FAAC 1603-080 User Manual

Installation/Owner’s Manual

1603

Barrier Gate Operator with Auto Spike System

1603

Use this manual for circuit board 1601-010 Revision V or higher.

1603-065-T-4-13

Date Installed:

Installer/Company Name:

Phone Number:

Leave Manual with Owner

UL 325 Compliant

Circuit Board Serial Number and Revision Letter:

1603 SPECIFICATIONS

Use this manual for the Model 1603 operators with circuit board 1601-010 Rev V or higher ONLY.

Class of Operation

Model 1603 - UL 325 Class II, III, IV – ETL Listed

Type of Gate

Single Traffic Lane Vehicular Barrier Gate Only

Arm Types

Aluminum – Straight or Folding Arm

Max Arm Length

14 Ft.

Max Spike Length

9 Ft. (Three 3-ft spike sections)

Gate Cycles

High Cycle

Speed

90° in approximately 1.5 seconds

Primary Entrapment Protection

Inherent entrapment sensing system (Type A)

Secondary Entrapment Protection

Provision for connection of a non-contact sensor (Type B1) and/or contact sensor (Type B2)

Model # Horsepower - Volts

1603-080 1603-081

Note: 208/230/460/575 VAC input voltage can be connected to the operator by installing an “Optional” High Voltage Kit (P/N 2600-266).

Convenience

Open

Yes

1/2 HP - 115 VAC 1/2 HP - 115 VAC

Amp

5.7

38.5”

1”

14.74”

15.5”

1603 Housing

WARNING

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm

at all times.

NO:

Pedestrians Bicycles Motorcycles

CONFORMS TO ANSI/UL-325

53382

CERTIFIED TO

CAN/CSA C22.2 NO. 247

VEHICULAR GATE OPERATOR

CLASS

MODEL

SERIAL

VOLTS PHASE

AMPS 60 Hz

MAX GATE LOAD

DoorKing, Inc., Inglewood, CA

4”

15.25”

43.6”

10.8”

Drawings not to scale

1603 Aluminum Arm

Folding arm assembly can be installed for low headroom application.

1603 Auto Spike System

Up to 3 spike sections can connect together.

Extension Section

P/N 1603-166

Spike Section

P/N 1603-163

14 Ft. Aluminum Arm Only P/N 1601-516

Aluminum Arm Mounting Kit P/N 1601-242

Aluminum Folding Arm Kit P/N 1601-610

Foam Padding for 14 Ft. Arm P/N 1601-260

End Cap

P/N 1610-240

DoorKing, Inc. reserves the right to make changes in the products described in this manual without notice and without obligation of DoorKing, Inc. to notify any persons of any such revisions or changes. Additionally, DoorKing, Inc. makes no representations or warranties with respect to this manual. This manual is copyrighted, all rights reserved. No portion of this manual may be copied, reproduced, translated, or reduced to any electronic medium without prior written consent from DoorKing, Inc.

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TABLE OF CONTENTS

SPECIFICATIONS 1

UL 325 Entrapment Protection Safety Information for Vertical Barrier Arm and Spikes

4-5

SECTION 1 - INSTALLATION OF OPERATOR

1.1 Operator Positioning and Conduit Requirements

1.2 Concrete Pad Requirements

1.3 Mount Operator

1.4 Dual Operator Installation (Primary/Secondary)

SECTION 2 - WIRING 9

2.1 High Voltage Wire Runs

2.2 High Voltage Terminal Connections

2.3 Main Terminal Description

2.4 Control Wiring

SECTION 3 - INSTALLATION OF AUTO SPIKE SYSTEM

3.1 Connect Sections Together on Concrete Pad

3.2 Test Spikes

3.4 Secure EACH Section to Concrete

SECTION 4 - LOOP DETECTOR LANE SETUPS

4.1 Entry Lane Only

4.2 Exit Lane Only

4.3 2-Way Traffic Lane

4.4 Ticket Spitter Entry Lane

4.5 Operator Timer ON Entry Lane (No Down Loop)

12 13 14

SECTION 5 - ARM INSTALLATION 20

5.1 Mounting Hub

5.2 Mounting Aluminum Arm

20 20

7 7

9 9

SECTION 6 - ADJUSTMENTS 21

6.1 1601 Circuit Board Description and Adjustments

6.2 DIP-Switch SW 1 and SW 2 Settings

6.3 Magnetic Limit Adjustment

6.4 Reverse Sensor Adjustment

6.5 Manual Operation of Arm and Spikes

22-24

25 25 26

SECTION 7 - OPTIONAL CONVENIENCE OPEN SYSTEM 27

7.1 Operating Mode

7.2 DC System Description

7.3 DIP-Switch Settings

27 28 28

SECTION 8 - OPTIONAL ACCESSORIES INSTALLATION 29

8.1 Contact Sensor (Reversing Edge)

8.2 Fan Kit

8.3 Heater Kit

29 30

SECTION 9 - TECHNICAL INSTRUCTIONS 32

9.1 Maintenance Schedule

9.2 Diagnostics Check

9.3 Troubleshooting

9.4 Accessories Parts List Wiring Schematics

32 33

33-34

36-37

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UL 325 Entrapment Protection

Class I

A vehicular gate operator (or system) intended for use in a home of one-to four single family dwelling, or a garage or parking area associated therewith.

Class II

A vehicular gate operator (or system) intended for use in a commercial location or building such as a multi-family housing unit (five or more single family units) hotel, garages, retail store or other building servicing the general public.

STATE PRISON

Class III Class IV

A vehicular gate operator (or system) intended for use in a industrial location or building such as a factory or loading dock area or other locations not intended to service the general public.

This table illustrates the entrapment protection requirements for each of the four UL 325 classes.

A vehicular gate operator (or system) intended for use in a guarded industrial location or building such as an airport security area or other restricted access locations not servicing the general public, in which unauthorized access is prevented via supervision by security personnel.

Classifications

Class I and II

Class III

Class IV

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UL 325

A - Inherent entrapment protection system. B1 - Provision for connection of, or supplied with, a non-contact sensor (photoelectric sensor or the equivalent).

When used as the PRIMARY device, must be monitored. B2 - Provision for connection of, or supplied with, a contact sensor (edge device or the equivalent).

When used as the PRIMARY device, must be monitored.

C - Inherent adjustable clutch or pressure relief device. D - Provision for connection of, or supplied with, an actuating device requiring continuous pressure to maintain

opening or closing motion of the gate. E - An inherent audio alarm.

Horizontal Slide, Vertical Lift, Vertical Pivot Swing and Vertical Barrier (arm)

Primary Protection

A B1, B2 or D A, B1, B2, C or DA or C

A, B1 or B2 A, B1, B2, D or E A, B1, B2, C or DA, B1, B2 or C

A, B1, B2 or D A, B1, B2, D or E A, B1, B2, C, D or EA, B1, B2, C or D

Secondary Protection Primary Protection Secondary Protection

Safety Information for Vertical Barrier Arm and Spikes

Reduce the risk of injury or death,

read and follow all instructions.

Familiarize yourself with safety warnings, instructions, illustrations, and wiring guidelines to ensure that the installation is performed in a safe and professional manner. Prior to installation check all local building codes

and ordinances to ensure compliance.

47GHT4

Important: Barrier gate operator CANNOT sense a person under

the raised arm.

This scenario is VERY DANGEROUS and MUST NEVER OCCUR!!

• Do not install the operator in such a way that the arm moves within 2 feet of a rigid object.

• Spike Warning. It is extremely important that the traffic spikes are clearly marked with a warning sign of potential hazard to

vehicles and the spike area is well illuminated.

• Speed limit through barrier area is 5 MPH. Install speed bumps, warning signs and hazard stripes where visible in the area

of the barrier gate, failure to do so may result in injury, damage to operator and vehicle.

• Users should be familiar with proper use of operator, these include; hardware operation, reversing functions and testing,

reversing loops, inherent reversing system, electric edges, photoelectric cells related external devices and possible hazards.

• Keep adults, children and objects away from operator and HAZARD ZONES.

• Pedestrians must be provided with a separate access.

• All electrical connections should be made in accordance with local electrical codes.

• Security features should be installed to avoid unauthorized use.

• Controls must be installed far enough away from the operator to avoid any contact when operating the controls but no

further away from the operator than 50 ft. If the installed hardware is in violation of these restrictions remove the operator from service immediately and contact your service dealer.

• When manually operating the gate operator arm, the user MUST make sure that the gate area is clear BEFORE operating the

controls.

• When removing the operator lift the arm to the full open position and shut off power at the service panel.

• Operators and components should be properly installed and maintained following the recommended service schedule,

test the operator monthly. Keep all debris away from operator housing vents and off of arm. Contact your service dealer for any maintenance or repairs.

• Vehicular operators can produce high levels of force, it is important that you are aware and eliminate possible HAZARDS;

Pinch Points, Entrapment Areas, Absence of Controlled Pedestrian Access, Traffic Backup.

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Safety Information for Vertical Barrier Arm and Spikes

Minimizes the potential of the arm closing when a vehicle is present. Number and placement of loop(s) is dependent on the application.

Down Loop

Separate

Hazard Stripes

No stopping or standing zone. Permanently painted on pavement and easily visible.

Pedestrian

Walkway

Located so pedestrians

cannot come in contact

with the barrier arm.

Traffic Light

Helps control traffic.

WARNING

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm at all times.

NO:

Pedestrians Bicycles Motorcycles

Photo Beam no higher than 27.5” above grade.

Speed Bump

Helps increase distance and time between vehicles.

Speed Limit Sign

Helps control traffic.

WARNING

MOVING ARM

can cause vehicle damage, serious injury or death.

STAY CLEAR

of arm at all times.

NO:

Pedestrians Bicycles Motorcycles

21” is typical for most installations.

Warning Signs

Permanently mounted and easily visible.

SPEED

LIMIT

Non-Contact Sensor

Minimizes the potential of the arm lowering on vehicular or other traffic that loops cannot sense.

STOP

SEVERE TIRE

DAMAGE

PROCEED ONLY WHEN

SPIKES ARE DOWN

NO PEDESTRIANS IN TRAFFIC LANE

Contact Sensor

Minimizes the potential of the arm lowering on vehicular or other traffic that loops cannot sense.

Spike Warning and Illumination

It is extremely important that traffic spikes are installed in an area that is illuminated and clearly marked with spike warning signs (DoorKing’s model 1615 illuminated warning sign kits).

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SECTION 1 - INSTALLATION OF OPERATOR

Prior to beginning the installation of the barrier gate operator, we suggest that you become familiar with the instructions, illustrations, and wiring guide-lines in this manual. This will help insure that your installation is performed in an efficient and professional manner.

The proper installation of the vehicular barrier gate operator is an extremely important and integral part of the overall access control system. Check all local building ordinances and building codes prior to installing this operator. Be sure your installation is in compliance with local codes.

1.1 Operator Positioning and Conduit Requirements

Arm is mounted on opposite side of operator from oncoming traffic.

Access Door

Conduit Runs

Traffic Direction

Operator Mounted on LEFT Side of Traffic Lane Preferred

The spikes will retract towards oncoming traffic.

Arm is mounted on opposite side of operator from oncoming traffic.

Traffic Direction

Operator Mounted on RIGHT Side of Traffic Lane

The spikes will be reversed from the left side mounting position and retract away from oncoming traffic.

Note: Operator shown mounted on the LEFT side (preferred).

Conduit Area

Access Door

Inside

Operator

Primary/Secondary Interconnection Cable (Dual Operator Application Only) Control and/or P.A.M.S. Wires (Low Voltage wire insulation) Loop Lead-In Wires (Low Voltage wire insulation) AC Input Power (High Voltage wire insulation)

• The conduit requirements are for a typical barrier gate operator installation. The conduit requirements for your

application may vary from this depending on your specific needs.

• Use only sweeps for conduit bends. Do not use 90° connectors as this will make wire pulls very

difficult and can cause damage to wire insulation.

• We suggest that minimum 3/4-inch conduit be used.

• Never run low voltage rated wire insulation in the same conduit as high voltage rated wire insulation.

• Be sure that all conduits are installed in accordance with local codes.

Illuminated Sign AC Input Power

(High Voltage wire insulation)

Conduit Runs

STOP

SEVERE TIRE

DAMAGE

PROCEED ONLY WHEN

SPIKES ARE DOWN

NO PEDESTRIANS IN TRAFFIC LANE

Sweep

YES

Access Door

Elbow

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1.2 Concrete Pad Requirements

The operator and auto spike system must ONLY be installed on a concrete pad with a minimum 6 inch depth. The concrete pad must be FLAT and LEVEL (Check local building codes for restrictions). Reinforced concrete recommended.

Note: Operator shown mounted on the LEFT side of traffic lane (preferred).

6”

15.5”

36”

Concrete length: 2 spike sections 147.5”

1.3 Mount Operator

Remove breather pin from gear

reducer AFTER the operator has

been secured in place.

DO NOT install operator

or spikes on asphalt.

36”

Embedded Wire M

36”

It is recommended that the “Spike” sections not exceed 9 feet (Three 3-Ft spike sections) for proper operation.

Concrete length: 3 spike sections 183.5”

Traffic Direction

6”

esh

20”

”

6”

32” Minimu

Center operator

and sp

of co

es al

crete pad.

ng length

6” Minimum

32” Min

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Access Door

Conduit

Inside Operator

Sleeve Anchors

Depth of concrete under the operator is determined by soil conditions and local building codes.

Secure the operator to the concrete pad with the mounting flange using 1/2” x 3” minimum sleeve anchors (not supplied).

Approximate position of conduit runs.

Sections MUST lay flat and level to operate properly!

Embedded Wire Mesh

DO NOT mount sections at this time.

Sleeve Anchor

1/2

1.4 Dual Operator Installation (Primary/Secondary)

For use in areas needing more than three 3-Ft spike sections (9 ft. of spikes) in a traffic lane. Up to six 3-Ft spike sections (18 ft. of spikes) can be used with dual operators.

Install dual operators the same as installing two single operators except for:

• There are no end cap sections used.

• Secondary spikes will face and rotate the opposite direction as the primary spikes

(Retract away from oncoming traffic).

• Operators need to be wired together with an interconnection cable (Sold separately).

• Each operator requires AC power.

• Both operator’s DIP-switches (SW 1, SW 2) must be set the same.

• Connect all loop detectors and access control devices to the PRIMARY operator ONLY.

Primary Operator

Circuit Board

TIME DELAY

Secondary Operator

Circuit Board

TIME DELAY

Settings using

UP LOOP

Down Loop

UP LOOP

2 3 4 5 6 7 8

UP Loop Detector

2 3 4 5 6 7 8

LEFT Side RIGHT Side

Primary

Operator

Traffic Direction

Inside Property

1601

POWER

1 2 3 4 5 6 7 81

SW 1

SW 1, switch 4 is ON.

1601

POWER

1 2 3 4 5 6 7 81

SW 1, switch 5 is OFF. SW 1, switch 8 is OFF.

DOWN LOOP

REVERSE SENSITIVITY

Set other DIP-switches based on gate operation

DOWN LOOP

REVERSE SENSITIVITY

preferences.

DOWN Loop Detector

NC NO

12345678 9 10 11 12 13 14

Jumper Wire

Jumper

Wire

123456 7 8910 11 12 13 14

Yellow Brown

Gray Orange

Primary/Secondary

Interconnection Cable

Sold separately from DoorKing.

4 wires used (8 - 18 AWG wires total).

Yellow

Brown

Gray

NC NO

Reverse loops

Orange

When using Reverse Loops:

DIP-Switch settings: SW 1, switch 4 is OFF. SW 1, switch 5 is OFF. SW 1, switch 8 is OFF. Set other DIP-switches based on gate operation preferences. See page 19 for reverse loop wiring.

Interconnection cable: The BROWN wire must be connected to SECONDARY TERMINAL #9 along with the GRAY wire. All other terminal wire connections are the same as shown above.

Traffic Lane

Traffic Direction

Secondary

Operator

Illustration shows four 3-ft spike sections (12 ft. of spikes).

Each operator controls two 3-ft spike sections.

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SECTION 2 - WIRING

Before attempting to connect any wiring to the operator, be sure that the circuit breaker in the electrical panel is in the OFF position. Permanent wiring must be installed to the operator as required by local electrical codes. It is recommended that a licensed electrical contractor perform this work.

Since building codes vary from city to city, we highly recommend that you check with your local building department prior to installing any permanent wiring to be sure that all wiring to the operator (both high and low voltage) complies with local code requirements.

THIS GATE OPERATOR MUST BE PROPERLY GROUNDED!!

2.1 High Voltage Wire Runs

The distance shown in the chart is measured in “Feet” from the operator to the power source. If 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. The wire table is based on stranded copper wire. Wire run calculations are based on the NEC recommended maximum 3% voltage drop on the power line, plus an additional 10% reduction in distance to allow for other losses in the system.

This table illustrates the high voltage AC power wire size and distance limitations.

Model

Type

1603 1/2 HP

“Optional” Heater Installation Note: When installing a heater, refer to the “high voltage AC power wire size and distance limitations” table on the instruction sheet with the heater kit for AC power wire run limitations.

“Optional” High Voltage Kit Installation Note: When installing the high voltage kit for 208/230/460/575 VAC input power,

refer to the “high voltage AC power wire size and distance limitations” table on the instruction sheet with the

Voltage

Required

115 5.7

Never run low voltage rated wire insulation in the same conduit as high voltage rated wire insulation.

Amps

Required

high voltage kit (P/N 2600-266) for AC power wire run limitations.

12 AWG 10 AWG 8 AWG 6 AWG

170 275 460 690

2.2 High Voltage Terminal Connections

• Route incoming high voltage power in it’s OWN conduit.

• Be sure wiring is installed in accordance with local codes.

Be sure to color code all wiring.

• It is recommended that a surge suppressor be installed on

the high voltage power lines to help protect the operator and circuit board from surges and power fluctuations.

• Dual operators (Primary/Secondary) require AC power to

each operator.

Wire Size / Max Distance in Feet

115 VAC

AC Power Terminal

White - Neutral

Black - 115 VAC Hot

Green - Chassis Ground

High Voltage

AC Power Wire

HotNeu

DANGER

HIGH VOLTAGE!

Chassis

Ground

Note: “Optional”

High Voltage Kit black and white wires connect the same as shown above.

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Keep wire clear of all moving parts.

DO NOT power up and cycle the operator until

the “DIP-Switches” have been set for the 1603 model (See pages 21 and 22). The operator will not function properly unless the switches have been correctly set.

External Power

Disconnect

Switch

Note: A separate power disconnect

switch may be needed in your area. Check

local building codes before installation.

AC POWER

OFF

2.3 Main Terminal Description

1234567891011121314

DOWN/REVERSE Input

UP INPUT or UP LOOP Output

UP Input

24 VAC - 250 mamp. max.

115 VAC Motor

115 VAC Power

115 VAC Neutral

ENABLE UP Input

MOMENTARY UP Input

REVERSE Input

NC NO

Dry Relay Contact

Low Voltage Common

Dry Relay Contact

DANGER

HIGH VOLTAGE!

Function is dependent on the setting of programming SW 1, switch 6. When switch 6 is OFF, this input will cause the operator to rotate the arm to the up position. If the arm is in the down cycle, this input will reverse the arm to the up position. If this terminal has a constant input, the arm will remain in the up position regardless of any down input or timer command to rotate down. When switch 6 is ON, this input will cause the operator to rotate the arm to the up position when it is down, and will cause the operator to rotate the arm to the down position when it is up. If the auto timer is turned ON (Not recommended if switch 6 is ON), this input will override the timer and rotate the arm to the down position. If the arm is in the down cycle, this input will reverse the arm to the up position.

Function is dependent on the setting of programming SW 1, switch 8. When switch 8 is ON, the function of this input is identical to terminal 6. When switch 8 is OFF, this terminal becomes the logic output of the up loop detector.

Function is dependent on the setting of programming SW 1, switches 1 and 4. With switch 1 OFF and switch 4 ON, activation and then deactivation of this input will rotate the arm to the down position, provided that the deactivation of the input happens while the arm is in the full up position. This input will override the auto timer if it is turned ON. If the arm is in the down position, traveling in the down cycle, or traveling in the up cycle, activation and deactivation of this input has no effect on the arm. With switches 1 and 4 are ON, activation and then deactivation of this input will rotate the arm to the down position after it reaches the full up position regardless of when the deactivation of the input occurred. When switch 4 is OFF, this input is identical to the reverse input, terminal 9.

1 2 3 4 5 6 7 8

SW 1

1 2 3 4 5 6 7 8

SW 1

2 3 4 5 6 7 8

SW 1

Function is dependent on the setting

of programming SW 1, switch 5. When switch 5 is OFF, activation of the down loop will activate the relay. When switch 5 is ON, activation of the UP loop will activate the relay.

Relay contacts can be set for Normally Open (NO) or Normally Closed (NC) operation.

Contact rating is 1 amp maximum at 24 Volts.

This input is used when sequencing the 1601 with a slide or swing gate operator in PAMS applications. This input is only active after a MOMENTARY UP input is received. Activation of this input will rotate the arm to the up position or reverse an arm in the down cycle to the up position.

1 2 3 4 5 6 7 8

SW 1

This input is used when sequencing the 1601 with a slide or swing gate operator in

PAMS applications. Activation of this input will rotate the arm to the up position one time, and activates the enable up input.

When the arm is in the down position, activation of this input has no effect. When the arm is in the up position, activation of this input will prevent the arm from rotating to the down position. If the arm is in the down cycle, activation of this input will reverse the arm to the up position.

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