FAAC 1603-080 User Manual
Installation/Owner’s Manual
1603
Barrier Gate Operator with Auto Spike System
1603
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:
Copyright 2013 DoorKing, Inc. All rights reserved.
TM
Copyright 2009 DoorKing, Inc. All rights reserved.
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
No
Yes
1/2 HP - 115 VAC
1/2 HP - 115 VAC
Amp
5.7
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
HP
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.
1603-065-T-4-13
1
TABLE OF CONTENTS
SPECIFICATIONS 1
UL 325 Entrapment Protection
Safety Information for Vertical Barrier Arm and Spikes
4-5
3
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)
10
12
12
13
14
15
15
16
18
19
SECTION 5 - ARM INSTALLATION 20
5.1 Mounting Hub
5.2 Mounting Aluminum Arm
20
20
6
6
7
7
8
9
9
11
17
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
21
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
31
SECTION 9 - TECHNICAL INSTRUCTIONS 32
9.1 Maintenance Schedule
9.2 Diagnostics Check
9.3 Troubleshooting
9.4 Accessories Parts List
Wiring Schematics
2
32
33
33-34
35
36-37
1603-065-T-4-13
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
1603-065-T-4-13
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
3
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.
9
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.
4
1603-065-T-4-13
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.
A
Down Loop
C
F
Separate
G
E
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.
G
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
B
C
Photo Beam no higher than 27.5” above grade.
Speed Bump
Helps increase distance
and time between vehicles.
Speed Limit Sign
Helps control traffic.
B
WARNING
MOVING ARM
can
cause vehicle damage,
serious injury or death.
STAY CLEAR
of arm
at all times.
NO:
Pedestrians
Bicycles
Motorcycles
D
21” is typical for most installations.
A
B
Warning Signs
Permanently
mounted and
easily visible.
SPEED
F
LIMIT
5
C
Non-Contact Sensor
Minimizes the potential of the arm lowering on
vehicular or other traffic that loops cannot sense.
STOP
SEVERE TIRE
DAMAGE
E
PROCEED ONLY WHEN
SPIKES ARE DOWN
NO PEDESTRIANS
IN TRAFFIC LANE
D
Contact Sensor
Minimizes the potential of the arm lowering on
vehicular or other traffic that loops cannot sense.
E
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).
1603-065-T-4-13
5
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.
6
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
NO
1603-065-T-4-13
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.
1
Concrete length: 3 spike sections 183.5”
2
Traffic Direction
6”
esh
20”
12
”
6”
6”
32” Minimu
Center operator
and sp
of co
es al
k
i
crete pad.
n
ng length
o
6” Minimum
m
3
32”
Min
1603-065-T-4-13
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
7
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
ON
1
UP
LOOP
2 3 4 5 6 7 8
UP Loop Detector
ON
2 3 4 5 6 7 8
ON
2 3 4 5 6 7 8
LEFT Side RIGHT Side
Primary
Operator
Traffic Direction
Inside Property
ON
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
ON
Traffic Direction
Secondary
Operator
Illustration shows four 3-ft spike sections (12 ft. of spikes).
Each operator controls two 3-ft spike sections.
8
1603-065-T-4-13
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.
1603-065-T-4-13
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
ON
OFF
9
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 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
ON
7
SW 1
1
2 3 4 5 6 7 8
SW 1
ON
6
1
2 3 4 5 6 7 8
SW 1
ON
12
Function is dependent on the setting
13
11
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.
NO
NC
1
2 3 4 5 6 7 8
ON
SW 1
8
This input is used when sequencing the
1601 with a slide or swing gate operator in
10
9
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.
10
1603-065-T-4-13
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