Posidrive Security Gate Installation, Operation, And Maintenance Manual

Transcript

PosiDRIVE Security Gate Installation, Operation, and Maintenance Manual Safety Notice To reduce the risk of severe personal injury or damage to equipment, turn off the power to the equipment before performing any maintenance or repairs. Failure to heed this warning could result in injury or even death of those who come in contact with the product. People’s lives and property depend on your safe installation and maintenance of equipment. Listed below are some important safety instructions and precautions which you should follow when working on any Federal APD equipment. Failure to follow all safety precautions and instructions can result in serious injury or property damage. Refer to the specific operational manual for a particular piece of equipment before beginning any service work. ❑ ❑ Frequently inspect the equipment to ensure that it is operating properly. Ensure that maintenance is performed by the factory or an authorized distributor at least twice a year. Safety Hints ❑ ❑ ❑ ❑ ❑ Use vibrant colors on parking equipment at entrance lanes and exit lanes. Always provide proper signage, both on the roadway and on other equipment. Maintain the manufacturer’s warning stickers on gate arms and on other equipment. Encourage the use of safety devices such as buzzers or flashing lights. Always recommend that sidewalks be parallel to entrance lanes and exit lanes. Safety Notice To prevent injury to pedestrians, maintenance personnel, persons on bicycles or motorcycles, monitor all activity in relation to entrance and exit lanes to ensure barrier gates are not accidentally lowered or raised. Take special care when commanding any equipment action from a centralized computer system, especially when the control equipment is not in your line of vision. Use Pictograms Federal APD, Inc. recommends using universally identifiable icons, or pictograms, in all entrance and exit lanes, roadways, posts and walls. Paint “No Pedestrian” pictogram on the roadway adjacent to the parking barrier gate. Pictograms depicting “No Motorcycles,” “No Wheelchairs,” “No Bicycles,” and “No Trucks” are also recommended. Safety Is Good Business As an institution, municipality, or private operator, it is important to be aware of the potential liabilities which may arise in normal parking operations. Adapting a “Safety First” attitude provides your business and your patrons with a safer environment. After all, safety is good business! COPYRIGHT PosiDRIVE Security Gate Version 6 ZMA-330 © 2008-2009 Federal APD, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of Federal APD, Incorporated. Printing Date First Version ..............................................July 2000 Second Version..........................................December 2000 Third Version.............................................February 2001 Fourth Version...........................................July 2001 Fifth Version..............................................December 2003 Sixth Version .............................................June 2009 Warranty Information Federal APD, Inc. warrants that the Products will be free from any defects in material and workmanship under normal use and service, wear and tear excepted, for a period of two years from the date of shipment from Federal APD. Exceptions to this warranty may include any products and/or accessories that are used with Federal APD equipment but are not manufactured by Federal APD Inc. In those instances where Federal APD is not the manufacturer of goods sold hereunder, Federal APD's warranty shall be the lesser of such manufacturers' warranty, or Federal APD's standard warranty. This warranty shall not apply to Products which have not been properly maintained or have been subjected to misuse, neglect, accident or damage, or which have been modified, changed, or reworked in any way, without prior written approval of Federal APD. Federal APD's sole obligation shall be to repair or replace, at Federal APD's option, any defective part or parts within such two year period. Upon Federal APD's written instructions, allegedly defective goods shall be returned to Federal APD for inspection. This warranty extends only to the original purchaser from Distributor/Dealer and shall not cover repair, labor, or replacement of parts that are by nature expendable. Distributor/Dealer agrees to deliver the Federal APD Limited Warranty then in effect to each of its customers at the time of the sale. Distributor/Dealer shall have no authority to bind Federal APD to any warranty beyond that extended therein. All Products are subject to design and/ or appearance modifications which are production standards at the time of shipment. Federal APD may, but shall not be required to, modify or update Products shipped prior to a current production standard. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL FEDERAL APD BE LIABLE FOR ANY LOSS OF PROFITS OR ANY INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF FEDERAL APD'S BREACH OF THIS WARRANTY OR ANY OTHER TERM OR CONDITION OF THIS AGREEMENT. Table of Contents CHAPTER 1 Introduction .................................................................................................................................... 1 PosiDRIVE Security Gate Operational Overview ..................................................................... 2 Manual Operation................................................................................................................ 2 Automatic Operation ........................................................................................................... 2 Free Mode ..................................................................................................................... 3 Pay Mode ...................................................................................................................... 4 Pay/Free Mode .............................................................................................................. 5 Power Failure Detection ...................................................................................................... 6 PosiDRIVE Structural Overview ............................................................................................... 6 Gate Enclosure (Cabinet) .................................................................................................... 6 Mechanical Components ..................................................................................................... 7 Drive Mechanism .............................................................................................................. 10 Electrical Components....................................................................................................... 10 Gate Arm ........................................................................................................................... 13 PosiDRIVE Controller....................................................................................................... 14 DIP Switches............................................................................................................... 15 Inputs........................................................................................................................... 15 Outputs........................................................................................................................ 16 Opening the Enclosure Door.................................................................................................... 16 Removing the Enclosure Cap................................................................................................... 16 CHAPTER 2 Installation..................................................................................................................................... 19 Installation Overview............................................................................................................... 20 Installing the Enclosure............................................................................................................ 20 Wiring the Gate........................................................................................................................ 23 Installing the Gate Arm............................................................................................................ 25 Install a Standard Gate Arm .............................................................................................. 26 Install a Folding Gate Arm ................................................................................................ 27 Change the Gate Arm Configuration................................................................................. 34 Setting the Mainsprings ........................................................................................................... 38 Disabling the Locked-Down Feature (Optional) ..................................................................... 40 Setting the DIP Switches.......................................................................................................... 42 CHAPTER 3 Maintenance and Repair.............................................................................................................. 45 Maintenance and Repair Overview.......................................................................................... 46 Performing Preventive Maintenance........................................................................................ 46 Grease Mainshaft Bearings................................................................................................ 47 Grease the Connection Rod Bearings................................................................................ 47 Troubleshooting a Problem...................................................................................................... 48 Locking, Unlocking, and Advancing the Gate Arm ................................................................ 49 Adding, Removing, or Replacing the Mainsprings.................................................................. 52 Aligning the Drive Mechanism................................................................................................ 54 PosiDRIVE Security Gate ZMA-330, Ver. 6 Table of Contents • i APPENDIX A Product Support............................................................................................................................57 Getting Help .............................................................................................................................58 Accessing the Distributor Resource Center..............................................................................59 APPENDIX B Order and Repair Procedures .....................................................................................................61 Placing an Order.......................................................................................................................62 Requesting a Repair..................................................................................................................62 Locate a Part Number ........................................................................................................63 Mainsprings .................................................................................................................64 Enclosure .....................................................................................................................65 Electrical Components ................................................................................................68 Standard Gate Arm......................................................................................................70 Folding Gate Arm........................................................................................................73 Drive Mechanism ........................................................................................................78 Index ..............................................................................................................................................83 ii • Table of Contents ZMA-330, Ver.6 PosiDRIVE Security Gate List of Figures Figure 1.1 Free Gate with Opening Loop...................................................................................... 3 Figure 1.2 Pay Gate ....................................................................................................................... 4 Figure 1.3 Pay/Free Gate ............................................................................................................... 5 Figure 1.4 Enclosure Components................................................................................................. 7 Figure 1.5 Mechanical Components .............................................................................................. 8 Figure 1.6 Electrical Components ............................................................................................... 11 Figure 1.7 Standard Gate Arm..................................................................................................... 13 Figure 1.8 Folding Gate Arm....................................................................................................... 14 Figure 1.9 PosiDRIVE Controller ............................................................................................... 14 Figure 1.10 Draw Latch............................................................................................................... 17 Figure 2.1 PosiDRIVE Security Gate Footprint Dimensions...................................................... 21 Figure 2.2 Gate Cabinet Warning Label (Part # 20-3469) .......................................................... 22 Figure 2.3 Wiring with the Federal APD Detector Harness........................................................ 24 Figure 2.4 Wiring with a Non-Federal APD Detector Harness................................................... 25 Figure 2.5 Standard Gate Arm Installation.................................................................................. 26 Figure 2.6 Gate Arm Warning Label (Part # 20-4343) ............................................................... 27 Figure 2.7 Dimensions for Folding Gate Arm Mounting Hole ................................................... 28 Figure 2.8 Installing the Cable Tower ......................................................................................... 29 Figure 2.9 Attaching the Fixed Section of the Folding Gate Arm to the Gate Flange ................ 30 Figure 2.10 Attaching the Folding Section to the Gate Arm Stabilizer....................................... 31 Figure 2.11 Attaching the Stabilized Folding Section to the Gate Arm Fixed Secton................ 32 Figure 2.12 Attaching the Cable Turnbuckle to the Gate Arm.................................................... 33 Figure 2.13 Gate Arm Configuration Components ..................................................................... 34 Figure 2.14 Pivot Bar................................................................................................................... 35 Figure 2.15 Set Screws ................................................................................................................ 36 Figure 2.16 Mainshaft Removal .................................................................................................. 36 Figure 2.17 Spring Adjustment Bolts .......................................................................................... 39 Figure 2.18 Down Bump Stop ..................................................................................................... 41 Figure 2.19 DIP switches in the Open Position........................................................................... 42 Figure 3.1 Motor Crank Position when the Gate Arm is Down .................................................. 51 Figure 3.2 Motor Crank Position when the Gate Arm is Up ....................................................... 51 Figure 3.3 Mainspring Connection Bar ....................................................................................... 53 Figure 3.4 Mainspring Attachment Points................................................................................... 53 Figure 3.5 Drive Mechanism Alignment ..................................................................................... 55 Figure B.1 Mainspring Parts........................................................................................................ 64 PosiDRIVE Security Gate ZMA-330, Ver. 6 List of Figures • iii Figure B.2 Enclosure Cap Parts ................................................................................................... 65 Figure B.3 Enclosure Door Parts ................................................................................................. 66 Figure B.4 Enclosure Cabinet Parts ............................................................................................. 67 Figure B.5 Electrical Sub-Panel Parts.......................................................................................... 68 Figure B.6 Detector Bracket and Backup Battery Assembly Parts.............................................. 70 Figure B.7 Standard Gate Arm Parts ........................................................................................... 71 Figure B.8 Folding Gate Arm and Stabilizer Parts ...................................................................... 73 Figure B.9 Folding Gate Arm Cable Tower Parts ....................................................................... 75 Figure B.10 Folding Gate Arm Adapter and Fixed Section Parts ............................................... 76 Figure B.11 Folding Gate Arm Packages .................................................................................... 77 Figure B.12 Drive Mechanism Installation Parts......................................................................... 78 Figure B.13 Drive Mechanism Frame Parts (View 1) ................................................................. 79 Figure B.14 Drive Mechanism Parts (View 2) ............................................................................ 80 iv • List of Figures ZMA-330, Ver.6 PosiDRIVE Security Gate CHAPTER 1 Introduction This chapter contains the following topics: PosiDRIVE Security Gate Operational Overview ..............................................2 Manual Operation .........................................................................................2 Automatic Operation.....................................................................................2 Free Mode ..............................................................................................3 Pay Mode................................................................................................4 Pay/Free Mode .......................................................................................5 Power Failure Detection ...............................................................................6 PosiDRIVE Structural Overview ........................................................................6 Gate Enclosure (Cabinet)..............................................................................6 Mechanical Components...............................................................................7 Drive Mechanism........................................................................................10 Electrical Components................................................................................10 Gate Arm.....................................................................................................13 PosiDRIVE Controller................................................................................14 DIP Switches ........................................................................................15 Inputs....................................................................................................15 Outputs .................................................................................................16 Opening the Enclosure Door .............................................................................16 Removing the Enclosure Cap ............................................................................16 PosiDRIVE Security Gate ZMA-330, Ver. 6 Introduction • 1 PosiDRIVE Security Gate Operational Overview The PosiDRIVE Security Gate is a low-maintenance security gate, with a microprocessor-based controller that protects roadways up to 20 feet (6 m). The PosiDRIVE gate has a variable operating time, from 1.5 to 6 seconds, depending on the length of the gate arm. The gate is capable of operating in an ambient temperature of -30°F (-34°C) to 140°F (60°C) without any adjustments. It can be configured as a righthand or left-hand flange gate without any additional hardware. The PosiDRIVE Security Gate works with several types of vend devices, such as vehicle detection loops, card reading devices, or ticket issuing devices. The gate controller inputs support both manual and automatic operation. Manual Operation For manual operation a toggle switch is wired into the Raise/Lower input on the gate controller (Figure 2.3, on page 24). When the toggle switch is placed in the “raise” position (i.e., the circuit is completed), the gate arm raises and remains in the up position until the toggle switch is moved to the “lower” position. Automatic Operation For automatic operation, one or more vend devices are wired into the Vend input on the gate controller (Figure 2.3, on page 24). Depending on the vend device(s), the lane runs in one of the following modes: ■ ■ ■ “Free Mode” on page 3 “Pay Mode” on page 4 “Pay/Free Mode” on page 5 For all automatic operation modes, a vehicle detection loop that resides under the gate arm (loop B) is wired into the B Presence input on the gate controller. The gate automatically lowers when the patron pulls off of the loop B. 2 • PosiDRIVE Security Gate Operational Overview ZMA-330, Ver.6 PosiDRIVE Security Gate Free Mode Free mode is used in a single-direction lane through which a patron enters or exits the facility free of charge. This mode requires two vehicle detector loop inputs: loop A and loop B. When a vehicle pulls onto the loop A, the gate arm raises. The gate arm lowers after the vehicle clears loop B. Figure 1.1 Free Gate with Opening Loop Loop B Loop A 1'-6" (.46 m) 1'-6" (.46 m) 6' (1.8 m) 2'-6" (.76 m) B 5' (1.5 m) MAX. 2'-6" (.76 m) A TRAFFIC FLOW PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Security Gate Operational Overview • 3 Pay Mode Pay mode is used in a single-direction lane in which controlled access is required to enter or exit the facility. This mode requires a vehicle detection loop (loop B) and a vend-device such as a card reader or a switch that a booth attendant uses to raise the gate. The gate arm lowers after the vehicle clears loop B. Note: An additional loop (loop A) may be used to enable the vend device, for example, the lane may contain a ticket issuing device that is activated when the patron pulls onto loop A. Figure 1.2 Pay Gate Vend Device Loop B Loop A (optional) 1'-6" (.46 m) 1'-6" (.46 m) 6' (1.8 m) 2'-6" (7.6 m) B 8'-3" (2.5 m) 9'-6" (2.9 m) 2'-6" (.76 m) A TRAFFIC FLOW 4 • PosiDRIVE Security Gate Operational Overview ZMA-330, Ver.6 PosiDRIVE Security Gate Pay/Free Mode Pay/free mode is used in a dual-direction lane. It requires two vehicle detection loops (loop A and loop B) and a vend-device such as a card reader. In the free direction, vehicle presence on loop A vends the gate. In the pay direction, the vend-device vends the gate. In either direction, the gate arm lowers after the vehicle clears the loop B. Figure 1.3 Pay/Free Gate Vend Device Loop B Loop A 1'-6" (.46 m) TRAFFIC FLOW IN 1'-6" (.46 m) 1'-6" (.46 m) 9'-6" (2.9 m) 6' (1.8 m) 2'-6" (.76 m) B 5' (1.5 m) 2'-6" (.76 m) A TRAFFIC FLOW OUT PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Security Gate Operational Overview • 5 Power Failure Detection The PosiDRIVE controller is able to sense when there is a power failure. If the controller is programmed to raise the gate arm during a power failure, the controller uses the power from backup battery assembly to raise the gate arm automatically. The gate arm stays in the up position until the power is restored. Note: If the controller is not programmed to automatically raise the gate, the gate must be raised manually. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. PosiDRIVE Structural Overview This section describes the following PosiDRIVE components: ■ ■ ■ ■ ■ ■ “Gate Enclosure (Cabinet)” on page 6 “Mechanical Components” on page 7 “Drive Mechanism” on page 10 “Electrical Components” on page 10 “Gate Arm” on page 13 “PosiDRIVE Controller” on page 14 Gate Enclosure (Cabinet) Federal APD, Inc. builds the PosiDRIVE gate enclosure using 0.090 inch galvanized steel. The enclosure is weather resistant and allows proper operation in all weather conditions and temperatures ranging from -30°F (-34°C) to 140°F (60°C). Louvres on the back and cutouts on the four bottom corners of the enclosure provide air circulation, thus preventing excessive moisture buildup. The enclosure is 15 inches W x 16 inches D x 42 inches H (38 cm W x 41 cm D x 107 cm H), finished in yellow or white powder coat paint. The enclosure consists of two pieces, a base and a removable cap. The base houses the power supply and electronics package as well as provides the main structure of the enclosure. In addition, the base provides reinforced flanges for installation, hookup points for the mainsprings, and mounting provisions for the drive mechanism. Figure 1.4 illustrates the main components of the gate enclosure. The enclosure cap is a removable piece that provides easy access to the drive mechanism without disrupting the operation of the gate. Inspection and maintenance can be performed easily by removing the enclosure cap. It is secured by four draw latches to the base, requiring no tools to remove or install. See “Removing the Enclosure Cap” on page 16. 6 • PosiDRIVE Structural Overview ZMA-330, Ver.6 PosiDRIVE Security Gate Figure 1.4 Enclosure Components Enclosure Cap Enclosure Base Gate Arm Enclosure Door Mechanical Components The PosiDRIVE gate is powered by a 150 watt, 24 VDC brushless DC gear motor. The motor is connected directly to a fully sinusoidal four-bar drive mechanism. A sinusoidal mechanism has the distinct advantage of providing smooth, progressive acceleration and a mechanical advantage at the limits of travel, where it is needed most. This arrangement eliminates the need for Vee-belts and their associated maintenance. One advantage of a brushless DC motor is that the gate can adjust the speed of the entire system depending on the size of the arm installed. Therefore, the same motor and gearbox can be used in all situations, allowing the flexibility of using any size gate arm. Another advantage to the brushless DC motor is the ability of the gate to know where the gate arm is at all times. The motor provides an output that is monitored by the controller. The controller interprets the signals to determine arm position and speed. Using this information, the PosiDRIVE gate operates like a full servo system, providing benefits such as not requiring mechanical contact to limit its travel, no limit switches, and an extremely sensitive collision detect system. The PosiDRIVE gate uses as many as four internal extension mainsprings to counterbalance the weight of the gate arm. The number of mainsprings and their adjustment must be properly set at the time of installation in order for the gate to function properly. When correctly set, these mainsprings offset the torque on the mechanism created by the weight of the arm, providing a safe, balanced system which greatly reduces the power required by the motor and increases the efficiency of the gate. Figure 1.5, on page 8 shows the PosiDRIVE mechanical components. Component descriptions follow the illustration. PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Structural Overview • 7 Figure 1.5 Mechanical Components Mainshaft Crank Part 1 Mainshaft Crank Part 2 Mainspring Adjustment Bolt Mainspring Pivot Bar Mainspring Crank Mainshaft Bearing Mainshaft Mechanism Frame To prevent a serious pinching injury including dismemberment, use care when working with the drive mechanism and alway terminate power prior to performing maintenance or repairs. Connecting Rod Motor Crank Mainspring Connection Bar Mainspring Table 1.1 Mechanical Component Descriptions Component Mechanism Frame 8 • PosiDRIVE Structural Overview Description Steel frame that forms the foundation for the PosiDRIVE mechanism. All of the drive components, including the motor and mainshaft are attached to the mechanism frame. ZMA-330, Ver.6 PosiDRIVE Security Gate Table 1.1 Mechanical Component Descriptions (Continued) Component Description Motor 24 VDC gear motor that powers the PosiDRIVE gate. The motor and gear box are contained in a single sealed housing for simplicity and maintenance-free operation. Motor Crank Link that is attached to the output shaft of the motor. This link is attached to the motor shaft by means of a friction clamp but also includes a keyed shaft to prevent slipping under all conditions. Connecting Rod Intermediate link in the PosiDRIVE system. The connecting rod incorporates two high quality spherical bearings for maximum life and excellent tolerance to misalignment. Mainshaft Crank Part 1 One of two combined pieces that attach to the mainshaft and provide the driving force to the mainshaft. Mainshaft Crank Part 2 The second of the main driving links. This piece is also designed to serve as an attachment point for the spring system. It incorporates a single high quality deep groove ball bearing that one end of the mainspring pivot bar rests in. Mainspring Crank Other link attached to the mainshaft that serves as the second attachment point for the spring system. Mainspring Pivot Bar Bar that rides in the pair of ball bearings in the mainshaft. It links and supports the mainspring adjustment bolts. Mainspring Connection Bar Bar to which the mainsprings are attached. The connection bar incorporates four shallow grooves to keep the mainsprings properly positioned. Mainspring Adjustment Bolts The two long bolts that connect the mainspring connection bar to the mainspring pivot bar. They provide the means to fine-tune the spring tension to a given arm. Mainshaft Shaft that carries the gate arm at one end and to which the driving links are attached. Mainshaft Bearings Large bearings mounted to the sides of the mechanism frame that carry the mainshaft. Gate Arm Flange Arm carrier that is attached to the end of the mainshaft. PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Structural Overview • 9 Drive Mechanism The drive mechanism in the PosiDRIVE gate is a direct drive, sinusoidal mechanism. This system provides a substantial mechanical advantage for the motor at the beginning and ending of a cycle when it is most needed. The result of this is that when the gate is at the extreme limits of travel, in the “full down” or “full up” position, the mechanism is “locked” and cannot be manually advanced by pushing the gate arm. In other words, at the full up and full down positions, the mechanism cannot be driven or advanced by any torque applied to the mainshaft. When servicing the PosiDRIVE gate, you must be aware of this. There are times, such as when setting the mainsprings, when you must operate the mechanism by hand, using the gate arm. It is also necessary at times during this procedure and others to ensure that the linkage is in the fully locked up position for safety. Raising the gate arm by hand will NOT bring the linkage into this position. It will bring it closed, but it will not be fully locked. In order to lock the mechanism, you must always advance the mechanism by hand for the last few degrees of travel. That is, if you raise or lower the arm by hand to what feels like the limits of its travel, the mechanism still must be manually advanced a small amount to ensure that it is in the locked position. If the mechanism is already locked, either up or down, then it becomes impossible to get it out of this position by moving the gate arm. The mechanism must be manually advanced out of the locked position before moving the gate arm. This is a side effect of the sinusoidal linkage and the variable mechanical advantage the system provides. For instructions on manually advancing the mechanism into and out of the locked positions, see “Locking, Unlocking, and Advancing the Gate Arm” on page 49. Electrical Components The use of a 24 VDC motor in the PosiDRIVE gate provides several electrical benefits. First, by using a low (non-hazardous) voltage throughout the system, the risk of shock to service personnel is greatly reduced. The PosiDRIVE gate utilizes a universal input 24 volt power supply. This supply can accept input voltages anywhere from 85 VAC to 264 VAC at 50 or 60 Hz. This allows the PosiDRIVE gate to be installed into virtually any voltage environment without modification, providing maximum flexibility. The nameplate rating for power consumption is 2 amps for 115 VAC and 1 amp for 220 VAC. The PosiDRIVE gate is also equipped with a backup battery assembly, which provides power to the controller and motor in the event of a power failure to allow the PosiDRIVE gate to raise the arm. It is not intended to operate the gate in a power failure mode, but just to provide the option of raising the gate to allow patrons to exit. It also does not power any loop circuits. Automatically raising the gate during a power failure is a configurable option. See “Setting the DIP Switches” on page 42. 10 • PosiDRIVE Structural Overview ZMA-330, Ver.6 PosiDRIVE Security Gate The PosiDRIVE gate can detect a line power failure and will wait (operating on battery power) for a period of 10 seconds before raising the arm. This eliminates false responses to transient (short term) power glitches. On detection of the return of line power, again a delay of 10 seconds is provided before normal operation is resumed. The backup battery assembly has ample power to provide this feature for several years before replacement. The door safety switch disconnects power to the motor under ALL circumstances. If the door safety switch is bypassed (not normally recommended) and the circuit breaker switch is turned off for any reason, after 10 seconds, the gate activates under battery power and raises the arm. The powerful drive mechanism can cause serious bodily injury. Do not bypass the door safety switch unless absolutely necessary. Figure 1.6, on page 11 shows the PosiDRIVE gate electrical components. Component descriptions follow the illustration. Figure 1.6 Electrical Components Safety Switch Motor Driver Board Manual/Auto Switch PosiDRIVE Controller Electical Subpanel Power Supply Circuit Breaker/Master Power Switch Junction Box Table 1.2 PosiDRIVE Electrical Component Descriptions Component Description Junction Box A junction is located on the electrical sub-panel below the circuit breaker, where an installer can mount a convenience outlet. PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Structural Overview • 11 Table 1.2 PosiDRIVE Electrical Component Descriptions (Continued) Component Description Circuit Breaker Switch This is the main overload protection mechanism for the entire gate. It is also the master power switch. CAUTION: The door safety switch disconnects power to the motor under ALL circumstances. If the door safety switch is bypassed (not normally recommended) and the breaker switch is turned off for any reason, the system will respond to this as a line power failure. After 10 seconds, the gate will activate under battery power and raise the arm. Use extreme caution when servicing the gate and be aware of this condition. This is why the door safety switch should not be bypassed unless absolutely necessary. Electrical Sub-Panel Steel panel mounted inside the enclosure, which holds all of the electrical components. PosiDRIVE Controller “Brain” behind the PosiDRIVE gate and its operation. It is a plug-in, microprocessor-based controller that monitors and directs all operations of the gate. It is capable of operating on input voltages ranging from 18 VDC to 32 VDC. Motor Driver Board “Brain” behind the brushless DC motor. It controls the proper operation of the motor as well as regulates the power delivered to the motor. Safety Switch A plunger-style switch that automatically terminates power to the motor when the enclosure door is open. To bypass the switch, pull out the plunger. To reactivate the switch, depress the plunger. The plunger springs back to the safe position. To avoid serious injury, use extreme caution when bypassing the safety switch. Make sure all technicians are clear of the drive mechanism and the gate arm path before bypassing the switch. Manual/Auto Switch 12 • PosiDRIVE Structural Overview Setting the switch to the Manual position raises the arm to the up position indefinitely. Setting the switch to the Automatic position causes the gate to resume normal operation. ZMA-330, Ver.6 PosiDRIVE Security Gate Table 1.2 PosiDRIVE Electrical Component Descriptions (Continued) Component Description Power Supply Unit that provides the 24 VDC power required by all components of the PosiDRIVE gate. The PosiDRIVE power supply can accept input voltages ranging from 85 VAC to 264 VAC at 50 or 60 Hz. Gate Arm The size of the standard PosiDRIVE gate arm (Figure 1.7, on page 13) ranges from 10 to 20 feet (3.05 m to 6 m) in length and is constructed of extruded aluminum. It is finished with white powder coat paint with reflective striping. The gate arm is 4 inches (100mm) in diameter and extends from the gate cabinet at a height of approximately 36 inches (91 cms) from the mounting surface. The standard gate arm is hollow and has molded plastic pieces that attach at the ends of the gate arm to prevent snow, ice, or debris from building up inside the gate arm. It is internally counterbalanced with two, three, or four adjustable extension mainsprings, depending on the length of the arm. The mainsprings balance the weight of the gate arm, reducing the power requirement by the motor. See “Setting the Mainsprings” on page 38. The PosiDRIVE gate can also support a folding gate arm (Figure 1.8, on page 14) for locations that have restricted overhead clearance. The standard folding gate arm is 10 ft. (3.05 m) in length and is constructed of clear white pine. It is finished in diagonal stripes of black and white enamel. Figure 1.7 Standard Gate Arm Gate Arm End Cap PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Structural Overview • 13 Figure 1.8 Folding Gate Arm PosiDRIVE Controller The PosiDRIVE Controller houses one DIP switch bank, which is marked “SW2” on the board. The PosiDRIVE Controller also houses the Reset switch (SW1) and connectors for several gate functions, including: The motor controller plugs into connector JP4. The Power Supply wires into J1. The Manual/Auto switch is connected into connector J1. Field Wiring connections are made into connector JS1. ■ ■ ■ ■ Note: Connectors JP1 and JP2 are for Federal APD use only. Figure 1.9 PosiDRIVE Controller 10 1 2 9 10 11 JP2 1 10 JP5 PWR ON 9 8 7 6 5 4 LOOP A LOOP B J4 VEND 1 RAISE 2 3 4 5 UP LMT 3 JP3 DWN LMT 2 1 SPARE 1 2 JP6 PWR FL JS1 3 SW2 AUX2 RLY3 RLY2 RLY4 RLY1 TACH BRAKE DIRECT TORQ LMT ENABLE AUX1 AUX3 AUX4 K4 4 5 6 K2 JP1 8 7 6 5 4 3 2 1 6 5 4 JS4 SW3 14 • PosiDRIVE Structural Overview K3 ZMA-330, Ver.6 JP4 JS2 K1 3 2 1 7 8 J1 PosiDRIVE Security Gate DIP Switches The SW2 DIP switches (Figure 1.9, on page 14) control the following functions: ■ Vend Counts—DIP switch 1 is used to enable or disable vend counts. If switch 1 is open, vend counts are disabled; if switch 1 is closed, vend counts are enabled. ■ Backout Gate Reset Time—DIP switches 3 and 4 are used to set the time, from 15 seconds to 60 seconds, that the gate arm stays up until a vehicle passes through the gate. ■ Gate Length—DIP switches 5 and 6 are used to program the controller for the length of the gate arm. ■ Backout Gate Arm Timeout—DIP switch 7 is used to indicate whether the gate arm remains raised for a specified period of time (determined by setting the Backout Gate Reset Time using DIP switches 3 and 4) or remains raised until the reset loop (B) is cleared. ■ Power Fail Raise—DIP switch 8 is used to set the gate’s behavior when a power failure occurs. Note: For DIP switch setting instructions, see “Setting the DIP Switches” on page 42. Also note, DIP switch 2 is unused. Inputs The PosiDRIVE Controller (Figure 1.9, on page 14) has the following inputs to support gate operation: ■ Loop A (connector JS1-2). Input from an external vehicle detector indicating a presence on the A Loop. ■ Loop B (connector JS1-3). Input from an external vehicle detector indicating a presence on the B Loop. ■ Vend (connector JS1-4). Input from an external device signalling the gate to vend. ■ Raise/Lower (connector JS1-5). Input from an external device signalling the gate to raise. This would be used with an external operator switch, which when enabled, raises the gate. PosiDRIVE Security Gate ZMA-330, Ver. 6 PosiDRIVE Structural Overview • 15 Outputs The PosiDRIVE Controller (Figure 1.9, on page 14) has the following external outputs: ■ Gate Up field output (connector JS2, 1 and 2). When the gate is down, outputs 1 and 2 are open. When the gate starts to travel upward, outputs 1 and 2 close (are connected) until the gate starts to travel downward again. ■ System Fault relay output (connector JS2, 3 and 4). When there is a system fault, outputs 3 and 4 are closed (connected). In a normal condition, outputs 3 and 4 are open. Opening the Enclosure Door Gate installation, maintenance, and repair typically call for opening the gate enclosure to access the gate’s electrical components. The enclosure door, which has a single T-handle lock, can be easily removed by unlocking the handle and lifting the door up and out. The door must be removed before the enclosure cap can be unlatched and removed. As the door is removed, the safety switch inside the door frame pops out to disconnect power to the gate motor, ensuring that the drive mechanism does not actuate while gate is open. This safety precaution is designed to prevent serious bodily injury. If your hands are in the path of the gate mechanism and the mechanism actuates, a severe injury, including dismemberment, can occur. If it is absolutely necessary to operate the gate with the cover removed, bypass the switch by pulling the plunger out. To reactivate the switch, depress the plunger fully. Removing the Enclosure Cap Gate installation, maintenance, and repair typically call for removing the gate enclosure cap to access the gate’s drive mechanism. 16 • Opening the Enclosure Door ZMA-330, Ver.6 PosiDRIVE Security Gate To remove the enclosure cap, follow these steps: 1. Remove the enclosure door by unlocking the handle and lifting the door up and out. Note the safety switch inside the door frame. As the door is removed, this switch disconnects power to the gate motor under all circumstances, allowing you to safely reach up under the cap to unlatch it and service the gate. If it is necessary to operate the gate with the cover removed, the switch may be bypassed by pulling the plunger out to the bypass position. The switch can be reactivated by depressing the plunger. It then acts as a safety switch again, preventing motor activity until the door is replaced. Use extreme caution if operating the gate with the door and/or enclosure cap removed. This is a powerful mechanism that can cause serious injury if not handled properly. It is strongly recommended that the cap be in position and latched and the door be installed when the gate is in operation. 2. One draw latch, which holds the cap in place, is located on each inside top corner of the enclosure base. Reach inside the enclosure and unhook all four latches. Figure 1.10 Draw Latch Enclosure Cap Draw Latch Enclosure Base 3. Lift the cap straight up and off. Use care when removing or replacing the cap so as not to damage any of the weather-stripping. 4. To replace the cap, lower the cap straight down on to the base, again using caution with the weather-stripping. Reach inside the enclosure and re-hook the draw latches. PosiDRIVE Security Gate ZMA-330, Ver. 6 Removing the Enclosure Cap • 17 18 • Removing the Enclosure Cap ZMA-330, Ver.6 PosiDRIVE Security Gate CHAPTER 2 Installation This chapter contains the following topics: Installation Overview ........................................................................................20 Installing the Enclosure .....................................................................................20 Wiring the Gate .................................................................................................23 Installing the Gate Arm .....................................................................................25 Install a Standard Gate Arm........................................................................26 Install a Folding Gate Arm .........................................................................27 Change the Gate Arm Configuration ..........................................................34 Setting the Mainsprings.....................................................................................38 Disabling the Locked-Down Feature (Optional)...............................................40 Setting the DIP Switches...................................................................................42 PosiDRIVE Security Gate ZMA-330, Ver. 6 Installation • 19 Installation Overview The installation procedures described in this section are broken into the following tasks: 1. “Installing the Enclosure” on page 20 2. “Wiring the Gate” on page 23 3. “Installing the Gate Arm” on page 25 4. “Setting the Mainsprings” on page 38 5. “Disabling the Locked-Down Feature (Optional)” on page 40 6. “Setting the DIP Switches” on page 42 Moving parts can cause serious bodily injury, and hazardous voltage can shock, burn, or cause death. Turn off the power to the gate and disconnect the battery before performing any maintenance or repairs. Installing the Enclosure This section explains how to install the PosiDRIVE Security Gate enclosure. Note: The base flange of the PosiDRIVE includes a series of holes designed to support retrofitting the PosiDRIVE gate into a previous Federal APD gate installation, such as the G-89, CG-90, G-90, or 500 Industrial Gate. It may be possible to use as many as three of the existing mounting bolts. Because the base of the PosiDRIVE is deeper than the previous gate, it is not possible to use all four existing bolts. Use three of the existing holes and drill new holes in the front two mounting holes. If the PosiDRIVE is being installed into an existing 500 Industrial Gate installation, you may need to position the gate closer to the curb to accommodate any existing conduit stub-ups. In this case, drill four fresh mounting holes. To install the gate on a concrete curb: Install the enclosure so that the end portion of the gate arm is more than 2 feet (62 cm) from any rigid object, such as a wall, when fully extended in the down position. If the distance is less than 2 feet (62 cm), a person may get trapped between the end of the gate arm and the rigid object, causing bodily injury to the individual. 1. Carefully remove the unit from the shipping crate without damaging the finish. Leave the enclosure bolted to the bottom pallet until you are ready for installation. 2. Open the gate enclosure door. 20 • Installation Overview ZMA-330, Ver.6 PosiDRIVE Security Gate 3. Remove the bolts that fasten the cabinet to the bottom pallet. 4. Mark the concrete for drilling as follows: a. Place the cabinet in the installation location, aligned according to the dimensions provided in Figure 2.1. Make sure that the center line of the cabinet is 18 inches from the curb line. b. Use pencil or chalk to mark the concrete through the selected anchoring holes. Figure 2.1 PosiDRIVE Security Gate Footprint Dimensions 15.00 3.00 9.00 1.00 14.00 16.00 0.75 DIA. 18.00 Measurements in inches CURB LINE 5. Remove the cabinet from the position, and follow the manufacturer’s instructions for installing the anchor bolts. Redhead #JS-38H, 3/8” x 3” stud anchor, or equivalent is the recommended anchor bolt. PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Enclosure • 21 6. Attach the cabinet to the anchor bolts as follows: a. Place the gaskets over the bolts. b. Set the cabinet on top of the gaskets, aligning the bolts up through the holes of the cabinet. c. Place the washers on the bolts. d. Screw the nuts onto the bolts, and tighten them to secure the cabinet. Nut Washer Cabinet Base Gasket Anchor Bolt 7. Make sure the warning label (Figure 2.2) affixed to either side of the enclosure is not obstructed by any objects. Figure 2.2 Gate Cabinet Warning Label (Part # 20-3469) 22 • Installing the Enclosure ZMA-330, Ver.6 PosiDRIVE Security Gate Wiring the Gate The PosiDRIVE Security Gate is wired to the incoming power source and to a vend device, such as a vehicle detector loop, a card reader, and/or a raise/lower switch. The gate wiring depends upon the devices your site uses. Refer to the engineering drawings supplied with the gate for wiring diagrams that are specific to your site’s configuration. Note: If you do not have the engineering drawings, obtain a copy from your distributor. If you are the distributor, contact Federal APD Customer Support to obtain a copy of the drawings. The PosiDRIVE optionally comes with a Federal APD Detector Harness that is used to interface Federal APD detector loops with the gate. This section provides diagrams for wiring the gate with or without the Federal APD Detector Harness. To prevent serious bodily injury and damage to the equipment: • Terminate the incoming AC power before wiring the gate. • Only a licensed electrician should wire the gate. To wire the gate: 1. Connect the incoming AC power feed wires to the pigtail leads inside the junction box (Figure 1.6, on page 11). 2. Per the engineering drawings included with the gate, connect the resident vend device to the PosiDRIVE Controller. Figure 2.3, on page 24, shows the wiring schematic when using the Federal APD Detector Harness. Figure 2.4, on page 25 shows the wiring schematic when using a generic detector harness. PosiDRIVE Security Gate ZMA-330, Ver. 6 Wiring the Gate • 23 Figure 2.3 Wiring with the Federal APD Detector Harness RAISE/LOWER SWITCH NC C NO 11 INPUT COMMON 10 NOT USED NOT USED NOT USED NOT USED NOT USED 9 8 7 6 N.O. CONTACT 5 VEND DEVICE 4 *B *B *F 3 2 1 JS1 SPLICE TYP. *D *E *D *E *A *C *H RAISE-LOWER VEND 'B' PRESENCE 'A' PRESENCE INPUT COMMON RESET DETECTOR LOOP VEND DETECTOR LOOP WHITE BLACK GREEN LOAD LOAD 5 AMP/2 POLE BREAKER FAPD PN-21-11929 * LEGEND: RESET DETECTOR HARNESS VEND DETECTOR HARNESS *FAPD DETECTOR HARNESS COLOR CODE: (REFERENCE DRAWING FCA-10141) PIN P/N 11-26498 P/N 12-0128 WHITE WHITE A RED BROWN B BLACK BLACK C BROWN RED D VIOLET ORANGE E ORANGE YELLOW F GRAY BLUE G GREEN GREEN H BLUE VIOLET I YELLOW GRAY J 24 • Wiring the Gate ZMA-330, Ver.6 PosiDRIVE Security Gate Figure 2.4 Wiring with a Non-Federal APD Detector Harness 11 INPUT COMMON 10 NOT USED RAISE/LOWER SWITCH C 9 NOT USED 8 NOT USED NC 7 NOT USED NO 6 NOT USED 5 RAISE-LOWER N.O. CONTACT VEND DEVICE 4 VEND 3 'B' PRESENCE RESET DET. N.O. CONTACT 2 VEND DET. N.O. CONTACT 'A' PRESENCE 1 INPUT COMMON JS1 Installing the Gate Arm The PosiDRIVE Security Gate supports standard gate arms and folding gate arms for sites with low overhead clearance. Installation procedures differ depending upon the type of gate arm you are installing. The gate is factory configured for left- or right-hand drive based on your site’s requirement; however, if you receive a gate that is not configured properly for your site, you can either send the gate back to the factory for re-configuration or you can change the gate’s configuration yourself. This section explains how to: ■ ■ ■ “Install a Standard Gate Arm” on page 26 “Install a Folding Gate Arm” on page 27 “Change the Gate Arm Configuration” on page 34 PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 25 Install a Standard Gate Arm To install a standard gate arm: To avoid severe personal injury, place the gate arm mechanism into the fully up, locked position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. Additionally, due to the length and weight of the gate arm, two technicians are required to perform this task. 1. Review the following illustration (Figure 2.5) to ensure that you have all of the required components. Figure 2.5 Standard Gate Arm Installation Mainshaft Gate Arm 3/8-16 UNC x 1.50” Hex Bolt Arm Clamp 3/8-16 UNC Hex Nut 3/8” Plain Washer Gate Arm Inserts 2. Place the gate arm inserts on either side of the gate arm. Position the inserts so that they are directly underneath the arm clamps. 3. Place the arm into the mainshaft and position the arm clamp over the arm. Make sure to align the holes in the arm clamp with the holes in the mainshaft. 4. Thread the mounting bolts through the mainshaft and through the arm clamp. 5. Fit the washers and hex nuts over the bolts and tighten. 26 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 6. Make sure the bright orange warning label, as shown in Figure 2.6, is installed on both sides of the gate arm. Figure 2.6 Gate Arm Warning Label (Part # 20-4343) MOVING ARM CAN CAUSE BODILY HARM OR VEHICLE DAMAGE. ! ! W A R N I N G W A R N I N G CARS ONLY: NO BICYCLES MOTORCYCLES OR PEDESTRIANS. 7. Set the mainsprings. See “Setting the Mainsprings” on page 38. Install a Folding Gate Arm Folding gate arms are installed on gates that are located in areas with low overhead clearance. To avoid severe personal injury, place the gate arm mechanism into the full “locked up” position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 27 To install a folding gate arm: 1. Drill two 3/8” holes into the side of the gate enclosure. Refer to the dimensions provided in Figure 2.7. Figure 2.7 Dimensions for Folding Gate Arm Mounting Hole Holes for Folding Gate Arm 2.50 63.50 2.00 50.80 2.00 50.80 FRONT OF ENCLOSURE Ø .38 9.53 2. To inhibit rust, paint the rims of the holes with the PosiDRIVE touch-up paint. 28 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 3. Install the cable tower (Figure 2.8) on the side of the gate enclosure using two 5/16-18 x 1” hex bolts, eight 5/16” plain washers, and two 5/16-18 Nylock hex nuts as follows: a. Align two washers over each of the holes that you drilled in the gate enclosure. b. Align the cable tower over the washers. c. Align one washer over each hole in the cable tower. d. Thread 1 hex bolt through each hole to fasten the cable tower to the gate enclosure. e. On the inside of the gate, place a washer on each bolt and tighten with a Nylock hex nut. 4. Install the cable on the cable tower (Figure 2.8) using a spacer, cable, one 3/8” plain washer, and one 3/8-16 Nylock hex nut as follows: a. Thread the spacer onto the cable tower spindle. b. Place the washer onto the spindle. c. Thread the Nylock hex nut onto the spindle and tighten. Figure 2.8 Installing the Cable Tower Spacer Spindle The two washers and two nuts on the inside of the gate are not shown on this illustration. Cable Cable Tower PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 29 5. Attach the fixed section of the folding gate arm to the gate arm flange (Figure 2.9) using the adapter, arm retainer, eight 3/8” lock washers, and eight 3/8” Nylock hex nuts, as follows: a. Place the studs that are on the back side of the adapter (the side where the studs are closer together) into the four flange holes and secure the adapter with four washers and four hex nuts. b. Place the retainer on the adapter front side studs. c. Place a washer on each of the adapter studs. d. Hand thread four hex nuts onto the adapter studs; do not tighten the nuts. e. Insert the fixed section of the folding gate arm between the adapter and the retainer. f. Tighten the hex nuts on the arm retainer so that the gate arm is secured. Figure 2.9 Attaching the Fixed Section of the Folding Gate Arm to the Gate Flange Adapter (front side) Folding Gate Arm Fixed Section Retainer Flange 30 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 6. Secure the folding section of the gate arm onto the gate arm stabilizer (Figure 2.10) using two 10-24 x 1.5 pan head screws, and two 10-24 Keps nuts, as follows: a. Align the holes on the folding gate arm section with the holes on the gate arm stabilizer. b. Insert a pan head screw into each hole. c. Place a Keps nut on each screw and tighten to secure the folding gate arm. Figure 2.10 Attaching the Folding Section to the Gate Arm Stabilizer Gate Arm Stablizer Folding Section of Gate Arm Pan Head Screws Keps Nuts PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 31 7. Attach the folding section with the gate arm stabilizer to the fixed section of the gate (Figure 2.11) arm as follows: a. Insert the two 3/8” bushings into either side of the hole on the fixed gate arm section. b. Align the hole on the bottom of gate arm stabilizer with the hole in the fixed arm section. c. Insert the shoulder screw into the bushings on the fixed gate arm section. d. Secure the shoulder screw with a 3/8” plain washer and Nylock hex nut. Figure 2.11 Attaching the Stabilized Folding Section to the Gate Arm Fixed Secton Folding Section with Gate Arm Stabilizer Plain Washer Nylock Hex Nut Shoulder Screw Fixed Gate Arm Section Bushing 32 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 8. Attach the cable turnbuckle to the gate arm (Figure 2.12) as follows: a. Place a 3/8” plain washer onto the 3/8-16 x 1.5” hex bolt. b. Insert the hex bolt into the eye of the cable turnbuckle. c. Secure the bolt to the turnbuckle eye using a 3/8” plain washer and 3/8-16 hex nut. d. Insert the hex bolt into the gate arm stabilizer and loosely secure it with a 3/8" lock washer and 3/8” hex nut. e. Adjust the 3/8” hex nut until contact is made between the plain washer and the turnbuckle eye. Do not tighten the nut against the turnbuckle eye. f. Using 2 wrenches, tighten the 3/8” hex nut on the far side of the gate arm stabilizer against the other 3/8” hex nut. When tight, the turnbuckle eye should be free to move between the two 3/8” plain washers. Figure 2.12 Attaching the Cable Turnbuckle to the Gate Arm Hex Nut Plain Washers Hex Nut Lock Washers Hex Bolt Cable Turnbuckle PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 33 Change the Gate Arm Configuration The PosiDRIVE is factory-configured for left- or right-hand drive based on your site’s requirements; however, if you receive a gate that is not configured properly, either return the gate to Federal APD for replacement or have a qualified technician change the gate’s configuration. No additional hardware is required to modify the gate’s configuration. This task requires removing and reinstalling the gate arm. If the gate is equipped with a standard gate arm, this task requires two technicians to ensure safety and avoid damage to the equipment. To change the gate arm configuration: Figure 2.13 Gate Arm Configuration Components Mainspring Pivot Bar Mainshaft Mainshaft Crank 1 Mainshaft Crank 2 3/8” Bolts and Nuts Mainshaft Bearing Arm Clamp Mainspring Adjustment Bar Mainspring 1. Remove the enclosure door, so that the door interlock safety switch de-activates the motor. 2. Turn off the power to the gate using the circuit breaker switch and disconnect the backup battery assembly, if applicable. 3. Remove the enclosure cap. See “Removing the Enclosure Cap” on page 16. 34 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 4. Manually raise the arm to the “up” position. To avoid serious injury, make sure that the mechanism is fully locked in the up position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 5. Loosen the 3/8” bolts and nuts used to hold the arm clamp to the mainshaft. 6. Remove the gate arm and arm clamp and set aside. 7. Unhook all of the mainsprings. Remove the mainspring hooks from the bottom flange first, and then unhook them from the mainspring connection bar (Figure 2.13). 8. Loosen the six clamping bolts on the spring crank and on the mainshaft crank (Figure 2.13). 9. Push the motor crank so that the mechanism moves towards the “down” arm position just far enough so that the spring crank is above the frame mechanism (Figure 2.13). 10. Slide the spring crank along the mainshaft until the mainspring pivot bar can be removed and then remove the pivot bar and set aside (Figure 2.14). Figure 2.14 Pivot Bar Slide the spring crank along the mainshaft. Remove the pivot bar and set aside. PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 35 11. Loosen the set screws in the mainshaft bearing collars (Figure 2.15). Figure 2.15 Set Screws Loosen set screws 12. Remove the 1/4-20 hex bolts that hold the side shield in place (Figure 2.16). 13. Slide the mainshaft out of the drive mechanism (Figure 2.16). 14. Remove the spring crank (Figure 2.16) and set it aside. Figure 2.16 Mainshaft Removal Slide mainshaft out of the drive mechanism. Remove spring crank and set aside. Side shield. 1/4-20 hex bolts. 1/4” flat washers. 15. Make sure that the surface of the mainshaft between the bearings is completely free of grease and contamination. Clean the mainshaft thoroughly with isopropyl alcohol if in doubt. The clamping mechanisms on the various cranks rely on static friction to function properly and any contamination may cause them to slip. 16. Insert the mainshaft into the mainshaft bearing on the desired side of the gate. 17. Slide the mainshaft through the mainshaft bearing, the mainshaft crank 1 and the mainshaft crank 2. 36 • Installing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 18. Insert and tighten the 1/4” flat washers and 1/4-20 hex bolts that hold the side shield in place. 19. Re-install the spring crank onto the mainshaft and slide the mainshaft into the opposing mainshaft bearing. 20. Align the end of the mainshaft so that it is flush with the mainshaft bearing. Note: A rubber hammer may be useful in moving the mainshaft through the mainshaft bearing. Never use a steel hammer as it may damage the mainshaft. 21. Re-install the mainspring pivot bar onto the spring crank. Note: Make sure that the mainspring pivot bar is level and square with the mainshaft crank and spring crank to avoid damaging the bearings. 22. Re-install the mainsprings. See “Adding, Removing, or Replacing the Mainsprings” on page 52. 23. Re-install the gate arm. See “Installing the Gate Arm” on page 25. a. Position and hold the gate arm in the fully vertical “up” position. b. Tighten the mainshaft crank clamping bolts. c. Tighten the spring crank clamping bolts. 24. Balance the gate arm. See “Setting the Mainsprings” on page 38. 25. Turn on the power to the gate and re-connect the backup battery assembly, if applicable. To avoid injury, stay clear of the gate arm path. When the gate powers up, the gate arm raises and lowers as part of the homing process. 26. Replace the enclosure cap. 27. Replace the enclosure door. 28. Verify that the positioning of the arm is correct. PosiDRIVE Security Gate ZMA-330, Ver. 6 Installing the Gate Arm • 37 Setting the Mainsprings The mainsprings are a vital part of the operation of the PosiDRIVE gate. They counterbalance the weight of the arm, allowing the PosiDRIVE to operate arms as large as 20 feet (6 m) with a relatively low powered motor. Too much spring (overbalance) or too little spring (underbalance) can adversely affect the operation of the PosiDRIVE. After installing the gate arm, set the mainsprings to ensure optimum gate performance. To avoid serious injury, two technicians are required to perform this task: one to handle the gate arm and the other to make mainspring adjustments. To set the mainsprings: 1. Open the gate enclosure. 2. Disconnect the circuit breakers to turn power off to the gate and disconnect the battery backup if applicable. 3. Manually advance the drive mechanism out of the “locked” position so the arm and linkage are free to move. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 4. Manually advance the arm to a 45 degree angle, but do not let go of the gate arm. If the gate does not have the correct number of mainsprings installed or if they are not adjusted properly, the gate arm can spring upward or fall to the down position and damage the drive mechanism. To prevent damage to the gate, carefully support the arm as you slowly lower it. If you feel the gate arm pulling upward or it feels like it will fall if you let it go, return the arm to the upright position and proceed with adjustment. If the gate arm feels balanced, slowly let it go. If it remains stationary at 45 degrees, the mainspring tension is correct. Replace the enclosure cap, turn on the power to the gate, and close the enclosure door. 38 • Setting the Mainsprings ZMA-330, Ver.6 PosiDRIVE Security Gate 5. Adjust the mainspring tension as follows: To avoid binding the spring adjustment bolts (Figure 2.17), make adjustments evenly; that is, turn each bolt once or twice and then apply the same number of turns to the other bolt. ◆ To increase spring tension, turn the spring adjustment bolts (Figure 2.17) clockwise. ◆ To decrease spring tension, turn the spring adjustment bolts (Figure 2.17) counterclockwise. Pay attention to the mainspring connection bar and the adjustment bolts. If you are reducing spring tension, NEVER relax the mainsprings to the point where they may detach from the connection bar. The mainsprings should never be fully relaxed and loose with the gate in the “up” position. Adjust the bolts until the gate holds the arm at the 45 degree angle. Figure 2.17 Spring Adjustment Bolts Spring Adjustment Bolts If, at the limits of adjustment, the gate arm does not balance, add or remove a mainspring. See “Adding, Removing, or Replacing the Mainsprings” on page 52. If you are increasing the tension and the adjustment is approaching the limit, consider adding a mainspring and using a lower adjustment to reduce the stress on the mainsprings. PosiDRIVE Security Gate ZMA-330, Ver. 6 Setting the Mainsprings • 39 Disabling the Locked-Down Feature (Optional) The PosiDRIVE Security Gate drive mechanism is designed to lock at the limits of travel. This feature prevents the gate arm from being moved manually when the gate is in the fully up or fully down position, which ensures: ■ The safety of the technician(s) that perform maintenance and repairs on the gate. For example, many procedures call for locking the gate in the up position to ensure the gate arm does not fall and the drive mechanism does not move while maintenance or repairs are preformed. ■ The security of the facility by preventing unauthorized entry. Although the locking the gate in the down position provides a higher level of security, it also increases the potential for damage to the gate if someone tries to manually raise the gate arm. As with any gate, applying an upward force to the outer end of the arm generates enormous force back through the drive mechanism that can damage the gate. Placing one or more washers under the down rubber bump stop (Figure 2.18) prevents the gate from becoming fully locked in the down position, yet allows the gate to come close enough to the locked position to provide significant resistance; thus, deterring most attempts to gain unauthorized access. To disable the fully locked down position: 1. Open the gate enclosure. See “Opening the Enclosure Door” on page 16. 2. Set the Auto/Manual Switch (Figure 1.6, on page 11) to the Manual position to raise the gate arm to the fully up position. 3. Reactivate the door safety switch by depressing the plunger. 4. Turn off the power to the gate using the circuit breaker switch and disconnect the backup battery assembly. 5. Remove the enclosure cap. See “Removing the Enclosure Cap” on page 16. 40 • Disabling the Locked-Down Feature (Optional) ZMA-330, Ver.6 PosiDRIVE Security Gate 6. Remove the down rubber bump stop (Figure 2.18). Figure 2.18 Down Bump Stop 1/4” Flat Washer Rubber Bump Stop 7. Place one or more 1/4" flat washer(s) on the neck of the down rubber bump stop and return the bump stop to its original position. To ensure safety, do not place washers under the Up Bump Stop. You must be able to place the gate in the fully locked up position to avoid serious bodily injury. 8. Ensure all technicians are clear of the drive mechanism and the gate arm path. 9. Connect the battery back up, turn on the circuit breaker switch, and pull out the door safety switch. The gate powers up and begins the homing process in which the arm travels up and down. 10. Once the gate arm settles in the down position, fully depress the door safety switch, disconnect the battery backup, and turn off the circuit breaker switch again. 11. Attempt to raise the arm manually and observe the resistance encountered. If the arm cannot be moved, add another washer. If the arm moves too easily remove a washer. Be sure the lock the arm in the up position before adding or removing washers. PosiDRIVE Security Gate ZMA-330, Ver. 6 Disabling the Locked-Down Feature (Optional) • 41 12. When the gate arm provides the appropriate amount of resistance, reconnect power and close up the gate as follows: a. Ensure all technicians are clear of the drive mechanism and the gate arm path. b. Replace the enclosure cap. c. Connect the battery backup. d. Turn on the circuit breaker switch. e. Close the enclosure door. Setting the DIP Switches Set the SW2 DIP switches on the PosiDRIVE Controller (Figure 1.9, on page 14) for the gate to function as intended. Figure 2.19 shows the DIP switches in the “open” position. Descriptions of the DIP switch functions follow the illustration. Note: DIP switch 2 is unused. Figure 2.19 DIP switches in the Open Position DIP Switch 1: Vend Counts The following table lists the DIP switch positions to enable or disable vend counts. Table 2-3 — Vend Count Enabled/Disabled DIP Switch Settings Values DIP Switch Positions Vend counts enabled DIP switch 1 closed Vend counts disabled DIP switch 1 open 42 • Setting the DIP Switches ZMA-330, Ver.6 PosiDRIVE Security Gate DIP Switches 3 and 4: Backout Gate Reset Time The following table lists the DIP switch positions to set the amount of time, from 15 seconds to 60 seconds, that the gate stays up to let the patron enter the facility. If DIP switch 7 is closed, enabling Backout Gate Arm Timeout, the gate automatically closes if loop-B does not detect the vehicle within the configured time. Note: This setting only affects the amount of time the patron has to pull onto loop-B. Once the patron pulls onto loop B, the gate arm stays up until the patron clears the loop. If DIP switch 7 is open, disabling Backout Gate Arm Timeout, DIP switches 3 and 4 are not applicable; the gate arm stays up until the patron clears loop B. Table 2-4 — Backout Gate Reset Time DIP Switch Settings Values DIP Switch Positions 15 seconds DIP switches 3 and 4 closed 30 seconds DIP switch 3 open, DIP switch 4 closed 45 seconds DIP switch 3 closed, DIP switch 4 open 60 seconds DIP switches 3 and 4 open DIP Switches 5 and 6: Gate Arm Length The following table lists the DIP switch positions for the various gate arm lengths. Table 2-5 — Gate Arm Length DIP Switch Settings Values PosiDRIVE Security Gate DIP Switch Positions 10-12 feet (3.05m 3.66m) DIP switch 5 open, DIP switch 6 closed 14-16 feet (4.27m 4.88m) DIP switch 5 closed, DIP switch 6 open 18-20 feet (5.49m 6.10m) DIP switch 5 open, DIP switch 6 open ZMA-330, Ver. 6 Setting the DIP Switches • 43 DIP Switch 7: Backout Gate Arm Timeout The following table lists the DIP switch positions to enable or disable Backout Gate Arm Timeout. Table 2-6 — Backout Gate Arm Timeout DIP Switch Settings Values DIP Switch Positions Backout Gate Arm Timeout disabled - gate arm stays up until vehicle clears loop B DIP switch 7 open Backout Gate Arm Timeout enabled - gate arm closes after time specified with DIP switches 3 and 4 elapses if vehicle is not detected on loop B DIP switch 7 closed DIP Switch 8: Auto-Raise The following table lists the DIP switch positions to enable or disable the autoraise function. Table 2-7 — Auto-Raise Function DIP Switch Settings Values DIP Switch Positions Automatically raise gate during a power failure DIP switch 8 open Do not raise gate during a power failure DIP switch 8 closed 44 • Setting the DIP Switches ZMA-330, Ver.6 PosiDRIVE Security Gate CHAPTER 3 Maintenance and Repair This chapter contains the following topics: Maintenance and Repair Overview ...................................................................46 Performing Preventive Maintenance .................................................................46 Grease the Connection Rod Bearings .........................................................47 Troubleshooting a Problem ...............................................................................48 Locking, Unlocking, and Advancing the Gate Arm..........................................49 Adding, Removing, or Replacing the Mainsprings...........................................52 Aligning the Drive Mechanism .........................................................................54 PosiDRIVE Security Gate ZMA-330, Ver. 6 Maintenance and Repair • 45 Maintenance and Repair Overview To keep the gate functioning properly, perform monthly and semi-annual preventive maintenance, such as checking the mechanical components and greasing bearings. Moving parts can cause bodily injury, and hazardous voltage can shock, burn, or cause death. Turn off the power to the gate and disconnect the backup battery before performing any maintenance or repairs. If the gate does not function properly, refer to the troubleshooting table provided in this chapter (Table 3-8) for help diagnosing and repairing the issue. Many gate adjustment and repair tasks call for advancing the gate arm to the fully up or fully down position and locking the drive mechanism into place. If this done via a raise/ lower switch, the drive mechanism automatically locks into the place; however, some tasks require moving the gate arm manually, in which case you must lock the drive mechanism by hand. This chapter explains how to perform the following maintenance and repair tasks: ■ ■ ■ ■ ■ “Performing Preventive Maintenance” on page 46 “Troubleshooting a Problem” on page 48 “Locking, Unlocking, and Advancing the Gate Arm” on page 49 “Adding, Removing, or Replacing the Mainsprings” on page 52 “Aligning the Drive Mechanism” on page 54 Performing Preventive Maintenance To keep the gate functioning properly, perform the following preventive maintenance tasks: ■ ■ Monthly: ◆ Inspect all warning labels to ensure that all are clear and readable. ◆ Inspect the gate enclosure for damage to ensure structural integrity of gate enclosure. ◆ Check mainspring tension to ensure that the gate is still properly balanced. Semi-annually: ◆ Check tightness on all fasteners on the drive system and gate arm, and check the gate mounting bolts to ensure the integrity of the drive mechanism. ◆ Grease mainshaft bearings to maintain bearing capacity and prevent internal corrosion. See “Grease Mainshaft Bearings” on page 47. ◆ Grease connecting rod bearings to maintain bearing capacity and prevent internal corrosion. See “Grease the Connection Rod Bearings” on page 47. 46 • Maintenance and Repair Overview ZMA-330, Ver.6 PosiDRIVE Security Gate Grease Mainshaft Bearings To grease the mainshaft bearings: 1. While the gate arm is in the down position, open the enclosure door and remove the enclosure cap. See “Removing the Enclosure Cap” on page 16. 2. Use a grease gun to inject heavy-duty synthetic grease into the grease fitting on each bearing housing. Mainshaft Bearings Grease the Connection Rod Bearings To grease the connection rod bearings: 1. Advance the gate to the up position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 2. Remove the enclosure door and cap. See “Removing the Enclosure Cap” on page 16. 3. Have another technician hold the gate arm in the up position. Holding the gate arm in the up position is necessary to avoid serious injury and damage to the gate. Once the connecting rod is removed, the gate arm is no longer balanced and can easily fall from the up position. PosiDRIVE Security Gate ZMA-330, Ver. 6 Performing Preventive Maintenance • 47 4. Unbolt and remove the connecting rod. Connecting Rod 5. Turn the spherical bearing element within the bearing housing so that the bearing surface is visible. 6. Apply bearing grease to the bearing surface and move the bearing element around to spread the grease evenly within the bearing housing. 7. Replace the connecting rod and connecting rod bolts. Troubleshooting a Problem If the PosiDRIVE gate fails to operate properly, use the following table to troubleshoot the problem. If you are still unable to correct the problem, contact your distributor. If you are the distributor, contact Federal APD. See Appendix A,“Product Support”. Table 3-8 — Troubleshooting Problem The gate is not operating. 48 • Troubleshooting a Problem Potential Cause Solution The main power is off. Turn the power on. The wiring connections may be loose. Check all wiring connections. The breaker switch may be tripped. Reset the breaker switch. Caution: if this is the problem, the cause of the current overload must be identified and fixed. The door safety switch is out. Make sure the access door is on and secured. ZMA-330, Ver.6 PosiDRIVE Security Gate Table 3-8 — Troubleshooting (Continued) Problem Potential Cause Solution The gate arm is not properly positioned, i.e., the gate arm is not horizontal when linkage is in the full down position. The drive mechanism has slipped. Adjust the drive mechanism. See “Aligning the Drive Mechanism” on page 54. The gate does not operate smoothly, landing excessively hard in the up or down positions. The mainspring is imbalanced. See “Setting the Mainsprings” on page 38. The gate arm begins to raise when commanded, and then stops and returns to the down position. There is a severe negative mainspring imbalance. See “Setting the Mainsprings” on page 38. The gate arm begins to lower, and then stops and returns to the raised position; this happens repeatedly. There is a severe positive mainspring imbalance. See “Setting the Mainsprings” on page 38. Locking, Unlocking, and Advancing the Gate Arm The PosiDRIVE Security Gate drive mechanism is designed to lock at the limits of travel. This feature prevents the gate arm from being moved manually when the gate is in the fully up or fully down position, which ensures: ■ The safety of the technician(s) that perform maintenance and repairs on the gate. For example, many procedures call for locking the gate in the up position to ensure the gate arm does not fall and the drive mechanism does not move while maintenance or repairs are preformed. ■ The security of the facility by preventing someone from manually lifting the gate arm to gain unauthorized access or to exit without paying a fee. PosiDRIVE Security Gate ZMA-330, Ver. 6 Locking, Unlocking, and Advancing the Gate Arm • 49 When performing maintenance or repairs, using the Auto-Manual switch on the PosiDRIVE controller (Figure 1.6, on page 11) is the easiest way to move the gate arm into the fully up or fully down position. Since the enclosure door must be open to access the Auto-Manual switch, and the door safety switch disables the drive motor when the door is open, this method requires bypassing the door safety switch (see “Safety Switch” on page 12). To avoid serious injury, always make sure that all technicians are clear of the drive mechanism and the path of the gate arm before bypassing the door safety switch. If a person’s hand is inside the gate enclosure when the drive mechanism actuates, serious injury, including dismemberment, can occur. Some procedures, such as setting the mainsprings or manually opening the gate during a power failure, require manually advancing the gate arm. Manually advancing the gate arm requires bumping the linkage out of the locked position. To avoid serious injury, always take the following precautions when manually advancing the gate arm: • Terminate all power to the gate; that is, turn off the circuit breaker and disconnect the battery backup (see “Electrical Components” on page 10). If the battery backup is not disconnected and the gate is programmed to automatically raise during a power failure, the drive mechanism begins raising the gate arm 10 seconds after the circuit breaker is turned off. • Have a second technician secure the position of the gate arm. This is especially important when lowering the gate arm. After bumping the linkage out of the locked position, the weight of the arm can cause the gate to descend. If your hand is not clear of the drive mechanism, serious injury, including dismemberment, can occur. To manually advance the gate arm: 1. Remove the gate enclosure cap. See “Removing the Enclosure Cap” on page 16. 2. If you are moving the gate arm from the fully up position, have a second technician secure the gate arm so that it does not descend while your hands are near the drive mechanism. 50 • Locking, Unlocking, and Advancing the Gate Arm ZMA-330, Ver.6 PosiDRIVE Security Gate 3. Push the motor crank hinge, shown in Figure 3.1 and Figure 3.2, to advance the mechanism out of the locked position. Figure 3.1 Motor Crank Position when the Gate Arm is Down To prevent a serious pinching injury including dismemberment, use care when working with the drive mechanism and alway terminate power prior to performing maintenance or repairs. Point at which you can move the mechanism to manually advance the gate arm out of the down position Figure 3.2 Motor Crank Position when the Gate Arm is Up Point at which you can move the mechanism to manually advance the gate arm out of the up position 4. Manually raise or lower the gate arm as far as possible. 5. Pull the motor crank to lock the drive mechanism linkage. When locked, the hinges in the linkage are aligned. If the mainsprings are not installed, locking the gate arm when it is in the up position is especially important to avoid serious injury. PosiDRIVE Security Gate ZMA-330, Ver. 6 Locking, Unlocking, and Advancing the Gate Arm • 51 Adding, Removing, or Replacing the Mainsprings The PosiDRIVE Security Gate is equipped with two or more mainsprings that provide the necessary tension to operate the gate arm. The required number of mainsprings depends upon the length of the gate arm. The following table lists the number of mainspring required for each available gate arm length: Gate Arm Length Number of Mainsprings 10 feet 2 12 feet 2 14 feet 3 16 feet 3 18 feet 4 20 feet 4 The mainsprings are installed at the factory. However, this procedure is provided in case you need to add, remove, or replace a mainspring. To prevent serious bodily injury: • Two people are required to add, remove, or replace a mainspring: one to hold the gate arm in the up position and the other to handle the mainspring installation or removal. • Lock the gate arm in the up position as described in “Locking, Unlocking, and Advancing the Gate Arm” on page 49. To install the mainsprings: 1. Open the gate enclosure and remove the enclosure cap. See “Removing the Enclosure Cap” on page 16. 2. If the gate arm is installed, the arm must be raised to up position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 52 • Adding, Removing, or Replacing the Mainsprings ZMA-330, Ver.6 PosiDRIVE Security Gate 3. From inside the gate enclosure, attach the top hook of the mainspring to the mainspring connection bar. Figure 3.3 Mainspring Connection Bar 4. Hook the lower end of the mainspring into the corresponding hole in the flange at the bottom of the gate (Figure 3.4). Make sure that the hole used in the flange corresponds with the position on the mainspring connection bar, i.e., first hole with first position, second hole with second position, etc. Note: If the gate requires only two mainsprings, place the springs in the 2nd and 3rd position. To remove a mainspring, reverse the procedure. Remove the mainspring hook from the bottom flange first, and then unhook it from the mainspring connection bar. Note: After the gate arm is installed, to achieve optimal balance of the gate arm and proper operation of the PosiDRIVE gate, set the mainsprings as described in “Setting the Mainsprings” on page 38. Figure 3.4 Mainspring Attachment Points Mainsprings Mainspring Attachment Points PosiDRIVE Security Gate ZMA-330, Ver. 6 Adding, Removing, or Replacing the Mainsprings • 53 Aligning the Drive Mechanism The PosiDRIVE is aligned at the factory; however, certain repairs may result in the need to realign the gate. Alignment is required when the gate arm is not parallel with the ground. This procedure requires two technicians. To align the gate: 1. Open the gate enclosure and remove the enclosure cap. See “Removing the Enclosure Cap” on page 16. 2. Use the Auto-Manual switch to raise the gate arm to the fully up and locked position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. To avoid serious injury, make sure that the drive mechanism is fully locked in the up position. 3. Turn off circuit breaker switch and disconnect the backup battery assembly to terminate all power to the gate. See “Electrical Components” on page 10. 4. Unhook all of the mainsprings from the bottom flange (Figure 3.4, on page 53). 5. With the assistance of a second person, bump the drive mechanism out of the locked position and slowly lower the gate arm to the horizontal position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 6. While the second person supports the arm, manually bump the linkage into the fully “locked down” position. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 54 • Aligning the Drive Mechanism ZMA-330, Ver.6 PosiDRIVE Security Gate 7. Loosen the clamping bolts on both of the mainshaft cranks and the mainspring crank. Figure 3.5 Drive Mechanism Alignment Mainshaft Crank Part 1 Mainshaft Crank Part 2 Mainshaft Mainspring Crank Mainshaft Bearing 8. While the second technician holds the gate arm at the desired down position, tighten all of the bolts on the cranks. 9. Carefully bump the linkage out of the locked position, manually raise the arm to the up position, and lock it into place. See “Locking, Unlocking, and Advancing the Gate Arm” on page 49. 10. Re-install the mainsprings. See “Adding, Removing, or Replacing the Mainsprings” on page 52. PosiDRIVE Security Gate ZMA-330, Ver. 6 Aligning the Drive Mechanism • 55 56 • Aligning the Drive Mechanism ZMA-330, Ver.6 PosiDRIVE Security Gate APPE NDIX A Product Support This appendix contains the following topics: Getting Help ......................................................................................................58 Accessing the Distributor Resource Center.......................................................59 PosiDRIVE Security Gate ZMA-330, Ver. 6 Product Support • 57 Getting Help If you have a product question that is not addressed in this manual, contact your Federal APD distributor. If you are a distributor or you do not have a distributor, call Federal APD Product Support at one of the telephone numbers listed in Table A-1. Whether you call, write, or fax, please have the following information available: ■ ■ ■ ■ ■ ■ ■ ■ A description of the events and the order in which they occurred The type of hardware you are using, with serial number and model number Firmware version, if applicable The type and configuration of software you are using Original sales order number Any messages that appear on your display screen and the exact wording Project name SRO number, if applicable Table A-1 — Federal APD Product Support Phone Numbers 58 • Getting Help Location Phone Fax United States (800) 527-4768 (248) 374-9610 Canada (800) 331-9144 (248) 374-9610 Central America South America (248) 374-9629 (248) 374-9610 Asia Australia China Hong Kong India Indonesia Korea Malaysia New Zealand Philippines Singapore Taiwan Thailand Vietnam (852) 2671-9880 (852) 2402-1912 ZMA-330, Ver.6 PosiDRIVE Security Gate Table A-1 — Federal APD Product Support Phone Numbers (Continued) Location Phone Fax Bahrain Egypt Europe Greece Greenland Iceland Jordan Saudi Arabia Turkey UAE (248) 374-9629 (248) 374-9610 Accessing the Distributor Resource Center If you are a distributor, visit the Distributor Resource Center on the Federal APD Web site at www.federalapd.com to: ■ ■ ■ Access product information Download software upgrades when they are available Review Frequently Asked Questions. Note: PosiDRIVE Security Gate A user ID and password are required to access the Distributor Resource Center. Obtain a user ID and password from Federal APD Sales Administration at (248) 374-9600. ZMA-330, Ver. 6 Accessing the Distributor Resource Center • 59 60 • Accessing the Distributor Resource Center ZMA-330, Ver.6 PosiDRIVE Security Gate APPE NDIX B Order and Repair Procedures This appendix contains the following topics: Placing an Order................................................................................................62 Requesting a Repair...........................................................................................62 Locate a Part Number .................................................................................63 Mainsprings..........................................................................................64 Enclosure..............................................................................................65 Electrical Components .........................................................................68 Standard Gate Arm...............................................................................70 Folding Gate Arm.................................................................................73 Drive Mechanism .................................................................................78 PosiDRIVE Security Gate ZMA-330, Ver. 6 Order and Repair Procedures • 61 Placing an Order To place an order: 1. Determine the applicable part number. See “Locate a Part Number” on page B-63. If the part number is not included in this manual, refer to the Federa APD Price Book or contact Order Entry and Preparation for part names, part numbers, prices, and delivery information at one of the following telephone numbers: ◆ ◆ Order Preparation: (800) 521-9330 or (248) 374-9629 Order Preparation in Canada: (800) 331-9144 2. Fill out a purchase order from your company. 3. Fax or mail the purchase order to: Federal APD, Inc. 42775 West Nine Mile Road Novi, Michigan 48375 USA Fax: (248) 374-9610 Requesting a Repair If a problem occurs with a product part, in many cases you can return the part to the Depot Repair Center for repair. All repairs require a: ■ Service Request Order (SRO) form. ■ Purchase order (PO) number. A PO number is required whether the repair is under warranty or not. For an additional charge, Federal APD offers Expedited Repair Service, which guarantees that the repairs are made within two working days from the date the part is received in the repair center. To request a repair: 1. Download an SRO form from the Distributor Resource Center on the Federal APD Web site at www.federalapd.com. Note: If you do not have access to the Distributor Resource Center, contact the Federal APD Product Support Operator at (248) 374-9629. 2. Acquire a PO number from your company. 62 • Placing an Order ZMA-330, Ver.6 PosiDRIVE Security Gate 3. Fill out the SRO form. In addition to the Customer and Product information, be sure to include the following information: ◆ In the Customer PO Number field, enter the PO number assigned by your company. A PO number is required whether the repair is under warranty or not. ◆ If the part is under warranty, enter the original sales order number in the Warranty box. ◆ If the part is no longer under warranty, check the Billable box. ◆ To expedite the repairs, check Yes next to Expedited Service Requested. Note: The cost of expedited service is indicated on the SRO form. 4. E-mail or fax the form to the e-mail address or fax number provided on the bottom of the form. Within 36 hours, you will receive an SRO number from Federal APD Order Entry/Product Support. 5. Ship the part to the Federal APD Repair Center at: Federal APD, Inc. Depot Repair Center (DRC) 42775 Nine Mile Road Novi, MI 48375 Include the SRO number on the shipping label. Federal APD cannot accept packages without SRO numbers. Locate a Part Number This section lists the part numbers for the components of the following: ■ ■ ■ ■ ■ ■ “Mainsprings” on page B-64 “Enclosure” on page B-65 “Electrical Components” on page B-68 “Standard Gate Arm” on page B-70 “Folding Gate Arm” on page B-73 “Drive Mechanism” on page B-78 PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 63 Mainsprings This section identifies mainspring part numbers. Figure B.1 Mainspring Parts 1 Table B-1 — Mainspring Part Numbers No. on Figure Part Number Description 1 50-25403 MAINSPRING, INDUSTRIAL GATE 64 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Enclosure This section identifies enclosure part numbers. It includes the following illustrations: ■ ■ ■ Figure B.2, Enclosure Cap Parts, on page B-65 Figure B.3, Enclosure Door Parts, on page B-66 Figure B.4, Enclosure Cabinet Parts, on page B-67 Figure B.2 Enclosure Cap Parts 1 2 3 Table B-2 — Enclosure Cap Part Numbers No. on Figure Part Number Description 1 20-11945 Label, PosiDRIVE logo (2 required) 2 50-14021Y Enclosure Cap, Posi Drive Yellow 50-14021W Enclosure Cap, Posi Drive White 50-14021S Enclosure Cap, Posi Drive Special 11-3226 WEATHERSTRIPPING, 1/8 X 3/8 3 PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 65 Figure B.3 Enclosure Door Parts 1 2 3 4 Table B-3 — Enclosure Door Part Numbers No. on Figure Part Number Description 1 n/a 10-24 Kep Nut (2 required) (metric = M5 x 0.8) 2 n/a 10-24 x 1/2 Flat Head Screw (2 required) (metric = M5 x 0.8 x 12) 3 11-0003 LOCK, T-HANDLE 4 50-14020Y Door Enclosure, PosiDrive Yellow 50-14020W Door Enclosure, Posi Drive White 50-14020S Door Enclosure, Posi Drive Special 66 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Figure B.4 Enclosure Cabinet Parts 1 2 3 4 5 Table B-4 — Enclosure Sub-Assembly Part Numbers No. on Figure Part Number Description 50-14018Y 50-14018W 50-14018S Enclosure Base, Posi Drive Yellow 2 11-3226 WEATHERSTRIPPING, 1/8 X 3/8 3 21-11944 Switch, Pushbutton w/ cheat interlock 4 n/a 10-24 Kep Nut (4 required) 5 10-4847 NAMEPLATE, LARGE FEDERAL APD 1 PosiDRIVE Security Gate Enclosure Base, Posi Drive White Enclosure Base, Posi Drive Special ZMA-330, Ver. 6 Requesting a Repair • 67 Electrical Components This section identifies the electrical component part numbers. It includes the following illustrations: ■ ■ Figure B.5, Electrical Sub-Panel Parts, on page B-68 Figure B.6, Detector Bracket and Backup Battery Assembly Parts, on page B-70 Figure B.5 Electrical Sub-Panel Parts 19 20 1 16 3 2 4 18 5 6 17 7 16 8 15 13 12 14 11 10 9 Table B-5 — Electrical Sub-Panel Part Numbers No. on Figure Part Number Description 1 20-11931 Electronics Subpanel 2 50-25799 Electronics Shield 3 21-11897 Motor Driver Board 4 See Description #10-24 x 1/2” Pan Head Screw 5 See Description #6-32 Keps Nut (small) 6 20-11912 DIN Rail (35mm) 7 See Description #6-32 Keps Nut 68 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Table B-5 — Electrical Sub-Panel Part Numbers (Continued) No. on Figure Part Number Description 8 See Description #6-32 x 3/8” Flat Head Screw 9 11-0700 Handy-Box Cover 10 11-0699 Handy-Box Duplex 11 11-3343 Grommet 12 21-11947 Fastener, Power Supply, Right Hand 13 21-11927 Power Supply, Industrial Gate 14 21-11947-2 Fastener, Power Supply, Right Hand 15 21-11929 Circuit Breaker, 5 AMP 2 Pole Time Delay 16 21-11946 PC Board Holder, DIN Rail Mtd. 17 22-10345 PC Board Assembly, Industrial Gate 18 11-1099 Switch, SPDT 19 20-11932 Switch Bracket, Raise/Lower 20 11-1099nut Switch Nut PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 69 Figure B.6 Detector Bracket and Backup Battery Assembly Parts 1 2 Table B-6 — Detector Bracket and Backup Battery Assembly Part Numbers No. on Figure Part Number Description 1 20-11999 DETECTOR BRACKET, PosiDRIVE GATE 2 21-11935 BATTERY BACKUP ASSY, PosiDRIVE GATE Standard Gate Arm You can purchase: ■ ■ ■ “Individual Components” on page B-71 “Gate Arm Assemblies” on page B-72 “Gate Arm Packages” on page B-72 70 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Individual Components Figure B.7 Standard Gate Arm Parts 1 3 5 2 6 4 Table B-7 — Standard Gate Arm Individual Part Numbers No. on Figure Part Number Description 1 50-25463 Gate Arm, Round 2 20-12186 Reflective Tape 3 50-14048 Label, Gate Arm PosiDRIVE Caution, Symbols 4 51-26545 Plastic End Cap 5 50-25099 Arm Clamp 6 50-25102 Anti-slip Insert PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 71 Gate Arm Assemblies Gate Arm Assembly includes all gate arm parts. Gate Arm Assembly part numbers are: ■ ■ ■ ■ ■ ■ 10 ft: 12 ft: 14 ft: 16 ft: 18 ft: 20 ft: 53-14065 53-14066 53-14067 53-14068 53-14069 53-14070 Gate Arm Packages Gate Arm Packages includes all gate arm parts and mainsprings. Gate Arm Package part numbers are: ■ ■ ■ ■ ■ ■ 10 ft: 53-14059 12 ft: 53-14060 14 ft: 53-14062 16 ft: 53-14063 18 ft: 53-14063 20 ft: 53-14064 72 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Folding Gate Arm This section shows the part numbers for the folding gate arm components and for the folding gate arm packages. It includes the following illustrations: Figure B.8, Folding Gate Arm and Stabilizer Parts, on page B-73 Figure B.9, Folding Gate Arm Cable Tower Parts, on page B-75 Figure B.10, Folding Gate Arm Adapter and Fixed Section Parts, on page B-76 Figure B.11, Folding Gate Arm Packages, on page B-77 ■ ■ ■ ■ Figure B.8 Folding Gate Arm and Stabilizer Parts 1 2 3 9 4 10 5 11 12 6 7 8 13 Table B-8 — Folding Gate Arm with Stabilizer Part Numbers No. on Qty. Figure Part Number Description 1 1 20-4828 Gate Arm, 10 ft. Tapered, Folding Section 2 1 20-0051 Gate Arm Stabilizer 3 2 See Description #10-24 x 1.50 Pan Head Screw PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 73 Table B-8 — Folding Gate Arm with Stabilizer Part Numbers (Continued) No. on Qty. Figure Part Number Description 4 3 See Description 3/8 - 16 UNC Hex Nut 5 17 See Description 3/8" Lock Washer 6 1 See Description 0.375 x 1.00 Shoulder Screw 7 2 20-0056 Bushing, 3/8" 8 1 20-4828 Gate Arm, 10 ft. Tapered, Fixed Section 9 8 See Description #10 - 24 Keps Nut Zinc Plated Steel 10 20 See Description 3/8” Plain Washer 11 3 See Description 5/16 - 18 UNC Nylock Hex Nut 12 7 See Description 3/8 - 16 UNC x 1.50" Hex Bolt 13 1 11-4127 3" Turnbuckle 74 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Figure B.9 Folding Gate Arm Cable Tower Parts 2 1 3 4 5 6 7 Table B-9 — Folding Gate Arm Cable Tower Part Numbers No. on Figure Qty. Part Number Description 1 1 20-3332 Spacer, Folding Arm Cable 2 20 See Description 3/8” Plain Washer 3 3.87’ 11-3335 Cable, 3/18" DIA Steel 4 3 See Description 3/8 - 16 UNC Hex Nut 5 1 50-14076 Cable Tower 6 10 See Description 5/16 - 18 UNC x 1” Hex Bolt 7 18 See Description 5/16" Plain Washer PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 75 Figure B.10 Folding Gate Arm Adapter and Fixed Section Parts 2 1 3 4 5 Table B-10 — Folding Gate Arm Adapter and Fixed Section Part Numbers No. on Figure Qty. Part Number Description 1 16 See Description 3/8 - 16 UNC Hex Nut Zinc Plated Steel 2 17 See Description 3/8" Lock Washer 3 1 50-14074 Adapter, Folding Arm 4 1 20-4828 Gate Arm 10 ft. Fixed Section 5 1 50-14075 Arm Retainer 76 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Figure B.11 Folding Gate Arm Packages D4 D5 D3 6.00 152.4 Type Left Hand Part # Right Hand Part # Clearance Arm Cable Vehicle Clearance from Length Length Clearance from Curb Roadway Std. 53-14078 53-14084 55-3/4” 40-1/2” 7’-4” 7’-3” 7’-9” ADA 53-14085 53-14086 70-3/4” 55-1/2” 8’-8” 8’-7” 9’-1” PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 77 Drive Mechanism This section identifies the drive mechanism component part numbers. It includes the following illustrations: ■ ■ ■ Figure B.12, Drive Mechanism Installation Parts, on page B-78 Figure B.13, Drive Mechanism Frame Parts (View 1), on page B-79 Figure B.14, Drive Mechanism Parts (View 2), on page B-80 Figure B.12 Drive Mechanism Installation Parts 1 2 3 4 Table B-11 — Drive Mechanism Installation Parts No. on Figure Part Number Description 1 n/a 5/16 Lock Washer (4 required) 2 n/a 5/16-18 x 3/4 Hex Head Cap Screw (4 required) 78 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Table B-11 — Drive Mechanism Installation Parts (Continued) No. on Figure Part Number Description 3 20-11914 SEAL, MAIN SHAFT INDUSTRIAL GATE 4 20-11913 SIDE SHIELD, MAINSHAFT INDUSTRIAL GATE Figure B.13 Drive Mechanism Frame Parts (View 1) 8 5 3 1 2 6 7 4 Table B-12 — Drive Mechanism Frame (View 1) Part Numbers No. on Figure Part Number Description 1 21-11908 Bump Stop 2 See Description 3/8” Lock Washer 3 20-11905 Motor Bearing Support 4 21-11906 Bearing, Motor Support 5 21-11896 Motor 6 20-11907 Motor Crank 7 See Description 3/8-16 UNC x 1.50” Hex Bolt PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 79 Table B-12 — Drive Mechanism Frame (View 1) Part Numbers (Continued) No. on Figure Part Number Description 8 50-26748 Connecting Rod Figure B.14 Drive Mechanism Parts (View 2) 7 8 10 12 11 9 14 2 3 15 4 6 5 1 13 Table B-13 — Drive Mechanism (View 2) Part Numbers No. on Figure Part Number Description 1 20-11918 Mechanism Frame 2 21-11901 Bearing Main Shaft 3 See Description 3/8” Lock Washer 4 See Description 3/8” Hex Nut 5 See Description 1/2-13 x 1-1/4 Hex Bolt 6 50-25566 Mainshaft Crank Part 1, Steel 7 See Description 3/8-16 UNC x 2” Hex Bolt 8 50-25567 Mainshaft Crank Part 2, Steel 9 21-11921 Bearing, Spring Crank 80 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Table B-13 — Drive Mechanism (View 2) Part Numbers (Continued) No. on Figure Part Number Description 10 20-11922 Mainspring Pivot Bar 11 See Description 1/2” Plain Washer, Zinc Plated 12 See Description 1/2-13 x 5 Hex Bolt 13 20-11923 Mainspring Connection Bar 14 20-11920 Spring Crank 15 50-25098 Mainshaft PosiDRIVE Security Gate ZMA-330, Ver. 6 Requesting a Repair • 81 82 • Requesting a Repair ZMA-330, Ver.6 PosiDRIVE Security Gate Index A AC mains .............................................................11 auto/manual switch ..............................................12 automatic operation ...............................................2 auto-raise, enabling..............................................44 B backout detection, enabling .................................44 backout time, setting............................................43 backup battery......................................................10 part number...................................................70 battery, backup.....................................................10 C cabinet components.....................................................6 description of ..................................................6 installing .......................................................20 footprint dimensions..............................21 opening .........................................................16 part numbers .................................................67 removing cap ................................................17 cable tower...........................................................29 cap, enclosure part numbers .................................................65 removing.......................................................17 circuit breaker switch description of ................................................12 part number...................................................69 components electrical, description of ...............................10 mechanical, description of..............................7 connecting rod description of ..................................................9 greasing bearings ..........................................47 controller..............................................................12 inputs ............................................................15 outputs ..........................................................16 overview .......................................................14 D dimensions enclosure installation, for .............................21 folding gate arm............................................77 DIP switches overview .......................................................15 setting ...........................................................42 door safety switch ................................................12 draw latch.............................................................17 PosiDRIVE Security Gate drive mechanism aligning .........................................................54 frame ...............................................................8 part numbers ..........................................80 installation part numbers ..........................................78 overview .......................................................10 part numbers .................................................78 E electrical components ..........................................10 description of ................................................10 electrical sub-panel ..............................................12 illustration of.................................................11 part numbers .................................................68 enclosure components.....................................................6 description of ..................................................6 installing .......................................................20 footprint dimensions..............................21 opening .........................................................16 part numbers .................................................67 removing cap ................................................17 enclosure cap part numbers .................................................65 enclosure door part numbers .................................................66 F flange, gate arm......................................................9 folding gate arm cable tower....................................................29 dimensions ....................................................77 overview .......................................................13 part numbers .................................................73 free mode ...............................................................3 G gate arm advancing manually ......................................49 aligning drive mechanism.............................54 changing configuration .................................34 defining length ..............................................43 dimensions for folding arm...........................77 disabling lock-down feature .........................40 flange ..............................................................9 folding gate arm overview ................................................13 part numbers ..........................................73 ZMA-330, Ver. 6 Index • 83 installing .......................................................25 folding gate arm ....................................27 standard gate arm ..................................26 locking ..........................................................49 lowering........................................................49 part numbers .................................................70 raising ...........................................................49 standard gate arm overview ................................................13 part numbers..........................................71 unlocking ......................................................49 Gate Up output.....................................................16 H handy-box ............................................................11 help ......................................................................58 I inputs....................................................................15 installation changing gate arm configuration ..................34 disabling lock-down feature .........................40 enclosure.......................................................20 installing the gate arm ..................................25 folding gate arm ....................................27 standard gate arm ..................................26 overview .......................................................20 setting DIP switches .....................................42 setting mainsprings.......................................38 wiring the gate ..............................................23 J junction box .........................................................11 part number...................................................69 L locked down feature.............................................40 Loop A input........................................................15 Loop B input ........................................................15 M main power feed ..................................................11 mainshaft bearings...........................................................9 crank ...............................................................9 description of ..................................................9 mainshaft bearings, greasing ...............................47 mainspring adjustment bolts..............................................9 connection bar ................................................9 crank ...............................................................9 installing .......................................................52 84 • Index pivot bar ..........................................................9 setting............................................................38 mainsprings adding ...........................................................52 description of ..................................................7 part numbers .................................................64 removing .......................................................52 replacing .......................................................52 setting............................................................38 maintenance, preventive ......................................46 manual operation....................................................2 manual/auto switch ..............................................12 mechanical components.........................................7 description of ..................................................7 modes free mode ........................................................3 pay mode.........................................................4 pay/free mode .................................................5 motor ................................................................7, 10 crank ...............................................................9 description of ..................................................9 power ............................................................12 motor driver board ...............................................12 part number...................................................68 O operation automatic ........................................................2 free mode .................................................3 pay mode .................................................4 pay/free mode ..........................................5 during power failure .......................................6 manual ............................................................2 operational overview..............................................2 optimum operating temperature.............................2 orders how to place..................................................62 outputs..................................................................16 overview installation ....................................................20 operational ......................................................2 structural .........................................................6 P part numbers drive mechanism...........................................78 electrical sub-panel .......................................68 enclosure .......................................................67 enclosure cap ................................................65 enclosure door...............................................66 folding gate arm............................................73 mainsprings...................................................64 standard gate arm..........................................71 ZMA-330, Ver.6 PosiDRIVE Security Gate pay mode................................................................4 pay/free mode ........................................................5 PosiDRIVE controller..........................................12 inputs ............................................................15 outputs ..........................................................16 overview .......................................................14 power failure backup battery ..............................................10 detection .........................................................6 enabling auto-raise feature ...........................44 gate operation, during.....................................6 power receptacle wiring illustration .........................................23 power supply..................................................10, 13 part number...................................................69 preventive maintenance .......................................46 problems, resolving..............................................48 R Raise/Lower input................................................15 repair requesting .....................................................62 Reset switch .........................................................14 right-/left-hand configuration ..............................34 S safety switch ........................................................12 sinusoidal mechanism............................................7 SRO .....................................................................62 structural overview ................................................6 System Fault output .............................................16 T technical support..................................................58 temperature, optimum............................................2 troubleshooting ....................................................48 V vend counts, enabling ..........................................42 Vend input ...........................................................15 W warning label, gate arm........................................27 wiring.............................................................23, 24 power receptacle...........................................23 PosiDRIVE Security Gate ZMA-330, Ver. 6 Index • 85 86 • Index ZMA-330, Ver.6 PosiDRIVE Security Gate For Sales and Service, Contact Your Local Federal APD Distributor: 42775 Nine Mile Road • Novi, Michigan 48375 • USA Tel: (248) 374-9600• Fax : (248) 374-9610 USA Toll Free: (800) 521-9330 • CN Toll Free: (800) 331-9144 www.FederalAPD.com © Federal APD, Inc. The features described in this manual may not be included with every model, and Federal APD reserves the right to modify its products and supporting documentation without notice.