration of incorporation Decla
14. 25 11 Spray the mechanics and the joint head with spray oil 12 Check if the screws and nuts for fastening boom connector have the required rating screw M12x180 rating 8 8 and nut M12 rating 8 42 ELKA 14 14 1 KOLOSS 60 120 Extra equipment Fixed support with electromagnet 1 Connect the flexible lead from the magnet to the cable from the barrier There is enough room in the lower part of the support for a junction box 2 Fit the forked part onto the foot and secure it in the required height 3 Remove the rubber tube from the boom at the point at which the anchor plate is to be secured 4 Push one of the securing pieces followed by the anchor plate into the slot of the boom until the plate is immediately above the magnet Drawing 27 5 Push the second securing piece up to the magnet 6 Push the securing pieces from both sides against the anchor plate and secure them with the screws Connecting the magnet in the barrier 12 gt kK 22 14 14 1 2 top bottom bottom top Magnet Drawing 28 1 The 1 5 seconds warning before opening must be activated Switch 2 on the logic board 2 The coil of the relay must be connected to the terminals 14 top and 14 bottom in the terminal block 3 Connect contact 11 of the relay to 1 bottom in the terminal block Connect contact 21 of the relay to 2 top in the terminal block 5 The leads to the magnet come from the contacts 12 and 22 of the
15. 3 3 2008 Limits Limitation of voltage changes voltage fluctuations and flicker EN 61000 4 2 2009 Electrostatic discharge immunity test EN 61000 4 3 2006 A1 2008 A2 2010 Electromagnetic field immunity test EN 61000 4 4 2004 A1 2010 Electrical fast transient burst immunity test EN 61000 4 5 2006 Surge immunity test EN 61000 4 6 2009 Immunity to conducted disturbances induced by radio frequency fields EN 61000 4 11 2004 Voltage dips short interruptions and voltage variations immunity tests EN 61000 4 13 2002 A1 2009 Harmonics and interharmonics including mains signalling at a c power port low frequency immunity tests EN 61000 6 2 2005 Generic standards Immunity for industrial environments EN 61000 6 3 2007 A1 2011 Generic standards Emission standard for residential commercial and light industrial environments EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Further we declare that the special technical documentation for this partly completed machinery is compiled in accordance with annex VII part B and we undertake to transmit relevant information to the market surveillance authorities upon request The partly completed machinery must not be put into service until it is incorporated into a machinery which has been declared in conformity with the provisions of the EC Machinery Directive and for which an EC declaration of conformity according to annex A was issued Empower
16. Installation and operating instructions Barriers KOLOSS 60 120 Translation of original installation and operating instructions D ID V3 0 12 12 ELKA Torantriebe GmbH u Co Betriebs KG Phone Dithmarscher Str 9 Fax 25832 Tonning E Mail Germany Internet 49 0 48 61 96 90 0 49 0 48 61 96 90 90 info ELKA Torantriebe de www ELKA Torantriebe de KOLOSS 60 120 Contents 1 Preface 1 1 General notes 1 1 1 Symbol explanation 1 2 Copyright 1 3 Information regarding installation instruction 2 Safety 2 1 General notes on safety 2 2 Notes on safety for the operation 2 3 Safety notes for the operation with radio remote control 2 4 Intended use 2 5 Danger which could emanate from the site of operation 3 Transportation and storing 3 1 Transportation inspection 3 2 Storing 3 3 Lifting heavy loads 4 Declaration of incorporation 4 1 Installation information for partly completed machinery 4 2 Declaration of conformity 4 3 Name plate 5 Function description 6 Technical Data KOLOSS 60 120 7 Installation KOLOSS 60 120 7 1 Adjusting the limit switches 7 2 Emergency release Friction clutch 7 3 Spring assembly 8 Controller MO 63 8 1 Connections 8 2 Further connections 8 3 Visual indication 8 4 Operating mode controller 8 4 1 Pre warning before opening VWA 8 4 2 Pre warning before closing VWZ 8 4 3 Automatic closure ZLA 8 4 4 Reversal on hitting obstacles REV 8 4 5 C
17. LED is lit when contact BTZ2 is closed BTS1 LED is lit when contact BTS1 is closed vas rot Eror code ang tor raio remote convo Table 6 Operating mode controller Switch off the mains supply before altering the operating mode dip switches 1 9 Pre warning before opening VWA The warning light flashing or amber light illuminates right after a signal to open if pre warning time before opening is activated The barrier opens after the pre warning time has elapsed S1 off and S2 off No pre warning time S1 off and S2 on 1 5s pre warning time before opening S1 on and S2 off 4 05 pre warning time before opening Pre warning before closing 2 The warning light flashing or amber light goes on right after a signal to close if pre warning time before closing is activated The barrier closes after the pre warning time has elapsed S3 off No pre warning time before closing S3 on 4 05 pre warning time before closing Automatic closure ZLA The open barrier closes automatically after the programmed stay open time has elapsed An earlier closing of the barrier is possible by BT or BTZ Is a stop signal given during the stay open time then the automatic closure is blocked and is only released again by a new signal BTA1 BZA2 or LS keep the barrier in the end position open even after the stay open time has 28 8 4 4 8 4 5 8 4 6 8 4 7 8 4 8 KOLOSS 60 120 elapsed Th
18. N Drawing 14 16 Release the barrier by loosening the friction clutch and adjust the initial tension of the springs through the spanner nut The barrier boom should now open independently to 30 45 Adjust the friction clutch according to the table below 17 Tighten the friction clutch with the nut manually then retighten the nut using the number of revolutions as specified in the table below by torque wrench CE KOLOSS 60 KOLOSS 90 KOLOSS 120 engaging approx 2 approx 2 Ya approx 17 40Nm 45Nm 65Nm Table 4 REMARK The above specifications are only values for orientation and might have to be corrected individually REMARK Remove from the barrier all tools and supports used for installation 18 Start the programming mode as described 8 6 1 Running time and automatic closure During start up of the barrier check that the rotating direction is correct If necessary change the direction of motor rotation by swapping the motor connections X1 20 und X1 22 The controller is connected via plugs to the terminal row X1 in the barrier and to all the micro switches in the barrier head All electrical connections are carried out at the terminal row X1 21 ELKA KOLOSS 60 120 TA Adjusting the limit switches Drawing 15 1 Limit switch CLOSE 2 Limit switch OPEN The position boom UP and boom DOWN are factory pre adjusted by the limit switches After installation the
19. S is lit socket B3 2 red jumper is removed Plug the detector into from the terminals 6 and 10 the socket B3 or replace in socket B3 but the loop the red jumper detector hasn t been inserted 3 The photo cell is activated Check it X1 9 top and X1 9 bu The green LED The photo cell is connected as Connect the photo cell LS is lit when the normally open as normally closed photo cell is free and not lit when an obstacle is present The green LED There is a permanent signal to 1 Check the open BTA is lit open button X1 2 bottom and 1 6 top Check the loop detector in socket B2 The green LED 1 Faulty limit switch closed Replace the limit switch SEZ is out and the red diagnostic LED flashes 4 times then a break 2 Wiring fault Check the wiring and plug V6 in the control box The green LED There is a permanent signal to Check the button X1 7 BTZ2 is lit the terminals BTZ2 bottom and X1 2 bottom top Table 7 When the controller gives an error code through the red Diag LED see the chapter Error code 36 KOLOSS 60 120 Fault finding continued Symptom Possible solution Delay before opening Warning is active Operating mode switch 1 2 off Delay before closing Operating mode switch 3 off The barrier does the following when it hits an obstacle SWitches off Reversing is not Operating mode switch activated 5 off tries to carry
20. and at least one contact is closed the barrier cannot be opened constant closed Push button V15 5 X1 7b CLOSE 2 When the contact 22 is opening the order close is given Push button 15 6 X1 4t STOP1 When the contact BTS1 is closed the barrier stops Stored signals are erased Automatic closure is blocked until the next signal Push button n c V15 6 X1 8b STOP2 When the contact BTS2 is open the barrier stops Stored signals are erased Automatic closure is blocked until the next signal Photo cell n c V15 8 X1 9b When the photo cell reports an obstacle the barrier cannot be closed During the opening of the barrier an existing obstacle is not report When an obstacle is reported during closing the barrier stops and reverses Additional functions of the photo cell depend on operating mode photo cell closing automatic and photo cell test Further connections Photo cell V4 4 X1 26b Power supply for photo cell transmitter 24V 24V only for photo cell test 26 Photo cell transmitter Gnd Uext 124V Uext 12V Gnd Display barrier open Display barrier closed Motor OPEN Motor CLOSE Red traffic light Amber or flashing light Green traffic light L1 L1 V12 1 V12 2 V12 3 V12 4 V15 12 V15 13 V15 14 V2 1 V2 2 V2 3 V2 4 V2 5 V2 6 V2 7 V2 8 X1 26t X1 1b X1 3b X1 2b X1 11t X1 12t
21. c cable conduit for later cable installation Thereby observe the cable entry points in the barrier Prepare on the foundation the fixation for the barrier using the drilling template Use heavy duty dowels or chemical fixings 516mm Remove the packing and prepare the barrier for the installation to the provided foundation Remove both doors using the supplied key and the hood using the internal butterfly nut Drawing 4 1 Road 15 ELKA KOLOSS 60 120 AN drawing 5 5 Connect sufficiently dimensioned ropes or belts see weight 6 Technical Data KOLOSS 60 120 page 11 at the four eyebolts at the ground plate to lift the barrier by crane or hoisting device onto the foundation Drawing 6 6 After the barrier has been connected to the foundation at the nine arranged points loosen the spanner nut of the spring assembly completely so that the barrier mechanism is without mechanical connection to the spring assembly 16 ELKA KOLOSS 60 120 ew Drawing 7 ATTENTION During the next step the mechanism is moved electrically Make sure that the range of movement is free from obstacles 7 Remove the red security screw from the barrier mechanism Drawing 8 1 red security screw 8 Make the electrical connection and move the barrier into position CLOSED using the on off switch 17 KOLOSS 60 120 Drawing 9 9 Switch the barrier off using the on off switch main swit
22. ch Insert the boom with KOLOSS 90 120 observe the label Boom 14 into the boom assembly and fasten it with the four bolts M12x180 Drawing 10 18 KOLOSS 60 120 10 Insert the installation aid 1 into the boom notch Connect a rope of at last 10m length as installation aid to the boom to pull the barrier boom later again into position OPEN 11 Now release the barrier using the emergency release key at the left housing side and push the barrier up until it is in the vertical position Drawing 11 1 installation aid 2 rope on site 12 Engage the barrier again and secure the mechanism with the red screw through the ground plate Drawing 12 1 red security screw 13 Now connect the spring assembly to the mechanism again using thespanner nut Do not pretension the springs Remove the red securityscrew 14 Loosen the friction clutch anti clockwise Pull the barrier boom against the spring force into position CLOSED Secure the boom using suitable 19 ELKA KOLOSS 60 120 measures e g a weight of min 75kg in this position und engage the friction clutch clockwise The springs are now tightened Drawing 13 ATTENTION The boom must be secured e g with a weight of min 75kg REMARK For KOLOSS 60 continue at point 15 a 15 Remove the installation aid Now mount the connection profile and the 2 using the six bolts M12 x 160 20 ELKA KOLOSS 60 120
23. e barrier closes immediately when a signal BTA1 BTA2 or LS is removed S4 off No automatic closure S4 on The barrier closes after the time which was saved during the setup Os up to 3005 Reversal on hitting obstacles REV When learning the running time during the setup the torque power for the reversing on obstruction is determined When the barrier boom hits an obstacle during closing and blocks the controller stops the movement or gives an open signal S5 off The closing boom stops when it hits an obstacle and re opens immediately S5 on The closing boom stops when it hits an obstacle and only moves when a new signal is received Counting ZAHL The signals open and close are counted by the controller 56 off No counting The barrier closes after one signal to close even after two signals to open S6 on Counting is activated The barrier closes after two signals to close if there were two consecutive opening signals Reversal during opening SZ When a close signal is received during opening the barrier will either open completely and then close or the barrier closes immediately S7 off The barrier always opens completely before reacting to a signal to close S7 on The opening barrier reverses immediately when it receives a signal to close Automatic closure by photo cell LSA The photo cell always gives a signal to close when the obstacle is not longer present S8 off
24. ed to draw up the declaration ELKA Torantriebe GmbH u Co Betriebs KG Dithmarscher Str 9 25832 T nning Germany T nning 25 01 2012 i i V Guido Christiansen Dipl Ing FH Chief Engineer Attachment Requirements of annex I of 2006 42 EG which are met The numbers relate to the chapters of annex I 1 1 2 1 1 3 1 1 5 1 1 6 1 2 1 1 2 3 1 2 4 1 2 6 13 1 1 3 2 1 3 4 1 38 1 39 1 5 1 1 5 6 1 5 11 1 6 1 1 6 3 1 7 1 partially 1 7 2 1 7 3 1 7 4 partially Drawing 1 4 1 4 2 4 3 gt Hl KOLOSS 60 120 Installation information for partly completed machinery The partly completed machinery must not be put into service until the final machinery into which it has to be incorporated has been declared in conformity with the provisions of the machinery directive The safety functions of the controller comply with EN ISO 13849 1 2008 Kat 2 PLc According to EC Directive 2006 42 EG the mains supply has to be equipped with an all pole circuit breaker WARNING Danger through voltage Danger of an electric shock 5 Only certified electricians VDE 0100 should connect the controller to the mains supply According to DIN EN 12453 for an application with passenger traffic depending on the type of use and type of activation suitable safety devices have to be installed additionally in order to provide the minimum level of protection Declaration of conformity
25. mage if it is not avoided REMARK Important notice for installation or functioning Copyright The operating manual and the contained text drawings pictures and other depictions are protected by copyright Reproduction of any kind even in extracts as well as the utilization and or communication of the content without written release certificate are prohibited Violators will be held liable for damages We reserve the right to make further claims Information regarding installation instruction This document is to be used as installation instruction for partly completed machinery according to machinery directive 2006 42 EG article 13 2 2 2 2 3 2 4 KOLOSS 60 120 Safety General notes on safety The valid regulations and standards have to be observed during installation and operation e g DIN EN 13241 1 DIN EN 12445 DIN EN 12453 etc Only the use of spare parts made by the original manufacturer is allowed Do not put a defective gate opener barrier into operation After set up installation every user of the equipment has to be instructed about the operation and function of the gate opener barrier In order to reduce the risk potential related to the movement of the barrier boom additional optical and or acoustical warning devices should be installed Notes on safety for the operation Children and not instructed persons are not allowed to operate the gate system barrier No persons objects
26. n Symptom Possible solution The yellow power LED No mains supply Check the mains lead is out and the fuses red diagnostic LED Programming is started Carry it out to the end flashes non stop The green LED 51 is The controller is Switch On Off switch lit switched off X1 4 top and X1 4 bottom off The greenLED BTS2is 1 The stop button is Release the button out pressed X1 8 top and bottom 2 Emergency release Lock the shaft in use 13 Wiring fault Check the wiring green LED SEA is 1 Faulty limit switch Replace the limit switch out and the red Diag open LED flashes 4 times then a break 2 Wiring faulty Check the wiring to the limit switch and plug V6 on the controller The green LED BTZ1 is There is a permanent Check the button X1 2 lit signal to close bottom top and 7 top When the controller gives an error code through the red Diag LED see the chapter Error code ATTENTION With the barrier type KOLOSS the LED BTS2 is not lit when the 1 emergency release key is attached at the gearbox or when the emergency release flap is open 35 KOLOSS 60 120 The open barrier doesn t react to signals to close The yellow power No mains supply Check the mains lead LED is out and the fuses The red Programming is started Carry it out to the end diagnostic LED flashes non stop The green LED 1 Loop detector is activated Check the detector in L
27. n Baum unten 2 ja 5 lt al 5 k 6000 ues Z 5 3 5 pra 2 a E Z 5 3 O m m o 9 za Drawing 19 32 KOLOSS 60 120 Important instructions when using loops for safety and closing When using a loop detector for safety remove the red jumper between contacts 6 and 10 on the socket B3 The socket B3 is always for the loop under the barrier boom and is prewired for safety and for closing when leaving the loop When B3 is equipped with a 2 channel detector the second channel may be used for an opening loop or a loop detecting that a vehicle is present The socket B2 is prewired for an opening loop in connection with a 1 channel detector Please see chapter Examples for use of loop detectors When all connections are completed and the barrier is closed only the following LEDs should be lit the yellow LED Vp for main power the green LED SEA and the green LED BTS2 If is not the case then see chapter Fault finding WARNING The reversal by obstruction can only work when the rod always moves to the rear of the housing never to the door gt Please check the direction of rotation of the transmission lever of the gearbox 33 KOLOSS 60 120 X1 ii di lt ATI IR In iil nal ji Hia nisl T Drawing 20 34 ELKA KOLOSS 60 120 11 Fault finding 11 1 closed barrier doesn t react to signal to ope
28. op B3 1 closing with both loops B3 1 or B2 Exit opening with loop B2 safety and closing with B3 1 Remove red jumper of socket B3 and jumper between the terminals 27 bottom and 6 bottom 40 Drawing 26 min 1000mm max 1500mm Aj KOLOSS 60 120 41 13 KOLOSS 60 120 Maintenance Maintenance KOLOSS 60 120 The maintenance intervals depend on the application and the frequency of operation Suggested maintenance is every 3 months The springs are designed for approx 100 000 movements 1 Check the spring assembly After more than 100 000 movements or if one or more springs are broken all springs have to be replaced completely 2 Make sure the boom is well balanced by the springs if necessary adjust the spring tension 3 Check barrier housing boom assembly boom connector and boom for accidents or other damage replace if necessary 4 Check the horizontal and vertical position of the boom adjust the limit switches if necessary 5 Make a visual inspection and retighten all screws if necessary 6 Check the potential equalisation for door and housing PE connection present 7 Check if installation and operating instructions are still complete 8 Check the safety devices and safety functions induction loop photo cell reversing function etc Check the barrier anchorage in the foundation 10 Grease the pillow block bearings and swivel heads with bearing grease min 25 to 1
29. or animals are allowed within the range of the gate movement barrier movement during opening or closing Never reach into moving parts of the gate operator gate or barrier Drive through the gate system barrier only after complete opening The gate system barrier has to be secured depending on the type of usage corresponding to the valid standards and regulations e g safety at the main and secondary closing edges The safety devices have to be checked regularly for functioning according to the standards and regulations at least once a year Safety notes for the operation with radio remote control The radio remote control should only be used if the area of movement of the gate barrier is always completely visible by the operator and thus it is assured that no person object or animal is present within this range of movement The radio remote control transmitters have to be carefully kept so that an unintentional use is impossible Radio remote controls should not be operated at radio technical sensitive locations like airports or hospitals Interferences by other properly operated radio communication installations which are used within the same frequency range cannot be ruled out Intended use The operational safety can only be ensured when the barrier is used as intended After installation the barriers of the series KOLOSS 60 120 serve as passage control of vehicle paths The controller is a component part of
30. ounting ZAHL 8 4 6 Reversal during opening SZ NNN N O mah NM NM N N N N N N N N N N N O O 8 4 7 8 4 8 8 5 8 6 8 6 1 8 6 2 10 11 11 1 11 2 11 3 11 4 12 13 14 14 1 15 15 1 15 2 15 3 KOLOSS 60 Automatic closure by photo cell LSA Photo cell test LSTST Photo cell test Programming Running time and automatic closure Personal code for radio remote External connections Layout in the barrier Fault finding The closed barrier doesn t react to a signal to open The open barrier doesn t react to signals to close Fault finding continued Error code Examples for use of loop detectors Maintenance Extra equipment Fixed support with electromagnet Layout KOLOSS 60 120 Layout KOLOSS 60 Layout KOLOSS 90 Layout KOLOSS 120 120 29 29 30 30 31 31 32 34 35 35 36 37 38 39 42 43 43 45 45 47 49 1 1 KOLOSS 60 120 Preface General notes These operating instructions must be available on site at all times It should be read thoroughly by all persons who use or service the appliances Improper usage or servicing or ignoring the operating instructions can be a source of danger for persons or result in material damage If the meaning of any part of these instructions isn t clear then please contact ELKA Torantriebe GmbH u Co Betriebs KG before yo
31. ration of incorporation for the installation of a partly completed machinery according to EC Machinery Directive 2006 42 EC annex part 1 B The manufacturer ELKA Torantriebe GmbH Co Betriebs KG Dithmarscher Str 9 25832 Tonning Germany We herewith declare that the partly completed machinery Product description Barrier Function Barrier for passage control of traffic ways designation KOLOSS 60 KOLOSS 90 KOLOSS 120 Serial number 8048000001201001 to 8048099991252999 for KOLOSS 60 8048200001201001 to 8048299991252999 for KOLOSS 90 8048400001201001 to 8048499991252999 for KOLOSS 120 Year of manufacture 2012 complies with the essential requirements of the following directive as far as possible with the scope of delivery see attachment for information regarding which requirements are met 2006 42 EG Machinery Directive 2006 95 EG Low Voltage Directive 2004 108 EG EMC Directive The following harmonized standards are applied EN ISO 12100 2 2004 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 60204 1 2007 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 60335 1 2002 A11 2004 A1 2004 A12 2006 A2 2006 A13 2008 A14 2010 Safety of household and similar electrical appliances part 1 General requirements resultant EN 61000 3 2 2006 A1 2009 A2 2009 Limits for harmonic current emissions EN 61000
32. relay e 43 KOLOSS 60 120 OPERATION 1 2 3 The relay switches off on receipt of a signal to open The magnet loses it s residual magnetism during the 1 5 seconds warning time The barrier opens after the 1 5 seconds The magnet switches on again when the barrier reaches the limit switch at the closed position 44 ELKA KOLOSS 60 120 15 Layout KOLOSS 60 120 15 1 Layout KOLOSS 60 FEN 3 NA DO 69 Drawing 29 Pos Qty Part name 1 1 Base frame 2 1 Main shaft 3 1 Motor gearbox KOLOSS 60 4 1 Mounting plate 5 1 Spring assembly KOLOSS 60 6 1 Cover frame right 7 1 Cover frame left 8 1 Hood 9 2 Boom holder support 10 1 Cover with door 11 1 Cover with door Table 10 45 KOLOSS 60 120 Drawing 30 Pos 1 2 3 4 Table 11 Stck Part name KOLOSS 60 Boom 6m Packing Accessories KOLOSS 60 46 ELKA 15 2 KOLOSS 60 120 Layout KOLOSS 90 Drawing 31 Pos Qty Part name 1 1 Base frame 2 1 Main shaft 3 1 Motor Gearbox KOLOSS 90 4 1 Mounting plate 5 1 Spring assembly KOLOSS 90 6 1 Cover frame right 7 1 Cover frame left 8 1 Hood 9 2 Boom holder support 10 1 Cover with door 11 1 Cover with door Table 12 47 KOLOSS 60 120 Drawing 32 Pos 1 2 3 4 Table 13 Qty 2 Part name KOLOSS 90 Packing Accessories KOLOSS 90 Boom 9m 48 ELKA KOLOSS 60 120 15 3 Layout KOLOSS 120
33. rements w I h Company entrance Safety area Industrial entrance etc Push button card reader desk top panel Radio remote control transmitter Hands free data capture Induction loop Emergency release Vandalism protection through friction clutch Connection of external safety systems 230V 50Hz 10A max 100 10 C to 70 C MO 63 656x720x1250mm Foundation frost proofed 1200x1200x1200mm Boom connector Housing Mechanical parts Degree of protection Table 2 central aluminium steel zinc coated lt 60 dB A IP 44 11 KOLOSS 60 120 Effective length mm 12 000 12000 support Totalweight kg 452 508 547 Table 3 12 KOLOSS 60 120 concrete B25 by customers Drilling template barrier housing 1200x1200x1200 Hole pattern fixed support Drawing 2 KOLOSS 60 120 Interior view ZA PT 2 lt Drawing 3 1 Mains power outlet 2 Controller 3 On Off switch 4 OPEN CLOSE switch 5 Limit switch REMARK For the barrier foundation we recommend a concrete strength class of 20 25 or higher and the use of chemical dowels M16 14 KOLOSS 60 120 Prepare a foundation with the measurements 1 200 x 1 200mm The foundation has to be frost free and with a horizontal surface which must be a least 30mm higher than the surrounding surface Before preparing the foundation lay enough cable or a plasti
34. t X1 26b 1 15 X1 2b X1 9t X1 9b Terminal X1 Drawing 18 For the photo cell test the controller MO 63 has to learn the quantity of photo cells which are connected by activating the dip switch 59 on and learning the running time again Programming The controller has to learn the following parameters e Running time for opening and closing Torque power for reversal on hitting an obstruction e Quantity of photo cells when the photo cell test is activated Time to stay open for automatic closure e Personal code for radio remote control 30 ELKA 8 6 1 8 6 2 8 6 2 1 8 6 2 2 KOLOSS 60 120 Running time and automatic closure 1 Push the learn button approx 3 seconds the red Diag LED starts flashing 2 Push the learn button again When the photo cell test is activated 59 the controller learns how many photo cells are connected During learning the Diag LED flashes at 1 second intervals then the learning of the running time starts automatically When the photo cell test is not activated S9 off the learning of the running time starts immediately 3 The Diag LED is lit during the learning of the running time The barrier closes if it is not closed already If it is closed then it opens and learns the running time for opening Then the Diag LED flashes at 1 second intervals and the controller learns the stay open time 4 After the required stay open time push the learn button again The barrier
35. u use the appliance This applies to all setup procedures fault finding disposal of material care and servicing of the appliance The accident prevention regulations and applicable technical regulations e g safety or electrical and environment protection regulations of the country in which the appliance is used also apply All repairs on the appliances must be carried out by qualified persons ELKA Torantriebe GmbH u Co Betriebs KG accepts no liability for damage which is caused by using the appliance for purposes other than those for which it is built ELKA Torantriebe GmbH u Co Betriebs KG cannot recognise every possible source of danger in advance If the appliance is used other than in the recommended manner the user must ascertain that no danger for himself or others will result from this use He should also ascertain that the planned use will have no detrimental effect on the appliance itself The appliance should only be used when all safety equipment is available and in working order All faults which could be a source of danger to the user or to third persons must be eliminated immediately All warning and safety notices on the appliances must be kept legible All electrical periphery equipment which is connected to the appliance must have a CE Mark which ensures that it conforms to the relevant EEC regulations Neither mechanical nor electrical alterations to the appliance without explicit agreement of the manufacturer are
36. w bujesadg Ed Sa Barrier open Barrier closed common an NAB SEA SEZ Transformer No boom M063 V2 Photo cell test 24 26V dc max 500 mA 12Vdc max 500 mA Motor Red light Green light Amber or flashing light N L1 N max 120W 230V 50Hz Drawing 17 EE 2 8 1 8 2 KOLOSS 60 120 Connections BT BTA1 BTA2 BTZ1A BTZ2 BTS1 BTS2 LS Single push n o V15 1 X1 5t button With the serial switching BT the barrier can be opened and closed Additional functions of BT depend on setting of the dip switches for automatic closure S4 and the counter settings S6 When the automatic closure is activated or the counter is deactivated then the barrier can be closed by BT otherwise the barrier will be opened When the automatic closure is blocked e g by a stop signal and the counter is activated then BT can only open the barrier Which means that closing by BT is not possible Push button OPEN n o V15 2 X1 6t and V15 3 X1 6b 1 2 When of the contacts 1 2 is open and the other is closing the barrier opens When the barrier is open and 1 or BTA2 is being closed then the barrier cannot be closed constant open Push button n o V15 4 X1 7t and V15 9 X1 10b CLOSE 1A and 1B When BTZ1A closes while BTZ1B is open or BTZ1B closes while BTZ1A is open the barrier closes When the barrier is closed
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