FAAC 1044682 User Manual
T HE 402 OPERATOR AND
November, 2003
402 Operator And
455 D Control Panel
Installation Manual
455 D C
NSTALLATION MANUAL
I
ONTROL PANEL:
CONTENTS
Important Safety Information 2
Technical Data 4
Unpacking the Operator 5
The 402 Compact Operator General Characteristics 6
Installation Instructions 6
Prepare the Gate 6
Manual Release Mechanism 7
Install the Operator 7
Install the 455 D Control Panel 9
Exploded View, 402 CBC 11
402 Parts List 12
Maintenance 26
Safety in Gate Design 26
Troubleshooting 27
Limited Warranty 28
The 455 D Control Panel General Description 14
Installing the 455 D Control Panel 14
Connect the Main Power Supply 14
Connect the Operator to the Control Panel 15
Check the Motor’s Direction of Rotation 15
Connect Other Devices 16
Set Other Operating Controls 18
Programming 20
Learning of Operating Times 22
Learning of Normal Times 22
Learning Times with Gatecoder 22
Automated Systems Test 23
Installation Instructions
The 455 D Control Panel
Logic Tables of 455 D Control Panel 24
FAAC International, Inc.
303 Lexington Avenue
Cheyenne, WY 82007
www.faacusa.com
November, 2003
Page 2
455 D Control Panel Installation Manual
402 Operator And
IMPORTANT SAFETY INFORMATION
Both the installer and the owner and/or operator of this
system need to read and understand this installation
manual and the safety instructions supplied with other
components of the gate system. This information
should be retained by the owner and/or operator of the
gate.
WARNING! To reduce the risk of injury or death
1. READ AND FOLLOW ALL
INSTRUCTIONS.
2. Never let children operate or play with gate
controls. Keep the remote control away from
children.
3. Always keep people and objects away from
the gate. NO ONE SHOULD CROSS THE PATH
OF THE MOVING GATE.
4. Test the gate operator monthly. The gate
MUST reverse on contact with a rigid object
or stop when an object activates the noncontact sensors. After adjusting the force or
the limit of travel, retest the gate operator.
Failure to adjust and retest the gate operator
properly can increase the risk of injury or
death.
5. Use the emergency release only when the
gate is not moving.
6. KEEP GATES PROPERLY MAINTAINED. Read
the owner’s manual. Have a qualified service
person make repairs to gate hardware.
7. The entrance is for vehicles only. Pedestrians
must use separate entrance.
8. SAVE THESE INSTRUCTIONS.
When installing the photo-beams supplied with this
unit two things need to be considered.
1. Care should be exercised to reduce the risk of
nuisance tripping, such as when a vehicle, trips
the sensor while the gate is in motion.
2. One or more photobeams shall be located
where the risk of entrapment exists, such as
the perimeter reachable by the moving gate
leaf.
GATE DESIGN
1. A gate is a potential traffic hazard, so it is important that you locate the gate far enough away
from the road to eliminate the potential of traffic
getting backed up. This distance is affected by the
size of the gate, how often it is used, and how fast
the gate operates.
2. The operator you choose to install on your gate
must be designed for the type and size of your gate
and for the frequency with which you use the
operator.
3. Your gate must be properly installed and must work
freely in both directions before the automatic
operator is installed.
4. An automatic operator should be installed on the
inside of the property/fence line. Do not install the
operator on the public side of the property/fence
line.
5. Pedestrians should not use a vehicular gate system.
Prevent such inappropriate use by installing
separate gates for pedestrians.
6. Exposed, reachable pinch points on a gate are
potentially hazardous and must be eliminated or
guarded.
7. Outward swinging gates with automatic operators
should not open into a public area.
8. The operating controls for an automatic gate must
be secured to prevent the unauthorized use of those
controls.
9. The controls for an automatic gate should be
located far enough from the gate so that a user
cannot accidentally touch the gate when operating
the controls.
10. An automatic gate operator should not be installed
on a gate if people can reach or extend their arms
or legs through the gate. Such gates should be
guarded or screened to prevent such access.
INSTALLATION
1. If you have any question about the safety of the
gate operating system, do not install this operator.
Consult the operator manufacturer.
2. The condition of the gate structure itself directly
affects the reliability and safety of the gate
operator.
3. Only qualified personnel should install this
equipment. Failure to meet this requirement could
cause severe injury and/or death, for which the
manufacturer cannot be held responsible.
4. The installer must provide a main power switch that
meets all applicable safety regulations.
5. Clearly indicate on the gate with the 2 warning signs
that are included (visible from either side of the
gate).
November, 2003
402 Operator And
455 D Control Panel Installation Manual
Page 3
6. It is extremely unsafe to compensate for a damaged
gate by increasing hydraulic pressure.
7. Devices such as reversing edges and photobeams
must be installed to provide better protection for
personal property and pedestrians. Install reversing
devices that are appropriate to the gate design and
gate application.
8. Before applying electrical power, be sure that the
voltage requirements of the equipment correspond
to your supply voltage. Refer to the label on your
operator system.
USE
1. Use this equipment only in the capacity for which it
was designed. Any use other than that stated should
be considered improper and therefore dangerous.
2. When using any electrical equipment, observe some
fundamental rules:
• Do not touch the equipment with damp or
humid hands or feet.
• Do not install or operate the equipment
with bare feet.
• Do not allow small children or incapable
persons to use the equipment.
3. If a gate system component malfunctions, turn off
the main power before making any attempt to repair
it.
4. Do not attempt to impede the movement of the
gate. You may injure yourself as a result.
5. This equipment may reach high temperatures
during operation; therefore, use caution when
touching the external housing of the operator.
6. Learn to use the manual release mechanism
according to the procedures found in this installation manual.
7. Before carrying out any cleaning or maintenance
operations, disconnect the equipment from the
electrical supply.
8. To guarantee the efficiency of this equipment, the
manufacturer recommends that qualified personnel
periodically check and maintain the equipment.
U.L. CLASS AND FAAC OPERATOR
Model
Class I: Residential Vehicular Gate Operator
402 750
422 760
412 400
620 640
885
Class II: Commercial/General Access Vehicular Gate Operator
400 640
620 885
Class III: Industrial/Limited Access Vehicular Gate Operator
400 640
620 885
Class IV: Restricted Access Vehicular Gate Operator
Duty Cycle Typical Use
• Home use
• Small apartment building, for
Limited duty
• Apartment buildings
Continuous duty
Continuous duty
• Very public access
• No public access
example, up to 4 units in a
building, with limited public
access
620 640
885
Continuous duty
• Prison rated security
Page 4
HE 402 COMPACT OPERATOR
T
Parameter 402 Operator
Physical dimensions:
Weight, lb (kg) 14-1/3 (6.5)
Length, in. (mm) 36 (914)
Width ´ height, in. (mm) 3-1/2 ´ 3-1/2 (90 ´ 90)
Motor speed, rpm 1400
90-deg opening time, sec 12
November, 2003
402 Operator And
455 D Control Panel Installation Manual
TECHNICAL DATA
Thrust and traction force, lb (kg) 0–1100
Maximum duty cycle, motor run time 50%
Power voltage required, VAC
(frequency, Hz)
Current draw, amps
115 VAC power source 2.4
220 VAC power source 1.2
Operating temperature range, deg F (deg C)
Thermal cut out, deg F (deg C) 212 (100)
Oil quantity, qt (liter) 1-1/2 (1.4)
Oil type FAAC XD 220 or Shell/Tellus 15
Gate leaf constraints
Maximum weight per leaf, lb (kg) 900 (410)
Maximum length per leaf, ft (m) 10 (3)
1
115 (50–60) + 10% or
230, +6 or -10% (50–60)
-4 to 131 (-20 to 55)
1
1
Your standard 220 VAC power source meets the specification for
the required power supply of 230 VAC, +6 or –10%.
November, 2003
402 Operator And
455 D Control Panel Installation Manual
UNPACKING THE OPERATOR
Page 5
When you receive your 402 Compact Operator, complete
the following steps.
Inspect the shipping box for physical damage such as
leaking oil or a torn carton. Then inspect the operator
after you remove it from the box. Notify the carrier
immediately if you note any damage because the carrier
must witness the damage before you can file a claim.
As you unpack the box, insure that all the parts listed
below are included (see Figure 1). If you have ordered a
kit (a pair of operators), you will have twice the quantity
of parts listed below (except where noted), and you will
also have a radio receiver and two transmitters.
1 Control panel box with control panel inside (only 1
per kit)
1 402 Operator unit
1 Protective cover for the operator
1 End cap or guard cover
1 Rear mounting bracket (for post or wall)
1 Rear mounting plate (use is optional)
1 2 in. (50 mm) operator pin with 1 nut for
attachment to rear mounting bracket
1 Mounting fork support
1 2-3/4 in. (70 mm) operator pin with 1 self-locking
nut for attachment to rear flange of operator
1 1-1/8 in. (29 mm) pin for fixing the front coupling
to the operator’s piston rod
2 E clips for either end of the pin fixing the front
coupling to the operator’s piston rod
1 Front mounting brackets
1 Nameplate (with 2 screws) for covering pressure
adjustment screws
1 Manual Release key
Figure 1. The 402 Compact Operator
1 Rear flange 8 Manual Release key
2 Operator casing containing pump and motor 9 Cover
3 Cylinder body 10 Cover end cap
4 Piston rod with hole for attaching to front mounting bracket 11 Cover fixing screw (1 of 2)
5 Green screw for adjusting pressure 12 Nameplate secured with screws
6 Red screw for adjusting pressure 13 Oil vent screw
7 Manual Release Mechanism 14 Oil loading cap
Page 6
November, 2003
402 Operator And
455 D Control Panel Installation Manual
THE 402 COMPACT OPERATOR
GENERAL CHARACTERISTICS
The 402 Compact Operator is an automatic, light-duty
gate operator it can accommodate a gate leaf up to 10 ft
(3m) in length and up to 900 lbs (410 kg) in weight.
Note: The 402 Compact Operators are
recommended for use with solid gates.
The self contained 402 operator is an electro-hydraulic
unit consisting of an electric motor, a pump, a valve
assembly and a hydraulic cylinder, all housed in an
anodized aluminum oil reservoir.
All models of the 402 operator have one hydraulic lock.
The CBC version is designed to lock when the piston is
extended. The CBA version is designed to lock when the
piston is retracted.
The hydraulic lock is a service device rather than a
security device. Additional external locks are
recommended under the following conditions:
• Your gate leaf is 10 ft or longer.
• Your installation site requires tight security.
• Your gate site is subject to vandalism.
• Your gate site is subject to strong or very
gusty wind.
• Your gate system has an open-hold-open
device.
The electronic control panel is a microprocessor-based
controller that accepts a range of product accessories
and reversing devices to allow flexibility in designing
the gate system. The 450 MPS control panel allows you
to set the opening/closing time, a leaf delay for a two-
not
leaf gate system, the operating logic for your gate
system, the pause time, the reversing stroke, and the
behavior of reversing devices.
For its protection, the single phase, bi-directional
electric motor shuts off automatically if its operating
temperature reaches 212 deg F (100 deg C). Also for the
protection and proper operation of the 402 operator,
each gate leaf on which it is installed must have a fixed
positive stop in both the open and closed positions.
The 402 Operator also includes a triangular key
operated Manual Release Mechanism and two bypass
valves which precisely control the force applied to the
gate leave(s). The Manual Release Mechanism is a key
operated device that disengages or engages the
hydraulic system of the 402 Operator. When the
hydraulic system is disengaged, you can open and close
the gate leaf by hand. Such manual operation of the
gate leaf is necessary during installation and useful
during power failures.
The two bypass valves located on the top of the
operator needs to be adjusted to meet the safety
standards of FAAC International, Inc. The standards
state the gate leaf should stop, if it encounters a force
greater than 33 lbs. (15 kg). Once the pressures are
adjusted, the by pass valve screws are covered so that
the pressures are not altered.
Additional reversing devices such as photobeams or
reversing edges should be installed to provide more
complete safety for people and property.
The electronic control panel is a microprocessor-based
controller that accepts a wide range of product
accessories and reversing devices. Thus allowing for
flexible gate system design.
INSTALLATION INSTRUCTIONS
Installing the 402 Compact Operator involves preparing
the gate, installing the operator(s), installing the control
panel, and fine-tuning the pressure adjustments on the
operator(s).
Note: The following installation instructions
assume you are fully capable of installing an
operator. This manual does not instruct you in
designing a gate, installing a gate, or basic
electrical wiring. The installation tasks discussed in
this manual are tasks peculiar to the 402 Operator.
PREPARING THE GATE
Before installing the 402 Operator, you need to prepare
the gate itself for the operator. Be sure to do the
following things:
1. Make sure that the gate is plumb.
2. Make sure that the gate moves smoothly on its
hinges without excessive friction by swinging
it open and closed by hand. Lubricate all the
gates’ moving parts.
3. Provide positive stops for the gate leaves in
the fully open and fully closed positions (see
Figure 2).
November, 2003
402 Operator And
455 D Control Panel Installation Manual
Figure 2.
Positive Stops
MANUAL RELEASE MECHANISM
Insert the key and turn it counterclockwise one full turn
to disengage the operator’s hydraulic system (see Figure
3). You can now move the gate leaf slowly by hand to
open or close the gate.
Operating the gate leaf by hand is necessary during
installation and is useful during power failures.
You re-engage the hydraulic system by turning the key
clockwise one full turn.
Turn the key counterclockwise 1/2 turn to disengage
the hydraulic drive
Figure 3. The Manual
Release key, bottom view
NSTALLING THE OPERATOR
I
Installing the model 402 operator consists of the
following steps:
1. Attaching the rear mounting bracket
2. Attaching the operator to the rear mounting
bracket
3. Attaching the front mounting bracket to the
operator
4. Attaching the operator to the gate leaf
5. Adjusting the hydraulic pressures for the
operator
Page 7
ATTACH THE REAR MOUNTING BRACKET
Attach the rear mounting bracket according to the
dimensions in Figure 4.
WARNING! You must achieve the A and B
dimensions, dimensions as specified in Figure
4. Modification of the rear bracket may be
necessary to achieve these dimensions (I.e.,
cutting or extending the bracket provided)
If you have a steel gate post, weld the rear bracket
directly to it. If the gate post is made of any other
material, attach the optional mounting plate, with
lag bolts or anchors, and weld the bracket to it.
For an outward swing gate refer to Figure 5.
ATTACH THE MOUNTING HARDWARE
Place the operator so that the red and green pressure
adjusting screws face up. Place the mounting fork (hex
cut up if you have a nylon rear fork) in the operator’s
rear flange, secure with the long brass pin and selflocking nut.
Attach the fork assembly to the rear mounting bracket
and secure with the short pint, washer, and nut.
Push the front pin through the front mounting bracket
then the piston red to temporarily attach them
together.
ATTACH THE FRONT MOUNTING BRACKET
TO THE OPERATOR
Insert the triangular key over the Manual Release
mechanism on the underside of the operator and
turn the key counterclockwise one turn.
For inward swing, pull the piston completely out and
push it back inward approximately 1/4 “ (6mm).
For outward swing, push the piston in completely
and pull it back out approximately 1/4“ (6mm).
NOTE: Be sure the operator is level and that
the gate is against the closed positive stop.
Hold the front mounting bracket flush against the
gate, mark the location of the front mounting
bracket, remove the operator from the gate.
Remove the front mounting bracket from the piston
rod.
NOTE: Clamping the front mounting bracket at
the marked location before checking the swing,
Page 8
November, 2003
402 Operator And
455 D Control Panel Installation Manual
as instructed below, will ensure proper location
of the front mounting bracket.
Bolt or weld the front mounting bracket to the
marked location on the gate.
WARNING! Do Not Weld the front mounting
bracket with the operator attached. Doing so
will seriously damage the operator.
ATTACH THE OPERATOR TO THE GATE
Re-attach the operator to the mounting brackets. Once
the operator is mounted and level, remove the vent
screw from the bottom of the valve body. Use a 3mm
hex wrench.
WARNING! Failure to remove the vent screw may
result in erratic operation of the operator or blown
seals.
Slowly move the gate open and close.
WARNING! The piston should not bottom out in
either direction. Doing so will seriously damage
the operator.
Be sure that the gate reaches the positive stop
before the piston bottoms out.
After checking the swing of the gate, secure all nuts and
bolts.
Once the operator is secure, install the protective cover
over the piston of the operator, first insert the two
spacers (items labeled 2 in Figure 6) in the front flange
of the operator as shown. The spacers dampen any
vibrations to the operator.
Next, slip the cover over the operator. The slit in the
cover should face the gate, and the cover should be
placed firmly over the rear of the operator cover (item 1
in the figure).
Finally, use the black plastic screws (items 3 and 4) to
fix the cover to the operator and the end cap (item 5).
Figure 4. An inward swinging gate, top view: important mounting dimensions
402 Standard
A 4-1/2 in. (114 mm)
B 4-1/2 in. (114 mm)
C 35-1/2 in. (902 mm)
D If greater than 2 in.
(50 mm), construct
a recess liner.
E Must be less than A
402 Standard
A 4-1/2 in. (114 mm)
B 4-1/2 in. (114 mm)
C 26-1/2 in. (673 mm)
E Must be less than A
Figure 5. An outward swinging gate, top view: important mounting dimensions
November, 2003
402 Operator And
455 D Control Panel Installation Manual
Page 9
Figure 6. Install the cover for the 402
Operator
INSTALLING THE 455 D CONTROL PANEL
Locate the control panel in the most convenient position
possible, considering the movement of the gate. Figure
6 shows a basic layout for a two-leaf gate with the 402
Compact Operator.
Installing the control panel consists of the following
general steps:
• Connecting the main power to the control
panel
• Connecting the activating device
• Connecting the operator to the control panel
• Checking the direction of the motor's rotation
• Connecting other devices to the control panel
• Set operating modes
The installer is responsible for grounding the gate and
operator systems, for providing the main power breaker
switch, and for making sure that the entire gate system
meets all applicable electrical codes.
For the complete 455 D Control Panel Installation
Instructions, see pages 14—25 of this manual.
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