1 Power-Up / Initialisation Procedure
This procedure must be carried out once each time the control panel is switched on from cold (i.e. after a full power-down). It initialises the door, checks the dock leveller, and prepares the loading bay for normal operation.
1
Apply power. Upon switching on the control panel, the red LED illuminates solid and the green LED remains off. Wait approximately 20 seconds for the system to complete its internal checks.
2
Watch for the ready signal. After approximately 20 seconds, the red and green LEDs begin flashing alternately — red on / green off, then green on / red off, continuously. This indicates the system is ready for the first operator input.
3
Press the "Door Open" button (once). The door will begin rising, automatically searching for the correct opening height. During travel:
Red LED — flashing
Green LED — flashing
4
Door reaches open position. Once the door has found the opening height and stopped:
Red LED — flashing
Green LED — solid
5
Press the "Park" button. This activates the dock leveller, driving it to its parked (home) position. During this cycle:
Red LED — flashing
Green LED — off
6
Dock leveller reaches parked (home) position. Once the dock leveller confirms it is parked:
Red LED — solid
Green LED — off
7
Press the "Door Closed" button. The door will descend and close fully. Once the door is confirmed closed:
Outside traffic light — green
Panel red LED — solid
Panel green LED — off
8
Initialisation complete. The loading bay is now initialised and ready for normal use.
Note: This full sequence is only required on initial power-up. Subsequent operations during normal use do not require repeating this procedure.
2 Normal Operation (Loading / Unloading)
After the initialisation procedure has been completed (Section 1), the loading bay is ready for normal day-to-day use. The following procedure is carried out for each vehicle arrival.
Indicator state at start of procedure
- Panel red LED — solid (ready for next trailer)
- Panel green LED — off
- Outside traffic light — green
1
Open the door. Press the Door Open button. The outside traffic light changes to red, and the door rises to its fully open position. Wait for the door to reach the top before proceeding.
2
Raise the dock. Press and hold the Raise Dock button. The dock leveller raises towards the top position.
Safety interlock: You must hold the Raise Dock button for more than 2 seconds. This timer ensures the main dock plate is fully raised before the lip extension function is enabled.
Warning: If you release the Raise Dock button before the 2-second timer completes, the dock will automatically return DOWN to its home (parked) position. You will need to restart from Step 2.
3
Extend the lip. Once the 2-second timer has elapsed, the Lip Out function becomes active. Press and hold the Lip Out button. The lip will extend towards the trailer floor. Continue holding until the lip reaches the trailer floor.
Important: Ensure minimum lip contact on the trailer is at least 50 mm. If the lip does not reach the trailer floor, do not proceed — check trailer alignment and reposition as necessary.
4
Dock floats to trailer floor. Release the Lip Out button. After a 2-second delay, the dock will float, lowering the deck and lip onto the trailer floor. Once the dock has settled:
Inside Panel LED changes from red to green
Outside traffic light — remains red
5
Load / unload. The bay is now ready for loading or unloading operations.
6
Park the dock leveller. Once loading/unloading is complete, press the Park button once. The dock leveller returns to its home (parked) position. Once parked:
Panel LED changes from green to red
Outside traffic light — remains red
7
Close the door. Press the Door Closed button. The door descends to the fully closed position. Once closed:
Outside traffic light — changes to green
Panel red LED — solid
Panel green LED — off
8
Bay ready for next trailer. The loading bay is now reset and ready for the next vehicle.
Quick Reference: Indicator Summary
| Bay State | Panel Red | Panel Green | Outside T/L |
|---|
| Ready / idle | Solid | Off | Green |
| Door opening / open | Solid | Off | Red |
| Dock raising | Solid | Off | Red |
| Dock resting on trailer (loading) | Off | Solid | Red |
| Dock parking (returning home) | Solid | Off | Red |
| Door closing | Solid | Off | Red |
| Ready for next trailer | Solid | Off | Green |
Key Safety Timers Summary
| Button | Hold Requirement | Behaviour if Released Early |
|---|
| Raise Dock | > 2 seconds | Dock returns DOWN to home position |
| Lip Out | Until lip reaches trailer floor | Lip stops extending; dock remains at current height |
3 Emergency Stop and Safety Reset Procedures
3.1 Emergency Stop (E-Stop) Activation
When the E-Stop button is pressed at any time:
- All movement stops immediately — this includes the door and the dock leveller, regardless of what operation is in progress.
- Panel red LED — flashing
- Panel green LED — off
- Outside traffic light — turns red (regardless of whether the door is open or closed)
3.2 Releasing the E-Stop
To release the E-Stop, pull out the E-Stop button. Upon release:
- Panel red LED — solid
- Panel green LED — flashing
The system is now in a reset-ready state. The reset procedure depends on what the dock and door were doing when the E-Stop was activated.
3.3 Reset Procedure A — Dock was at Home (Parked) when E-Stop was pressed
Use this procedure if the dock leveller was in its home/parked position at the time the E-Stop was activated.
1
Release the E-Stop (if not already done). Red LED solid, green LED flashing.
2
Press the Door Open button. The door will travel to the fully open position. If the door was already at the top, it will remain there — no movement occurs.
3
Wait for the reset timer. Once the door is at the top, the green LED will continue flashing for 10 seconds. Do not operate any controls during this time.
4
Reset complete. Once the green LED goes out, the system is reset and you may close the door or deploy the dock.
Important: The outside traffic light will only return to green once the door is fully closed after the reset is complete.
3.4 Reset Procedure B — Dock was Deployed or in the Trailer when E-Stop was pressed
Warning: If the E-Stop was activated while the dock leveller was raised, mid-travel, or resting on a trailer, a full power cycle and initialisation is required.
1
Switch OFF the power isolator. Turn the main power isolator to the OFF position. This removes all power to the control panel.
2
Pull out the E-Stop button. Physically pull the E-Stop button to its released position.
3
Switch ON the power isolator. Restore power to the control panel.
4
Carry out the full Power-Up / Initialisation Procedure. Follow Section 1 from the beginning. This will re-home the dock leveller and prepare the bay for normal use.
3.5 Door Safety Edge / Torque Switch Reset
The door is fitted with a safety edge and a torque switch that detect obstructions during the closing cycle. If either is triggered:
- The door stops immediately during closing
- Panel red LED — solid
- Panel green LED — flashing
These LED states will persist until the door travels back up to the fully open position and the reset timer completes.
1
Press the Door Open button — the door will travel back up to the fully open position.
2
Once at the top, the green LED will flash for 10 seconds.
3
Once the green LED goes out, the system is reset and you may close the door or deploy the dock.
4
Outside traffic light will only turn green once the door is fully closed.
Important: If the safety edge or torque switch triggers repeatedly, do not keep resetting. Inspect the door area for obstructions or damage before attempting another close cycle.
Quick Reference: E-Stop and Safety Trip LED States
| Event | Panel Red | Panel Green | Outside T/L |
|---|
| Normal idle | Solid | Off | Green |
| E-Stop pressed | Flashing | Off | Red |
| E-Stop released (reset mode) | Solid | Flashing | Red |
| Safety edge / torque trip | Solid | Flashing | Red (unchanged) |
| Door at top, 10 sec timer active | Solid | Flashing | Red (unchanged) |
| Reset complete, door open | Solid | Off | Red |
| Reset complete, door closed | Solid | Off | Green |
Key Safety Rules Summary
- E-Stop always makes outside traffic light go red — even if the door is closed.
- Red flashes, green off when E-Stop is pressed. When released, red goes solid and green flashes.
- Reset requires door to go to the top and complete the 10-second green LED timer.
- Outside traffic light only returns to green after the door is fully closed.
- Dock deployed/in trailer + E-Stop = full power cycle required (cannot just reset via Door Open button).
4 Operator Requirements and Access Restrictions
4.1 Authorised Operators Only
This loading bay control panel must only be operated by personnel who have received formal training on its use and have been authorised by the site supervisor or facilities manager.
Untrained personnel must not attempt to operate the door, dock leveller, or any control panel functions under any circumstances.
4.2 Control Panel — Internal Access
Warning: The control panel enclosure must not be opened by operators or site staff. Internal components carry hazardous voltages and are protected by safety interlocks.
Only qualified loading bay engineers are permitted to access the interior of the control panel. Unauthorised opening of the enclosure may result in:
- Risk of electric shock or injury
- Damage to equipment
- Voiding of any warranty or service agreement
If a fault is suspected that requires internal access, contact your approved loading bay service provider.
5 Maintenance and Servicing
5.1 Scheduled Service Interval
The loading bay equipment must be serviced every 6 months by a qualified loading bay engineer. This service must include as a minimum:
- Inspection and testing of all safety systems (E-Stop, safety edge, torque switch)
- Inspection of door tracks, rollers, and drive mechanism
- Inspection of dock leveller structure, hinges, and lip
- Checking all electrical connections and control panel components (internal)
- Lubrication of moving parts as required
- Functional test of full power-up sequence (Section 1)
- Functional test of normal operation sequence (Section 2)
- Verification of all LED indications and external traffic light
5.2 Operator Daily Checks
Operators should carry out the following visual checks before first use each day:
- Confirm no visible damage to door, dock leveller, or surrounding structure
- Confirm control panel buttons move freely and are not damaged
- Confirm E-Stop button is in the released (out) position
- Confirm outside traffic light is functional (green when bay is idle)
- Confirm door area is clear of obstructions
If any daily check fails, do not use the bay. Report the issue to your supervisor and contact a loading bay engineer.
6 Sign-Off Pages
6.1 Trained Operators Register
The following personnel have received training on the safe operation of this loading bay control panel and are authorised to operate the equipment.
| Name | Signature | Date Trained | Trained By |
|---|
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6.2 Service Engineer Record
The following service visits have been carried out by qualified loading bay engineers.
| Date of Service | Engineer Name | Company | Work Carried Out | Signature |
|---|
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Document History
| Version | Date | Changes Made | Author |
|---|
| 0.1 | | Initial release | |
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7 Technical Specifications
7.1 Electrical Ratings
| Equipment | Voltage | Phase / Configuration | Motor Rating / Notes |
|---|
| Door opener | 230V AC | Single phase | Delta motor, ½ HP |
| Dock leveller | 400V AC | Three phase, star connected | 1 HP |
| Traffic light (external) | 24V DC | — | Signal light |
| Control panel LEDs | 24V DC | — | Status indicators (red/green) |
| Dock light | 230V AC | Single phase | Illumination inside bay |
7.2 Internal Protection
The control panel is fitted with the following internal protective devices:
| Device | Protected Circuit |
|---|
| Motor overload | Dock leveller motor |
| MCB | Door motor circuit |
| MCB | Control circuit (traffic light, LEDs, dock light, 24V DC supply) |
Important: Overload and MCB settings are factory-configured. Do not adjust or bypass these devices. If a protective device trips repeatedly, contact a loading bay engineer.
7.3 Incoming Supply Requirements
The panel requires the following incoming supply connection:
| Parameter | Requirement |
|---|
| Supply type | Three-phase and neutral |
| Voltage | 400V AC (phase-to-phase) / 230V AC (phase-to-neutral) |
| Protective conductor | Earth required |
| Incoming protection | 16A Type C MCB (to be provided at the distribution board) |
| Phase configuration | Star connected (three-phase + N + E) |
Important: All electrical installations must comply with local regulations and be carried out by a competent person. The supply must include appropriate over-current protection and isolation for each circuit. The incoming 16A Type C MCB must be installed at the feeding distribution board by a competent person.