DoorKing 1602 User Manual

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Page 1

PLASTIC FOLDING ARM KIT

Installation

DoorKing Part Number

1601-083

This kit is designed for the 1600 model barrier gate operators only. Recommended for low headroom applications.

Kit Includes:

Cut this arm first for the height limitations.

Determining First Arm Length

Cut this arm second for the traffic lane width. Note: Second arm can be a different size than the first.

Determining Second Arm Length

Cut Arms to Length

Traffic Lane Width

Total Height

Pre-Crimped Eyelet

Cable Attachment Assembly

Cable

2 Plastic Arms

(Connected)

Arm Hinge

8 Self Tapping Screws

Cable Clamp

Cable Eyelet

Locking Eye BoltLocking Turnbuckle

Note: Completed folding arm assembly shown in the UP position to illustrate the total height.

Note: Completed folding arm assembly shown in the DOWN position to illustrate traffic lane width.

120 Glasgow Avenue

Inglewood, California 90301 U.S.A.

Page 2

1601-083-C-5-08

DoorKing Part Number

1601-083

Top View of

Operator Housing

Side View of

Operator Housing

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Hub

Existing Stud

Important: Do not adjust cable too tight or it will bind.

Adjusting and Locking Cable Assembly

After adjusting cable tension, lock turnbuckle with nuts to keep turnbuckle from twisting.

Rotate arm up and down. Adjust cable tension with turnbuckle to level outer arm. Make sure that cable assembly is not binding or twisting and everything moves freely.

Lock eye bolt with nut to keep eye bolt from twisting.

Inner Arm

Outer Arm

Cable Eyelet MUST be installed in turnbuckle.

Cable Clamp

Install eye bolt into arm hinge with vise-grips. Attach arm hinge to inner arm with 4 self-tapping screws.

Allow turnbuckle to loosen or tighten.

Install inner arm on hub.

Install cable. Cable MUST clear hub!

Cut off excess cable.

Remove stud from operator housing and assemble as shown.

Bushing

Operator Housing

Adjust to clear hub.

Pre-Crimped Eyelet

Bolt Head (Inside Housing)

Washer (Inside Housing)

Locknut

Install outer arm with 4 self-tapping screws.

Installing Arms

Page 3

Note: Completed folding arm assembly shown in the UP position to illustrate the total height.

WOOD FOLDING ARM KIT

Installation

DoorKing Part Number

1601-084

This kit is designed for the 1600 model barrier gate operators only. Recommended for low headroom applications.

Kit Includes:

Cut this arm first for the height limitations.

Determining First Arm Length

Cut this arm second for the traffic lane width. Note: Second arm can be a different size than the first.

Determining Second Arm Length

Cut Arms to Length

Traffic Lane Width

Total Height

Pre-Crimped Eyelet

Cable Attachment Assembly

Cable

2 Wood Arms

Cable Clamp

2 Hinge Plates

Cable Eyelet

Locking Turnbuckle

Note: Completed folding arm assembly shown in the DOWN position to illustrate traffic lane width.

120 Glasgow Avenue

Inglewood, California 90301 U.S.A.

4 Bolts with Locknuts (Small)

Bolt with Bushing and Locknut (Medium)

Bolt with Brass Bushing and Locknut (Large)

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm

at all times.

NO:

Pedestrians Bicycles Motorcycles

WARNING

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm

at all times.

NO:

Pedestrians Bicycles Motorcycles

WARNING

Page 4

1601-084-D-5-08

DoorKing Part Number

1601-084

Top View of

Operator Housing

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Hub

Existing Stud

Important: Do not adjust cable too tight or it will bind.

Adjusting and Locking Cable Assembly

After adjusting cable tension, lock turnbuckle with nuts in position shown to prevent turnbuckle from rubbing against hinge plates when the arm is in the UP position.

Rotate arm up and down. Adjust cable tension with turnbuckle to level outer arm. Make sure that cable assembly is not binding or twisting and everything moves freely.

Inner Arm

Outer Arm

Install inner arm on hub.

Install hinge plates.

Install cable. Cable MUST clear hub!

Remove stud from operator housing and assemble as shown.

Bushing

Operator Housing

Adjust to clear hub.

Pre-Crimped Eyelet

Bolt Head (Inside Housing)

Washer (Inside Housing)

Locknut

Installing Arms

Installing Cable

Attachment Assembly

Side View of

Operator Housing

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm

at all times.

NO:

Pedestrians Bicycles Motorcycles

WARNING

Cable Eyelet MUST be installed in turnbuckle.

Cable Clamp

Allow turnbuckle to loosen or tighten.

Cut off excess cable.

Bushing

Turnbuckle

Bolt (Medium)

Bolt (Large)

4 Bolts (Small)

Brass Bushing

Installing Hinge Plates

ING

cau

us in

y o

all

time

WAR

NING

Locknut

4 Locknuts

ter A

Inner Arm

Page 5

DoorKing Part Number

MODEL 1601 FAN KIT

1601-093

This kit is designed for the 1600 model barrier gate operators only. Recommended for hot and humid climates. An automatic thermostat will control heat and humidity inside operator housing.

Kit Includes: Fan Assembly with black and white wires, 5 wire ties,

3 double stick wire tie mounts, 2 plastic wire restrainers and 3 nylon lock nuts.

Installation

Shut off ALL power to operator

Turn off the DC convenience open power switch on certain operator models FIRST then shut off the AC input power to the operator from the circuit breaker.

Route fan wires as shown. Use supplied

wire stays and existing wire restrainers.

Keep wires clear of all moving parts.

Lock Nut

Mount fan using 3 existing threaded studs and lock nuts supplied. Slide mounting tabs over existing air duct.

Housing Studs

Lock

Nut

Threaded

(Existing)

Mounting

Tab

Mounting

Tab

Existing Air Duct

Threaded Air Duct Stud (Existing)

Existing Wire Restrainers

1601-093-B-5-11

Wire Stays

Existin Air Duct

Connect the fan power

wires according to operator model type.

Exhaust Vents

Neutral

DANGER

HIGH VOLTAGE!

Hot

Neutral

1212 345

115 VAC Hot

115 VAC Models 230 VAC/460 VAC Models

Fan switch settings.

OFF - Turns the fan off.

Air

Flow

Keep intake vents clear of debris.

Intake Vents

ON - Turns the fan on continuously. AUTO - Normal setting. Automatically turns the fan ON when the

temperature rises above 90°F inside the housing, and turns the fan OFF when the temperature drops below 90°F.

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 6

DoorKing Part Number

1600 115 VAC - 3.3 AMP HEATER KIT

1601-092

This kit is designed for the 1600 model barrier gate operators only. For cold weather climates where temperatures routinely drop below 40°F (4°C). A built-in thermostat will automatically control the temperature inside operator housing.

High Voltage AC Input Power for the 1600 Barrier Gate Operator with a Heater

DO NOT use the “high voltage wire size and distance requirements” table in the Installation/Owner’s manuals to determine the high voltage AC input power wire size and distance requirements for the barrier gate operator because of a much greater current draw when using the heater. Use the table below to determine the wire size and distances for your chosen barrier gate operator when a heater is installed. EACH operator should have a “Dedicated” circuit breaker at the power source.

If the high voltage AC input power wiring is greater than the maximum distance shown, it is recommended that a service feeder be installed. When large gauge wire is used, a separate junction box must be installed for the operator connection. Wire run distances are based on NEC guidelines for copper wire allowing a maximum 3% voltage drop on the line. The calculated distance was then further reduced by 10% to allow for other loses in the system. Never run low voltage rated wire insulation in the same conduit as high voltage rated wire insulation.

High voltage AC input wire size and distance requirements for a 1600 with a heater.

Operator

and

Heater

Model Horsepower Volts 12 AWG 10 AWG 8 AWG 6 AWG

Amps

Wire Size / Distance in Feet

1601

1603

1602

1/2 HP

1 HP

115

230

460

115

230

460

9.0

4.6

2.4

13.0

6.5

3.3

105

420

1615

295

1175

175

675

2585

120

475

1880

290

1125

4310

200

795

3136

435

1685

6465

300

1190

4705

In bi-parting (dual) barrier gate applications, high voltage AC input power

is required for EACH 1600 operator with heater.

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 7

DoorKing Part Number

Installation of Heater

1601-092

Kit Includes: Heater / mounting plate, 2 locknuts, 5 wire ties, 3 double stick wire tie mounts, and 2 plastic wire restrainers.

Shut off ALL power to operator.

Turn off the DC convenience open power switch on certain operator models first then shut off the AC input power to the operator from the circuit breaker.

Route heater wires as shown.

Use supplied wire stays and existing wire restrainers.

Keep wires clear of all moving parts

and the heater vents.

Mount Heater

Locate existing threaded studs in operator. Heater MUST be mounted on mounting plate. Place the 2 supplied washers between the operator wall and the mounting plate to create an air gap.

CAUTION: Heat will be

transferred to the outside wall of the operator if NO air gap exists between the heater and the inside wall of the operator.

Locknut

Washer

Mounting

Plate

Operator

Threaded

Stud

(Existing)

Operator

Threaded

Stud

(Existing)

Washer

Existing Wire Restrainers

Wire Stays

DANGER

HOT!

Air Gap

Locknut

Power Connection

Connect the heater power wires according to operator AC power type.

DANGER

HIGH VOLTAGE!

Neutral

115 VAC Models

Heater Switch

AUTO - Normal setting. Automatically turns the heater ON when the

temperature drops below 40°F inside the operator, and turns the heater OFF when the temperature rises above 40°F inside the operator.

OFF - Turns the heater off. ON - Turns the heater on continuously. The heater will become VERY

HOT when running continuously.

Hot

212 345

230 VAC/460 VAC Models

Neutral

115 VAC Hot

1601-164-G-7-11

120 Glasgow Avenue

Inglewood, California 90301 U.S.A.

Page 8

ALUMINUM ARM FOLDING KIT

This kit is designed for the 1600 model barrier gate operators only. Recommended for low headroom applications.

DoorKing Part Number

1601-310

Kit Includes:

Cable Attachment Assembly

Pre-Crimped Eyelet

2 Aluminum Arms with End Caps

Installation

Cable

Clamp

Cable Eyelet

Cut Arms to Length

Locking Eye BoltLocking Turnbuckle

(Connected)

Arm Hinge

8 Self Tapping Screws

Note: Completed folding arm assembly shown in the UP position to illustrate the total height.

Cut this arm

first for the height limitations.

Total Height

Determining First Arm Length

Note: Completed folding arm assembly shown in the DOWN position to illustrate traffic lane width.

Cut this arm second for the

traffic lane width. Note: Second arm can be a different length than the first.

Determining Second Arm Length

Traffic Lane Width

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 9

Installing Arms

DoorKing Part Number

1601-310

Existing Stud

Top View of

Operator Housing

Hub

Install arm on hub.

Cable Eyelet MUST be installed in turnbuckle.

Adjust to clear hub.

Bushing

Locknut

Cut off excess cable.

Remove stud from operator housing and assemble as shown.

Bolt Head (Inside Housing)

Washer (Inside Housing)

Operator Housing

Pre-Crimped Eyelet

Install cable. Cable MUST clear hub!

Cable Clamp

Allow turnbuckle to loosen or tighten.

Install eye bolt into arm

hinge with vise-grips. Attach arm hinge to arm with 4 self-tapping screws.

Install second arm

with 4 self-tapping screws.

Side View of

Operator Housing

Adjusting and Locking Cable Assembly

After adjusting cable tension, lock turnbuckle with nuts to keep turnbuckle from twisting.

Lock eye bolt with nut to keep eye bolt from twisting.

Inner Arm

Rotate arm up and down. Adjust cable tension with turnbuckle to level outer arm. Make sure that cable assembly is not binding or twisting and everything moves freely.

Important: Do not adjust cable too tight or it will bind.

Outer Arm

1601-265-C-6-11

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 10

PLASTIC FOLDING ARM KIT

This kit is designed for the 1600 model barrier gate operators only. Recommended for low headroom applications.

Kit Includes:

Locking Eye BoltLocking Turnbuckle

(Connected)

Arm Hinge

8 Self Tapping Screws

Pre-Crimped Eyelet

2 Plastic Arms

Cable Attachment Assembly

Cable

Cable Clamp

Cable Eyelet

Installation

Cut Arms to Length

Note: Completed folding arm assembly shown in the UP position to illustrate the total height.

DoorKing Part Number

1601-083

Cut this arm

first for the height limitations.

Total Height

Determining First Arm Length

Note: Completed folding arm assembly shown in the DOWN position to illustrate traffic lane width.

Cut this arm second for the

traffic lane width. Note: Second arm can be a different size than the first.

Determining Second Arm Length

Traffic Lane Width

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 11

Installing Arms

DoorKing Part Number

1601-083

Existing Stud

Top View of

Operator Housing

Hub

Install inner arm

on hub.

Cable Eyelet MUST be installed in turnbuckle.

Adjust to clear hub.

Bushing

Locknut

Cut off excess cable.

Remove stud from operator housing and assemble as shown.

Bolt Head (Inside Housing)

Washer (Inside Housing)

Operator Housing

Pre-Crimped Eyelet

Install cable. Cable MUST clear hub!

Cable Clamp

Allow turnbuckle to loosen or tighten.

Install eye bolt into arm

hinge with vise-grips. Attach arm hinge to inner arm with 4 self-tapping screws.

Install outer arm

with 4 self-tapping screws.

Side View of

Operator Housing

Adjusting and Locking Cable Assembly

After adjusting cable tension, lock turnbuckle with nuts to keep turnbuckle from twisting.

Lock eye bolt with nut to keep eye bolt from twisting.

Inner Arm

Rotate arm up and down. Adjust cable tension with turnbuckle to level outer arm. Make sure that cable assembly is not binding or twisting and everything moves freely.

Important: Do not adjust cable too tight or it will bind.

Outer Arm

1601-266-B-6-11

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 12

WOOD FOLDING ARM KIT

This kit is designed for the 1600 model barrier gate operators only. Recommended for low headroom applications.

Kit Includes:

Pre-Crimped Eyelet

2 Wood Arms

Cable Attachment Assembly

4 Bolts with Locknuts (Small)

Cable

Bolt with Bushing and Locknut (Medium)

Cable Clamp

Cable Eyelet

Bolt with Brass Bushing and Locknut (Large)

Locking Turnbuckle

Installation

Cut Arms to Length

Note: Completed folding arm assembly shown in the UP position to illustrate the total height.

DoorKing Part Number

1601-084

2 Hinge Plates

Cut this arm

first for the height limitations.

Total Height

Determining First Arm Length

Determining Second Arm Length

Note: Completed folding arm assembly shown in the DOWN position to illustrate traffic lane width.

Cut this arm second for the

traffic lane width. Note: Second arm can be a different size than the first.

Traffic Lane Width

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 13

Installing Cable

Attachment Assembly

Adjust to clear hub.

Pre-Crimped Eyelet

Bushing

Locknut

Existing Stud

Top View of

Operator Housing

Installing Arms

Remove stud from operator housing and assemble as shown.

Bolt Head (Inside Housing)

Washer (Inside Housing)

Operator Housing

Inner Arm

Locknut

DoorKing Part Number

1601-084

Installing Hinge Plates

Bolt (Medium)

Turnbuckle

Bolt (Large)

Bushing

4 Bolts (Small)

Brass Bushing

Outer Arm

Install cable. Cable MUST clear hub!

Hub

Install inner arm on hub.

Cut off excess cable.

Cable Clamp

Cable Eyelet MUST be installed in turnbuckle.

Adjusting and Locking Cable Assembly

After adjusting cable tension, lock turnbuckle with nuts in position shown to prevent turnbuckle from rubbing against hinge plates when the arm is in the UP position.

Inner Arm

Rotate arm up and down. Adjust cable tension with turnbuckle to level outer arm. Make sure that cable assembly is not binding or twisting and everything moves freely.

4 Locknuts

Install hinge plates.

Allow turnbuckle to loosen or tighten.

Outer Arm

Side View of

Operator Housing

1601-267-B-6-11

Important: Do not adjust cable too tight or it will bind.

120 Glasgow Avenue

Inglewood, California 90301 U.S.A.

Page 14

DoorKing Part Number

1601 Manual Release Kit

This kit is designed for the 1601 barrier gate operator WITHOUT the convenience open option. It provides an interlock power cut-off switch when manually using crank tool to move the arm up or down. DO NOT install on convenience open models.

1601-270

Kit Includes: Pre-wired Interlock assembly,

Double motor pulley, Crank tool, 2 spring clips with lock nuts.

Installation

Shut off the AC input power to the operator from the circuit breaker.

Use existing wire restrainers to run wires.

Keep wires clear

Mount spring clips with lock nuts on existing threaded studs inside access door.

Crank Tool

Storage

Replace existing single motor pulley with double motor pulley. Align motor pulley with gear reducer pulley.

Mount interlock assembly using existing hardware.

of all moving parts

Interlock Assembly

ear

Reducer

Wiring Interlock

DANGER

HIGH VOLTAGE!

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Replace the existing AC power switch wire connected to terminal #2 with interlock cut-off switch wires.

NC NO

Existing 115 VAC Power Terminal Wire

Interlock Cut-Off Switch

AC Power Switch

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Page 15

Manual Operation

1. Unlock and remove access door.

2. Remove crank tool from inside access door.

3. Flip interlock assembly door up, power will be disabled from operator.

4. Insert crank tool into motor pulley as shown.

5. Rotate crank tool to manually move operator arm up or down.

DoorKing Part Number

1601-270

Access Door

Crank Tool

Storage

Interlock Assembly Door

1601-270-C-5-10

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.