GFA LB 700 Installation Instructions Manual

Wiesenstraße 81 • 40549 Düsseldorf www.gfa-elektromaten.de [email protected]

1 Specifications ............................................................................................................... 5 2 Recommended installation ............................................................................................ 6 3 Installing the housing .................................................................................................... 6 4 Check the power supply connection .............................................................................. 7 5 Wiring the dock leveller to the control ............................................................................ 8 6 Rapid adjustment .......................................................................................................... 9 7 PCB overview ............................................................................................................. 11 1 Terminal diagram ........................................................................................................ 12 2 Control programming .................................................................................................. 13 3 Programmingtable....................................................................................................... 14 4 Description of dock-leveller functions .......................................................................... 19 Dock leveller with hinged lip ................................................................................................... 19 Dock leveller with telescopic lip (2 valves) ............................................................................. 20 5 Description of functions of additional components ....................................................... 22 Wheel-block sensor (X5) ........................................................................................................ 22 Vehicle detector, external (X6) ............................................................................................... 22 Mechanism for release/locking of dock leveller/door (X7) ...................................................... 22 Position sensor for dock leveller (X8)..................................................................................... 22 Traffic lights / Lighting (X9) .................................................................................................... 22 Vehicle shelter (X10).............................................................................................................. 23 6 Control-device connection diagram for T801 (optional) ................................................ 24 7 Control-unit status display ........................................................................................... 25 8 Declaration of incorporation / Declaration of conformity ............................................... 27 Symbols Warning! Possible injury or danger of death! Warning! High voltage! Danger of death! Note! Important information!

Intended use The controller is intended for the actuation of dock levellers with a hinged wedge lip or an extendible lip. Operating safety is ensured only when the controller is used as intended. No liability is accepted for any use other than that described in these instructions. Modifications are allowed only with the consent of the manufacturer. Unauthorised changes render the manufacturer’s declaration void. Information on safety The system must be installed and commissioned by trained, qualified personnel only. Only qualified electricians may work on the electrical systems. They must be able to assess the work they are assigned, recognise potential sources of danger, and implement suitable safety measures. Installation work must be performed only when all power supplies are disconnected. Observe the applicable safety and accident prevention regulations and standards. Covers and protective equipment Operate only with the system’s own covers and protective equipment. Make sure that gaskets are properly seated and screw unions adequately tightened. Replacement parts Use only original replacement parts.

10 A tr. Max hydraulic unit power 1,5 kW Number of valves 2 Valve voltage 24 V DC Max valve current 1,0 A Max controller power input 30 VA Internal fusing 1,6 A tr. External lighting fusing 1,6 A tr. Traffic lights maximum power 40 W Loading ramp light maximum power 150 W Tubular motor maximum current / maximum power 1,0 / 230 A / W Maximum load current for ventilator control 1,0 A Maximum power of the fan motor 1~ 230V 0,55 kW Protection class IP 65 Ambient temperature 5-40 °C

Your dock leveller can be put into operation quickly and safely when you follow the recommended procedure below: • Install the housing • Check the power supply connection • Wire the dock leveller to the controller • Rapid adjustment The dock leveller can now be operated. • Install additional components • Program additional components and functions 3 Installing the housing The dock leveller controller must be fitted vertically to a plane foundation free of vibrations. The installation site must be seen clearly from the dock leveller room.

Warning - Danger to life from electric current!  Switch the mains OFF and check that the cables are de-energised  Observe the applicable regulations and standards  Make a proper electrical connection  Use suitable tools Important note – External fuse! Control must be saved against short circuit and overload by an external fuse, max. 10A delayed, in the mains supply. An automatic cut off switch is required, regarding the supply for three-phase or single-phase. Main supply connection Alternative main supply connection 1.1 1.2 1.3 1.4 L2 L1 L3 PE X 1.1 1.2 1.3 1.4 L2 L1 L3 N PE 3~ 400V, N, PE X

Once installed, the dock leveller controller must be wired to the electrical componentry of your dock leveller system. Connecting the hydraulic motor M 3~ 1 2.1 2.2 2.3 2.4 V U W PE X M1 Hydraulic motor X2 Dock leveller controller terminal block Dock leveller system terminal for hinged lip 3.2 3.1 + - Y1 X X3 Dock leveller controller terminal block Y1 Platform / hinged lip valve Dock leveller system terminal for extendible lip 3.1 + - Y1 3.4 3.3 + - Y2 X X ⓐ 3.1 + - Y1 3.4 3.3 + - Y2 X ⓑ X3 Dock leveller controller terminal block Y1 Platform valve Y2 Extendible lip valve

After switching ON the controller, you can select the function for the dock leveller. 1. Switch ON 2. Select menu Press and turn the selector 3. Select hinged lip or extendible lip 4. Save program item Press the selector and select next program function by repeating the procedure from 2 Continue for all further settings.

2. Select the program function 3. Time selection Min lip advance time 0,1 - 3,0 Seconds Max lip advance time 1,0 - 20,0 Seconds Max platform raising time 1,0 - 20,0 Seconds Autoreturn raising time 1,0 - 20,0 Seconds Autoreturn lowering time 1,0 - 20,0 Seconds Parameters for extendible lip mode 2. Select the program function 3. Time selection Min lip advance time 0,1 - 3,0 Seconds Max lip advance time 1,0 - 20,0 Seconds Max lip retract time 1,0 - 20,0 Seconds Min platform raising time 0,1 - 3,0 Seconds Max platform raising time 1,0 - 20,0 Seconds Autoreturn raising time 1,0 - 20,0 Seconds Autoreturn lowering time 1,0 - 20,0 Seconds Autoreturn reverse 0,0 - 1,5 Seconds 5. Exit programming Rapid adjustment ends automatically when the last program function is set. The controller switches to P0.

2.1 1.1 2.2 1.2 2.3 1.3 2.4 1.4 9.1 5.1 5.2 5.3 6.1 6.2 6.3 7.1 7.2 7.3 7.4 8.1 8.2 9.2 9.3 9.4 9.5 9.6 9.7 9.8 1.6 1.5 X2 X1 X9 X10 F2= 1,6A tr. F1= 1,6A tr. X3 X5 X6 X7 X8 S1 V1 X4 SR 10.1 10.2 10.3 10.4 10.5 3.1 3.2 3.3 3.4 3.6 3.5 7.5 + - + - + - Ser.Nr. : xxxxxxxx Artikel Nr. 20-30004984 HW x.x SW x.x X1 Power supply terminal X9 Traffic light indicators / lighting X2 Hydraulic motor terminal X10 Vehicle shelter X3 Valve terminal V1 Display X4 Command key S1 Adjusting knob X5 Wheel chock sensor F1 Controller fusing X6 Vehicle detector F2 Traffic light indicators / lighting fusing X7 Dock leveller unlock/lock X8 Dock leveller position sensor SR Seriennumber

X1 Supply X2 Hydraulic motor X3 Dock leveller valves 1.1 1.2 1.3 1.4 L2 L1 L3 N PE X ① 2.1 2.2 2.3 2.4 V U W PE X M 3~ 1 ② 3.2 3.1 + - Y1 ⓐ 3.1 + - Y1 3.4 3.3 + - Y2 X ⓑ 3.1 + - Y1 3.4 3.3 + - Y2 X ⓒ 3~ 400V, N, PE M1: Motor Hinged lip Extendible lip Extendible lip X5 Wheel chock sensor X6 Vehicle detector 5.1 5.2 5.3 S1 ⓐ X S1 R1 5.1 5.2 5.3 ⓑ X A1 5.1 5.2 5.3 + - S ⓒ X 6.1 6.2 6.3 S2 ⓐ X S2 R2 6.1 6.2 6.3 ⓑ X A2 6.1 6.2 6.3 + - S ⓒ X S1: Changeover R1: 8k2 A1: Sensor S2: Changeover R2: 8k2 A2: Sensor Resistance Sensor unit Resistance Sensor unit S1: NO contact 24V DC S2: NO contact 24V DC X7 Ramp/door unlock X8 Dock leveller position sensor 7.1 7.2 7.3 X KR A4 7.5 A4 X KT 8.1 8.2 X S3 A4: Door controller A4: Door controller S3: NO KR: NO (floating) KT: NO (floating) X9 Traffic light indicators / lighting X10 Vehicle shelter 9.1 9.2 9.3 H1 H2 ① X 9.4 9.5 9.6 H4 H3 ② X 9.7 9.8 H5 ③ X 10.1 10.2 10.3 M 1~ 2 UZ N L U1 Z1 CB KZ1 KU1 X X 10.4 10.5 A 3 K L N L ext traffic light int traffic light lighting CB: Operating capacitor A3: Fan controller H1: Red H3: Red H5: Headlamp M2: Tubular motor 1~ 230V, KL: NO contact (floating) H2: Green H4: Green KU1: NO (floating) KZ1: NO (floating))

1. Switch ON programming Press the selector for three seconds until 00 appears on the display 2. Adjustment Turn the selector until the program function you want appears, and confirm 3. Select function Turn the selector and select the function you want 4. Set program Press the selector, and select the next program item or switch OFF programming 5. Switch OFF programming Turn the selector until 00 appears on the display, and confirm

confirmation 3 Setting 4 Storing Operating mode Dock leveller with hinged lip Press setting button Dock leveller with telescopic lip (2 valves) Energy-saving mode Off Press setting button On Positions Minimum extension duration, lip 1.0 - 3.0 Seconds Press setting button Maximum extension duration, lip 1.0 - 20.0 Seconds Maximum retraction duration, lip 1.0 - 20.0 Seconds Minimum lifting duration, ramp 0.1 - 3.0 sSeconds Maximum lifting duration, lip 1.0 - 20.0 Seconds Lifting duration, “Auto return” function 1.0 - 20.0 Seconds Lowering duration, “Auto return” function 1.0 - 20.0 Seconds Retraction, automatic 0.0 - 1.5 Seconds

confirmation 3 Setting 4 Storing Wheel-block sensor Without sensor Press setting button With sensor Vehicle detector Without detector Press setting button With detector Position sensor for dock leveller Without sensor Press setting button Sensor with permanent contact Sensor with pulse contact Signals Red/green traffic lights, external No lights Press setting button 0 to 360 Seconds Red/green traffic lights, internal No lights Press setting button With lights With lights and wheel-block sensor monitoring Dock-leveller headlamp Off Press setting button On with button On with OPEN door

confirmation 3 Setting 4 Storing Release / Locking of dock leveller / door Off Press setting button Release via door contact Release via door contact and vehicle detector Release via door contact and door release via vehicle detector Vehicle shelter None Press setting button Tubular motor function Fan function Tubular-motor and fan functions “On / Off” control for vehicle shelter None Press setting button Automatic “on / off” via door Manual “on / off” via button Manual “on” via button / automatic “off” via door Automatic “on” via door / manual “off” via button “On / Off” control via wheel- block sensor

confirmation 3 Setting 4 Storing Hinged wedge sensor 00 = Telescopic lip 01 = sensitive 20 = insensitive Press setting button Maintenance Maintenance cycle counter pre-selection 01-99 corresponds to 1,000- 99,000 cycles to be counted down Press setting button Response of maintenance cycle counter Indication in “CS” display with previously-set value Press setting button Changeover of the auto-reset function to hold-to-run with “CS” display and set value

Display Cycle counter info, 7-digit display Press setting button M HT ZT T H Z E Coefficients of powers of ten from one million down to one are displayed successively M = HT = ZT = T = 1,000,000 100,000 10,000 1,000 H = Z = E = 100 10 1 Info on last two faults Press setting button The two most recent faults detected are indicated alternately Program change info, 7- digit display Press setting button M HT ZT T H Z E Coefficients of powers of ten from one million down to one are displayed successively M = HT = ZT = T = 1,000,000 100,000 10,000 1,000 H = Z = E = 100 10 1 Software version info Press setting button The program version is displayed. System 2. Menu selection and confirmation 3 Setting 4 Storing Deleting of all settings apart from those for cycle and program- change counters Press “Open” button Keep “Auto return” button pressed for 3 seconds Delete Press “Open” button Keep “Auto return” button pressed for 3 seconds Delete

The rapid adjustment procedure must have been completed and the dock leveller has to be at its home position Dock leveller with hinged lip Pressing the “Open” button The platform is raised. The hinged lip automatically folds out to the top limit position. Releasing the “Open” button Platform stops rising and is slowly lowered. The process is complete when the hinged lip rests on the loading surface. Movement across the dock leveller is now Pressing the “Auto return” button The dock leveller is automatically raised and then lowered again until its home position is reached

Pressing the “Open” button ① The platform is raised. Releasing the “Open” button Platform stops rising and is lowered after 2 seconds, provided that no further command is issued. Pressing the “Telescopic lip” button ② The telescopic lip extends. Releasing the “Telescopic lip” button The telescopic lip stops moving and the platform is slowly lowered. The process is complete when the telescopic lip rests on the loading surface. Movement across the dock leveller is now possible. Telescopic lip correction If the telescopic lip is extended, it is retracted by pressing the “Open” button ①.

The dock leveller is automatically raised and then lowered again until its home position is reached

Wheel-block sensor (X5) If the wheel block is placed against a tyre of the vehicle, the dock leveller can be operated. The external traffic lights change from green to red. Activation with menu 3.1 Vehicle detector, external (X6) If the vehicle is detected by the detector, the external traffic lights change from green to red. Activation with menu 3.2 Mechanism for release/locking of dock leveller/door (X7) The “door - dock leveller” or “dock leveller - door” sequence is controlled via the lock contact. It is possible to incorporate a vehicle detector for the release function. The door release contact is switched with the dock leveller at its standby position. Activation with menu 5.1 Position sensor for dock leveller (X8) The detection of the dock leveller at its standby position is achieved via an external additional contact. Activation with menu 3.3 Traffic lights / Lighting (X9) The dock-leveller control system has outputs for a headlamp as well as internal and/or external red/green traffic lights. External red/green traffic lights The green lamp indicates to the driver the operational readiness status of the dock leveller for docking. Once the lorry has docked, the traffic lights change to red. Here, a wheel-block sensor or vehicle detector needs to be used. If no sensor is connected, the traffic light changes to red as soon as the home position is left. The changeover from red to green is controlled via a time period setting. The time period starts as soon as the dock leveller has again reached its home position. If a wheel-block sensor is active and engaged, there will be alternate flashing of the red and green traffic lights after the changeover period has elapsed.

green signal at the traffic lights. Activation with menu 4.1 Internal red/green traffic lights The green lamp indicates that movement across the dock leveller is possible. For all other statuses, the red lamp will be lit. With the traffic lights, a non-engaged wheel-block sensor can be indicated during loading. If the wheel-block sensor is not engaged for longer than 3 seconds, the traffic light changes to red. If such a “fault” occurs, the “Open” button has to be pressed to change the traffic lights to green. Activation with menu 4.2 Headlamp If the dock leveller is operated or the door reaches the OPEN limit position, the headlamp illuminates the leveller area. Activation with menu 4.3 The outputs for the internal/external red/green traffic lights and the headlamp are protected from short-circuiting via a shared 1.6-A fuse. Vehicle shelter (X10) There are 3 isolated contacts available for connecting the vehicle shelter. For a tubular motor, two of the contacts are interlocked. With the third contact, a fan can be activated. Activation and selection with menu 5.2 The vehicle shelter can be automatically activated and deactivated via a button or a wheel- block sensor. Activation and selection with menu 5.3.

S14 “Open” control button W Connection cable S15 “Stop” control button X Terminal strip S16 “Close” control button X20 Plug-in connector T801 Control unit 7.1 1 7.2 3 7.3 4 X 7.4 7.5 1.5 N 1.6 L X X20 S14 S15 S16 8K2 2 5 6 ge gn br ws rs gr PE 1 2 1 2 3 4 5 6 ws br gn ge gr rs PE 1 2 T 801

The dock-leveller control unit can display up to three different statuses, one after the other. The displayed status code consists of a letter and a number. Here a distinction is made between a fault display (letter F) and an operation display (letter P). Display Fault description Measures for fault correction Emergency stop activated Check whether the emergency-stop control device is engaged or whether the connecting lines have a cable break. Ramp locked Open door until top limit position is reached. No vehicle recognition with vehicle detector Move vehicle closer to the dock leveller. Check the alignment of the detection unit, if required. Wheel-block sensor not activated Check whether the wheel-block sensor is being activated properly or the connecting lines have a cable break. If monitoring with internal traffic lights, reset fault status by pressing “Open” button Input key switch operated Check whether key switch has been operated. Fall below minimum extension duration for lip Movement was stopped too soon; reset the fault status with the next command (any command). Maximum extension duration for lip exceeded Check the hydraulic and mechanical systems for stiffness. Possibly correct the time setting in the program. Fall below minimum lifting duration for platform Movement was stopped too soon; reset the fault status with the next command (any command). Maximum lifting duration for platform exceeded Check the hydraulic and mechanical systems for stiffness. Possibly correct the time setting in the program. Maximum lifting duration for “Auto return” function exceeded Control button control input faulty. Switch control off and on. Replace control if necessary.

Processor fault Reset by switching off and on via the mains switch. Replace the control unit if necessary. ROM error Reset fault status by switching off and on via mains switch. Replace the control unit if necessary. Register error RAM error Hydraulic motor fault Control unit has detected an erroneous motor current value. Hinged wedge sensor too sensitive. Check motor and connecting lines. Current monitor of valve 1 activated Control unit has detected a lack of current at a valve. Check valve functioning and whether the connecting lines have a cable break. Current monitor of valve 2 activated Current monitor of valve 3 activated Display Position and status description The dock leveller is in a position that has not been detected by the control unit, e.g. following activation of power supply. The dock leveller is in its home position. The dock leveller is in its float position. The dock leveller is between the home position and the float position. The “Auto return” button has been pressed and the dock leveller returns to its home position automatically.

Declaration of incorporation within the meaning of Machinery Directive 2006/42/EC for partly completed machinery, Appendix II Part B Declaration of conformity within the meaning of EMC Directive 2014/30/EU within the meaning of RoHS Directive 2011/65/EU We, GfA ELEKTROMATEN GmbH & Co. KG declare under our sole responsibility that the following product complies with the above directives and is only intended for the control of a dock leveller. Dock leveller LB 700 Part no.: 20070000 We undertake to transmit in response to a reasoned request by the appropriate regulatory authorities the special documents on the partly completed machinery. This product must only be put into operation when it has been determined that the complete machine/system in which it has been installed complies with the provisions of the above- mentioned directives. Authorised representative to compile the technical documents is the undersigned. Düsseldorf, 10.08.2018 Stephan Kleine CEO Signature The following requirements from Appendix I of the Machinery Directive 2006/42/EC are met: 1.1.2, 1.1.3, 1.1.5, 1.2.1, 1.2.2, 1.2.3, 1.2.4.2, 1.2.5, 1.2.6, 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.9, 1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.7, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.6.1, 1.6.2, 1.6.4, 1.7.1.1, 1.7.1.2, 1.7.2, 1.7.3, 1.7.4.3. Standards applied: EN 1398:2009 Dock levellers - Safety requirements EN 61000-6-2:2005 Electromagnetic compatibility (EMC) Part 6-2 Generic standards – Immunity standard for industrial environments EN 61000-6-3:2007 Electromagnetic compatibility (EMC) Part 6-3 Generic standards – Emission standard for residential, commercial and light-industrial environments