Doorking 6002 6003 6400 Manual

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Doorking 6002 6003 6400 Manual | Manualzz

Owner’s Manual

Standard or Deluxe Control Box for:

6002 * 6003 * 6400

Vehicular Swing Gate Operators

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Copyright 2009 DoorKing, Inc. All rights reserved.

CONTROL BOXES SPECIFICATIONS

Class of Operation

Type of Gate

Voltage / Phase

Back-Up Power

Models 6002, 6003 and 6400 - UL325 Class I

Residential Vehicular Swing Gates Only

115 VAC 60 Hz Single Phase Input Power – 24 VDC Operating Power

24 VDC battery power during power outages.

Standard Control Box

P/N 4302-111

16.5”

1

2

3

4

5

6

7

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Deluxe Control Box

P/N 4302-112

12.5”

4.25”

24.5”

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

14.5”

ON

OFF

115 VAC convenience outlets to power auxiliary power transformers.

4.25”

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.

6400-065-D-4-09 1

6002 and 6003 SPECIFICATIONS

6002

Class of Operation

Type of Gate

Model 6002 - UL325 Class I

Residentail Vehicular Swing Gates Only

Motor RPM 1400

Voltage / Phase 115 VAC Single Phase Input Power – 24 VDC Operating Power

Cycles Per Hour

Speed

Entrapment Protection

10 Per Hour with AC connected

90° in approximately 15 seconds

Primary - Inherent entrapment sensing system (Type A)

Secondary - Provision for connection of a non-contact sensor (Type B1)

3.5”

49.25”

3”

Drawings not to scale

6003

Class of Operation Model 6003 - UL325 Class I

Type of Gate Residential Vehicular Swing Gates Only

Motor RPM 1400

Voltage / Phase 115 VAC Single Phase Input Power – 24 VDC Operating Power

5.75”

3.75”

2

Cycles Per Hour

Speed

Entrapment Protection

10 Per Hour with AC connected

90° in approximately 15 seconds

Primary - Inherent entrapment sensing system (Type A)

Secondary - Provision for connection of a non-contact sensor (Type B1)

5”

2.5”

Rod Extends 14”

2.5”

32.5”

3.25”

6400-065-D-4-09

6400-065-D-4-09

6400 SPECIFICATIONS

Class of Operation Model 6400 - UL325 Class I

Type of Gate Residential Vehicular Swing Gates Only

Motor Torque 300

Voltage / Phase 115 VAC Single Phase Input Power – 24 VDC Operating Power

Current 3

Max Gate Weight 300

Max Gate Length 10

Cycles Per Hour

Speed

Entrapment Protection

20 Per Hour with AC connected

90° in approximately 20 seconds

Primary Inherent entrapment sensing system (Type A)

Secondary Provision for connection of a non-contact sensor (Type B1)

Underground Operator

17”

1 1/2” Dia. Plastic

Drainage Pipe

(Not Supplied)

Drive

Arm

Linkin g Arm

Manual

Release

8 1/2” 8 1/2”

Linking Arm

2”

Manual

Release

Locking

Bracket

19”

15 3/4”

Pivot

Point

2 1/4”

12”

6”

7 3/8”

Pivot

Point

2 5/8”

3

4

TABLE OF CONTENTS

SPECIFICATIONS

Control Box, Standard and Deluxe Specifications

6002 Specifications

6003 Specifications

6400 Specifications

SAFETY

Gate Construction

Important Safety Instructions

Instructions regarding intended installation:

Important Notices

UL325 Entrapment Protection

Glossary

Swing Gate Requirements

Swing Gate Protection

SECTION 1 - INSTALLATION OVERVIEW

Installation of 6002 Actuator Arm

Removing 6002 Actuator Cover

6002 Manual Release

Cover the Holes on Top

6002 “Opening to the Inside”

6002 “Opening to the Outside”

Mounting 6002 Actuator Arm

Installation of 6003 Actuator Arm

6003 Manual Key Release

6003 “Opening to the Outside”

6003 “Opening to the Inside”

Mounting 6003 Actuator Arm

Installation of 6400 Underground Operator

6400 Single Hinge Setup

6400 Two Hinge Setup

6400 Gate Opening Direction

6400 Dual Gates Opening in Either Direction

17-19

20-22

6400-065-D-4-09

6

6

6-7

9

10

7

8

11

12

13-16

1

2

2

3

SECTION 2 - INSTALL CONTROL BOX

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2.2 Installation of Warning Signs

SECTION 3 - WIRING

3.1 Wiring ( s )

3.2 Secondary Entrapment Protection Wiring

3.5 Loop Detector Wiring

3.6 High Voltage Wiring and Battery Connection

SECTION 4 - ADJUSTMENTS

4.4 Inherent Entrapment Sensing Adjustment

Soft Shutdown and Resetting

Hard Shutdown and Resetting

SECTION 5 - MAINTENANCE AND TROUBLESHOOTING

5.1 Maintenance

5.3 Troubleshooting

6400-065-D-4-09

Control Box, Deluxe or Standard Wiring Diagram

Model 6002, 6003 and 6400’s Wiring Diagrams

23

23

35

35

35-36

36-37

37

38

39

5

30

30

31-32

32

32-33

33-34

23

24

24

25

26

27

28

29

Gate Construction

Vehicular gates should be constructed and installed in accordance with ASTM F2200; Standard Specification for Automated

Vehicular Gate Construction. For a copy of this standard, contact ASTM directly at 610-832-9585; [email protected]; or www.astm.org

.

Important Safety Instructions

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 gate. NO ONE SHOULD CROSS THE PATH OF THE MOVING GATE.

4. Test the operator monthly. The gate MUST reverse on contact with a rigid object or stop or reverse when an object

activates the non-contact 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!

6

Instructions regarding intended installation:

• Install the gate operator only if:

1. The operator is appropriate for the construction of the gate and the usage class of the gate.

2. All openings of a horizontal slide gate are guarded or screened from the bottom of the gate to a minimum of 4 feet

(1.22 m) above the ground to prevent a 2 ¼ inch (57.2 mm) diameter sphere from passing through the openings

anywhere in the gate, and in that portion of the adjacent fence that the gate covers in the open position.

3. All exposed pinch points are eliminated or guarded.

4. Guarding is supplied for exposed rollers.

• The operator is intended for installation only on gates used for vehicles. Pedestrians must be supplied with a separate

access opening. The pedestrian access opening shall be designed to promote pedestrian usage. Locate the gate such that

persons will not come in contact with the vehicular gate during the entire path of travel of the vehicular gate.

• The gate must be installed in a location so that enough clearance is supplied between the gate and adjacent structures

when opening and closing to reduce the risk of entrapment. Swinging gates should not open into public access areas.

• The gate must be properly installed and work freely in both directions prior to the installation of the gate operator. Do not

over-tighten the operator clutch, pressure relief valve or reduce reversing sensitivity to compensate for a damaged gate.

• For gate operators utilizing Type D protection:

1. The gate operator controls must be placed so that the user has full view of the gate area when the gate is moving.

2. A warning placard shall be placed adjacent to the controls.

3. An automatic closing device (such as a timer, loop sensor, or similar device) shall not be employed.

4. No other activation device shall be connected.

• Controls intended for user activation must be located at least ten feet (10’) away from any moving part of the gate and

where the user is prevented from reaching over, under, around or through the gate to operate the controls. Outdoor or

easily accessible controls should have a security feature to prevent unauthorized use.

• The Stop and/or Reset button must be located in the line-of-sight of the gate. Activation of the reset control shall not

cause the operator to start.

• A minimum of two (2) WARNING SIGNS shall be installed, one on each side of the gate where easily visible.

• For gate operators utilizing a non-contact sensor:

1. See the instructions on the placement of non-contact sensors for each type of application.

2. Care shall be exercised to reduce the risk of nuisance tripping, such as when a vehicle trips the sensor while the gate

is still moving in the opening direction.

3. One or more non-contact sensors shall be located where the risk of entrapment or obstruction exist, such as the

perimeter reachable by a moving gate or barrier.

6400-065-D-4-09

• For gate operators utilizing contact sensors:

1. One or more contact sensors shall be located where the risk of entrapment or obstruction exist, such as at the

leading edge, trailing edge, and post mounted both inside and outside of a vehicular horizontal slide gate.

2. One or more contact sensors shall be located at the bottom edge of a vehicular vertical lift gate.

3. One or more contact sensors shall be located at the pinch point of a vehicular vertical pivot gate.

4. A hardwired contact sensor shall be located and its wiring arranged so that the communication between the sensor

and the gate operator is not subjected to mechanical damage.

5. A wireless contact sensor such as one that transmits radio frequency (RF) signals to the gate operator for

entrapment protection functions shall be located where the transmission of the signals are not obstructed or

impeded by building structures, natural landscaping or similar obstructions. A wireless contact sensor shall function

under the intended end-use conditions.

6. One or more contact sensors shall be located at the bottom edge of a vertical barrier (arm).

Important Notices

Vehicular gate operator products provide convenience and security. However, gate operators must use high levels of force to move gates and most people underestimate the power of these systems and do not realize the potential hazards associated with an incorrectly designed or installed system. These hazards may include:

• Pinch points

Entrapment areas

• Reach through hazards

Absence of entrapment protection devices

Improperly located access controls

Absence of vehicle protection devices

• Absence of controlled pedestrian access

In addition to these potential hazards, automated vehicular gate systems must be installed in accordance with the UL-325

Safety Standard and the ASTM F2200 Construction Standard. Most lay persons are unaware of, or are not familiar with, these standards. If an automated vehicular gate system is not properly designed, installed, used and maintained, serious injuries or death can result. Be sure that the installer has instructed you on the proper operation of the gate and gate operator system.

Be sure that the installer has trained you about the basic functions of the required reversing systems associated with your gate operating system and how to test them. These include reversing loops, inherent reversing system, electric edges, photoelectric cells, or other external devices.

• This Owner’s Manual is your property. Keep it in a safe place for future reference.

• Be sure that all access control devices are installed a minimum distance of 10 feet away from the gate and gate operator, or in such a way that a person cannot touch the gate or gate operator while using the device. If access control devices are installed in violation of these restrictions, immediately remove the gate operator from service and contact your installing dealer.

• Loops and loop detectors, photo-cells or other equivalent devices must be installed to prevent the gate from closing on vehicular traffic.

• The speed limit for vehicular traffic through the gate area is 5 MPH. Install speed bumps and signs to keep vehicular traffic from speeding through the gate area. Failure to adhere to posted speed limits can result in damage to the gate, gate operator, and to the vehicle.

• Be sure that all persons who will use the gate system are familiar with the proper use of the gate and gate operator and are familiar with the possible hazards associated with the gate system.

• Be sure that warning signs are permanently installed on both sides of the gate in an area where they are fully visible to traffic.

• It is your responsibility to periodically check all entrapment protection devices. If any of these devices are observed to function improperly, remove the operator from service immediately and contact your installing or

• Follow the recommended maintenance schedule.

• Do not allow children to play in the area of the operator or to play with any gate-operating device.

• To remove the gate operator from service, operate the gate to the full open position and then shut off power to the operator at the service panel.

6400-065-D-4-09 7

UL325 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

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.

Class IV

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.

This table illustrates the entrapment protection requirements for each of the four UL325 classes.

8

UL325

Classifications

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

Primary Protection Secondary Protection Primary Protection Secondary Protection

Class I and II

Class III

Class IV

A

A, B1 or B2

A, B1, B2 or D

B1, B2 or D

A, B1, B2, D or E

A, B1, B2, D or E

A or C

A, B1, B2 or C

A, B1, B2, C or D

A, B1, B2, C or D

A, B1, B2, C or D

A, B1, B2, C, D or E

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.

6400-065-D-4-09

Glossary

GATE - A moving barrier such as a swinging, sliding, raising, lowering, or the like, barrier, that is a stand-alone passage barrier or is that portion of a wall or fence system that controls entrance and/or egress by persons or vehicles and completes the perimeter of a defined area.

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

COMMERCIAL / GENERAL ACCESS VEHICULAR GATE OPERATOR - 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), hotels, garages, retail store, or other building servicing the general public.

INDUSTRIAL / LIMITED ACCESS VEHICULAR GATE OPERATOR - CLASS III - A vehicular gate operator (or system) intended for use in an industrial location or building such as a factory or loading dock area or other locations not intended to service the general public.

RESTRICTED ACCESS VEHICULAR GATE OPERATOR - CLASS IV - 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.

VEHICULAR BARRIER (ARM) OPERATOR (OR SYSTEM) - An operator (or system) that controls a cantilever type device (or system), consisting of a mechanical arm or barrier that moves in a vertical arc, intended for vehicular traffic flow at entrances or exits to areas such as parking garages, lots or toll areas.

VEHICULAR HORIZONTAL SLIDE-GATE OPERATOR (OR SYSTEM) - A vehicular gate operator (or system) that controls a gate which slides in a horizontal direction that is intended for use for vehicular entrance and exit to a drive, parking lot, or the like.

VEHICULAR SWING-GATE OPERATOR (OR SYSTEM) - A vehicular gate operator (or system) that controls a gate which moves in an arc in a horizontal plane that is intended for use for vehicular entrance and exit to a drive, parking lot, or the like.

SYSTEM - In the context of these requirements, a system refers to a group of interacting devices intended to perform a common function.

WIRED CONTROL - A control implemented in a form of fixed physical interconnections between the control, the associated devices, and an operator to perform predetermined functions in response to input signals.

WIRELESS CONTROL - A control implemented in means other than fixed physical interconnections (such as radio waves or infrared beams) between the control, the associated devices, and an operator to perform predetermined functions in response to input signals.

INHERENT ENTRAPMENT PROTECTION SYSTEM - A system, examples being a motor current or speed sensing system, which provides protection against entrapment upon sensing an object and is incorporated as a permanent and integral part of the operator.

EXTERNAL ENTRAPMENT PROTECTION DEVICE - A device, examples being an edge sensor, a photoelectric sensor, or similar entrapment protection device, which provides protection against entrapment when activated and is not incorporated as a permanent part of an operator.

ENTRAPMENT - The condition when an object is caught or held in a position that increases the risk of injury.

6400-065-D-4-09 9

Swing Gate Requirements

The operator is intended for installation only on gates used for vehicles.

Pedestrians must be supplied with a separate access opening. The pedestrian access opening shall be designed to promote pedestrian usage. Locate the gate such that persons will not come in contact with the vehicular gate during the entire path of travel of the vehicular gate.

(ref. UL325 56.8.4.b)

Closed Gates

Closed Gate

A If space is greater than 4 inches, entrapment protection in this area is required. ASTM F2200 7.1.1.1 and 7.1.1.2

B If space is less than 16 inches, entrapment protection in this area is required. ASTM F2200 7.1.1.1 and 7.1.1.2

A

B

Not Allowed

Closed Gate

With the hinge mounted on the corner of the pilaster, eliminated and protection is not required for this area.

OK

10

Gates shall have smooth bottom edges, with vertical bottom edged protrusions not exceeding 0.50 inches. ASTM F2200 4.3

6400-065-D-4-09

Swing Gate Protection

D

Reverse Loop

Minimizes the potential of the gate closing when a vehicle is present.

Number and placement of loops is dependent on the application.

C

Non-contact Sensor

Minimizes the potential of the gate closing on vehicular or other traffic that loops cannot sense.

Shadow Loop

Provides a hold open command to the operator(s) only if the gate(s) are at the full open position.

C

D

D

Warning Signs

Permanently mounted and easily visible from either side of the gate.

Moving Gate Can Cause

Serious Injury or Death

KEEP CLEAR! Gate may move at any time without prior warning.

Do not let children operate the gate or play in the gate area.

This entrance is for vehicles only.

Pedestrians must use separate entrance.

Reverse Loop

Minimizes the potential of the gate closing when a vehicle is present.

Number and placement of loops is dependent on the application.

Separate Pedestrian

Walkway

Located so pedestrians cannot come in contact with the vehicular gate.

Automatic Exit Loop

(Optional) will provide an open command to the gate operator(s) when a vehicle is exiting the property.

6400-065-D-4-09 11

12

SECTION 1 - INSTALLATION OVERVIEW

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

6002

The proper installation of a vehicular swing 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 your operator. Be sure your installation is in compliance with local codes.

Important:

Consider hinge placement on a pilaster when installing the gate. Placing hinges close to the edge of the pilaster can eliminate a potential entrapment area (See Swing Gate Requirements on page 10).

Installing 6002 Actuator Arm

Pages 13 through 16

Installation instructions for the 6002 actuator arm ONLY. After 6002 arm has been installed, continue to Section 2 for control box installation.

6003

Installing 6003 Actuator Arm

Pages 17 through 19

Installation instructions for the 6003 actuator arm ONLY. After 6003 arm has been installed, continue to Section 2 for control box installation.

6400

Installing 6400 Underground

Operator

Pages 20 through 22

Installation instructions for the 6400 underground operator ONLY.

After 6400 has been installed, continue to Section 2 for control box installation.

6400-065-D-4-09

Removing 6002 Actuator Cover

Remove 3 screws and slide cover off.

DO NOT remove this screw.

6002 Manual Release

The actuator arm can be manually operated in case of power failure. Never manually release the arm until you have verified that

ALL power has been shut-off to it (Including batteries).

OPE

N

E N

O P

OPE

N

E N

O P

180°

OPE

N

E N

O P

Use key to unlock and remove the cover.

Remove allen wrench from inside of cover.

Insert allen wrench and turn 180° to release the arm.

Cover Holes on Top

Cover the exposed holes on top of the

6002 arm with the aluminum tape.

Do not cover the holes on the bottom of 6002 arm.

6400-065-D-4-09 13

6002 “Opening to the Inside”

Front Bracket Pivot Point

46 3 /

4

” Closed Position

Rear Bracket Pivot Point

3 1 /

8

Front Bracket

Do not install the actuator in fully extended (Bottomed out) position.

This will damage the arm. See page

16 to prevent this from happening.

Closed Position

(Cover Off)

Gate Hinge Pivot Point

7”

Rear Bracket

7”

Mechanically Attaching Brackets to Surfaces

When mounting brackets with bolts to the wall and/or gate, weld reinforcing steel plates to the brackets. Completely weld around brackets. The brackets must be perpendicular to the wall and/or gate and horizontally level.

Bolts with

Lock Washers

(Not Supplied)

90°

Concrete

Sleeve

Anchors

(Not Supplied)

Open Position

(Cover On)

Reinforced

Steel Plate

(Not Supplied)

Front Bracket

(Supplied)

Reinforced

Steel Plate

(Not Supplied)

Rear Bracket

(Supplied)

Support Bar

A support bar must span the entire length of the gate to support the gate pickets. The pickets will bend if not supported.

Actuator arm and brackets MUST be level!

14

Gate in Closed Position

6400-065-D-4-09

6002 “Opening to the Outside”

Mechanically Attaching Brackets to Surfaces

When mounting brackets with bolts to the wall and/or gate, weld reinforcing steel plates to the

Front Bracket Pivot Point brackets. Completely weld around brackets. The brackets must be perpendicular to the wall and/or gate and horizontally level.

Concrete

Sleeve

Anchors

(Not Supplied)

Bolts with

Lock Washers

(Not Supplied)

Reinforced

Steel Plate

(Not Supplied)

Front Bracket

(Supplied)

Reinforced

Steel Plate

(Not Supplied)

Fabricated

Reinfor ced

Stee l Plat e plied)

(Not Sup

90°

3 1 /

8

Open Position

(Cover Off)

Rear Bracket

(Supplied)

Do not install the actuator in fully extended (Bottomed out) position.

This will damage the arm. See next page to prevent this from happening.

7”

Rear Bracket Pivot Point 7”

Front Bracket

Gate Hinge Pivot Point

Closed Position

(Cover On)

Addition to rear bracket must be fabricated to reach wall.

Support Bar

A support bar must span the entire length of the gate to support the gate pickets. The pickets will bend if not supported.

Actuator arm and brackets MUST be level!

Gate in Closed Position

6400-065-D-4-09 15

16

Mounting 6002 Actuator Arm

Gate must be in good working condition before the actuator arm can be installed. Determine what direction the actuator arm will open the gate “Opening to the Inside” or “Opening to the Outside”(See 2 previous pages).

Gate Support Bar

A support bar that spans the entire length of the gate must be installed to keep the pickets from bending. Do not mount the front bracket directly to gate pickets!

Prevent Powered Shaft Bottoming Out

It is very important that the powered shaft is not fully extended when installed on the gate (bottoming out). This will damage the arm. To prevent this, manually release the arm and fully extend the powered shaft. Rotate it back two full turns before installing the arm.

Fully Extended (Bottomed Out)

Manually release with allen wrench.

OPEN

Powered Shaft

N O PE

Powered shaft rotated back 2 turns.

Clevis Pins

OPEN

Note: Front clevis pin MUST fit into countersunk hole to allow retaining ring to be installed.

Front Pin

(Long)

Rear Pin

(Short)

N O PE

Retaining Ring

Retaining Ring

Bracket Fabrication

The brackets need to be fabricated before the arm can be installed. Brackets will vary in size depending on the opening direction of the gate and the thickness of the wall the actuator arm will attach to. They can be attached to the wall and gate by welding and/or mechanically, depending on the type wall and gate. The brackets must be perpendicular to the wall and/or gate and horizontally level. Make sure the brackets will be VERY secure when fastened to the wall and gate.

Welding Brackets to Surfaces

If brackets are going to be welded to the gate and/or wall, only tack weld the brackets with the arm attached. Protect the arm from welding sparks during tack welding.

Remove arm before completely welding around the brackets. Make sure the

brackets are level when tack welding them! The arm will not operate properly if not level.

Actuator arm and brackets MUST be level!

After the 6002 actuator arm has been mounted to the gate, proceed to page 23 to install the control box.

6400-065-D-4-09

6003 Manual Key Release

Powered Shaft

Manually key release the actuator. Powered shaft can be pulled out.

CLOSE

OPEN

6003 “Opening to the Inside”

Front Bracket Pivot Point

47.5” Closed Position

Rear Bracket Pivot Point

Front Bracket

Do not install the actuator in fully extended (Bottomed out) position. This will damage the arm. See page 19 to prevent this from happening.

Cut Off

Excess

Bracket

Closed Position

Gate Hinge Pivot Point

7”

Attaching Brackets

The brackets must be securely mounted and level.

Sleeve Anchors

(Not Supplied)

Lock Washers

(Not Supplied)

Front Bracket

Bolt to support bar.

90°

7”

Open Position

2”

2 1/2 ”

Wall

3”

Rear Bracket Options

Assemble straight out (shown) or 3 different angles.

Angled Configurations

Straight

Angles will reduce operators distance from wall. See next page.

5 1/2 ”

Support Bar

A support bar must span the entire length of the gate to support the gate pickets. The pickets will bend if not supported.

Actuator arm and brackets MUST be level!

Cut Off

Excess

Bracket

Gate in Closed Position

6400-065-D-4-09 17

6003 “Opening to the Outside”

Attaching Brackets

The brackets must be securely mounted and level.

Front Bracket

Bolt to support bar.

Sleeve Anchors

(Not Supplied)

Front Bracket

Pivot Point

Cut Off

Excess

Bracket

Lock Washers

(Not Supplied)

Support

Bracket

(Supplied) ted ced

Fabrica

Reinfor

Steel Plates

(Not Supplied)

Rear Bracket

Bolt support bracket to fabricated steel plate with supplied lock nuts.

90°

Rear Bracket

Fabrication

A rear bracket will need to be fabricated.

The bracket will vary in size depending on the gate hinge inset. It can be attached to the wall by welding or bolting, depending on the type wall. The bracket MUST be level and VERY

secure to the wall. Extreme force will be exerted on this bracket during gate cycling.

Cut Off

Excess

Bracket

Front Bracket

7”

Rear Bracket Pivot Point

Closed Position

7”

Do not install the actuator in fully extended (Bottomed out) position. This will damage the arm. See next page to prevent this from happening.

Open Position

Gate Hinge Pivot Point

Addition to support bracket must be fabricated to reach wall.

Support Bar

A support bar must span the entire length of the gate to support the gate pickets. The pickets will bend if not supported.

Actuator arm and brackets MUST be level!

18

Gate in Closed Position

6400-065-D-4-09

Mounting 6003 Actuator Arm

Gate must be in good working condition before the 6003 actuator arm can be installed. Determine what direction the actuator arm will open the gate: “Opening to the Outside” or “Opening to the Inside”(See 2 previous pages).

Gate Support Bar

A support bar that spans the entire length of the gate must be installed to keep the pickets from bending. Do not mount the front bracket directly to gate pickets!

Prevent Powered Shaft Bottoming Out

It is very important that the powered shaft is not fully extended when installed on the gate (bottoming out). This will damage the arm. To prevent this, manually release the arm and fully extend the powered shaft. Rotate it back two full turns before installing the arm.

Fully Extended (Bottomed Out)

Powered Shaft

CLOSE

OPEN

Manual Release

Rotate back 2 turns before installing.

Rear Bracket Configurations for Different Gate Hinge Insets

This illustrates when the gate is “Opening to the Inside” Only.

Gate Hinge Pivot Point

7”

Closed Gate Position

Front bracket and operator always stay in a fixed location.

Rear bracket is adjusted for gate hinge inset.

40.5” Fixed Distance

Gate Hinge

No Gate Hinge Inset

47.5”

5 1/2 ”

Thin Wall

7” Fixed Distance between gate hinge pivot point and arm’s rear pivot point.

7”

Small Gate Hinge Inset

3”

Medium Gate Hinge Inset

2 1/2 ”

7”

Thick Wall

Large Gate Hinge Inset

7”

2”

Welding Brackets to Surfaces

If brackets are going to be welded to the gate and/or wall, only tack weld the brackets with the arm attached. Protect the arm from welding sparks during tack welding.

Remove arm before completely welding around the brackets. Make sure the

brackets are level when tack welding them! The arm will not operate properly if not level.

After the 6003 actuator arm has been mounted to the gate, proceed to page 23 to install the control box.

6400-065-D-4-09 19

6400 Single Hinge Setup

The gate weight will be on the foundation box of the 6400. It is recommended that the concrete is reinforced around the foundation box to handle the weight of the gate (300 lbs max.). It is preferred that a heavy gate be supported by two hinges instead of the foundation box (See next page).

The foundation box MUST have a drain pipe installed with the correct slope for proper drainage. Improper drainage of the foundation box will result in stagnant water that will eventually lead to operator failure.

Wall or

Post

2 1/2” Hinge pivot point.

Flange Hinge

P/N 1200-009

Sample Hinge

Important: Hinge pivot point MUST be plumb with foundation box pivot point.

Run 3/4” condui with sweeps fro fou ndat ion bo will be mo m x to unted.

Foundation box MUST be level and flush with driveway surface.

2 5/8” operator pivot point.

3”

3”

3” around foundation box.

Driveway

Foundation

Box

1 1/2” pipe sloped to drain.

Embedded Wire Mesh

The depth of the concrete is determined by specific installation requirements, soil conditions and local building codes.

Foundation Box

Slope 1 1/2” drainage pipe away from foundation box to nearest drain (Not supplied).

3”

Single Hinge Gate Connection

Important: Remove all parts from inside of foundation box before mounting into concrete.

20

Grease

Filler

Hole

Fab ricated

M etal

Brac

Fabr ica kets ted U-Channel (No

(Not

Suppl ied)

Man ual t Supp lied)

Relea se

Apply Grease

Weld both sides of

U-channel to manual release.

Manual

Release

Unlock and pull release handle to manually operate the gate.

Weld everything to gate.

Manual

Release

Protect the manual release from welding sparks during welding.

After the foundation box has been mounted and the gate has been connected to it, proceed to page 22 to install components in the box.

6400-065-D-4-09

6400 Two Hinge Setup

The gate weight is supported by the gate hinges and NOT on the foundation box. This is preferred for heavy gates.

The foundation box MUST have a drain pipe installed with the correct slope for proper drainage. Improper drainage of the foundation box will result in stagnant water that will lead to operator failure eventually.

Wall or

Post

Ball Bearing Hinge

P/N 1200-039

Sample Hinges

2 3/4” Hinge pivot point.

Important: Hinge pivot points MUST align with foundation box pivot point.

Run 3/4” condui with sweeps f founda t rom l box

Foundation box MUST be level and flush with driveway surface.

2 5/8” operator pivot point.

3” around foundation box.

Driveway

Foundation

Box

1 1/2” pipe sloped to drain.

Good

Drainage

The depth of the concrete is determined by specific installation requirements, soil conditions and local building codes.

Slope 1

Foundation Box drain (Not sup plied

).

pipe away

to

nearest

3”

Two Hinge Gate Connection

3”

3”

Important: Remove all parts from inside of foundation box before mounting into concrete.

Gate is supported by hinges and does not have to rest on foundation box.

Grease

Filler

Hole

Fabric ated U-Channe

Manual l (Not Supp lied)

Relea se

Apply Grease

Weld both sides of

U-channel to manual release.

Manual

Release

Unlock and pull release handle to manually operate the gate.

Do not weld gate to U-channel.

Manual

Release

Protect the manual release from welding sparks during welding.

After the foundation box has been mounted and the gate has been connected to it, proceed to page 22 to install components in the box.

21 6400-065-D-4-09

6400 Gate Opening Direction

The drive motor orientation determines the opening direction of the gate. It can be unbolted and flipped 180° to allow the gate to open in either direction. See setups below for your specific opening direction. Factory setup opens gate counter-clockwise.

Close

Gate

Open Counter-Clockwise

Close

Gate

Open Clockwise

Drive

Motor

Drive

Arm g

Arm

Linking Arm

Open

Gate

Limit

Plate

DIP-Switch switch 1-ON

Open Counter-Clockwise Limit Plate

Close Limit Position

Brown/White

Yellow/White

Arms shown in open position.

Drive

Arm

Limit

Plate

Open Clockwise Limit Plate

Close Limit Position

Purple/White

Gray/White

Drive

Motor

Open

Gate

DIP-Switch switch 1-OFF

Limit Plate

SW 1

Open Limit Position

Purple/White

Gray/White

Limit sensors are factory set in the

“Open counter-clockwise” position.

Limit Plate

SW 1

Open Limit Position

Brown/White

Yellow/White

Limit sensors must be slid 90° clockwise on limit plate to be in the correct “Open clockwise” position.

Note: Final limit adjustments will be made after AC power has been connected.

6400 Dual Gates Opening in Either Direction

The secondary operator motor wires must be reversed if dual operators are used (Blue wire to #1 and Brown wire to #2).

See page 24 for more information.

Open

Gate

Open

Gate

Primary Operator

Opens Clockwise

Secondary Operator

Opens Counter-Clockwise

DIP-Switch

SW 1, switch 1-OFF

DIP-Switch

SW 1, switch 2-ON

Linking g

Close

Gate

Close

Gate

Li nk ng

Arm

Arm g

Li Li nk nkin

SW 1

Close

Gate

Close

Gate m

Ar g ing Arm nk

Li

22

DIP-Switch

SW 1, switch 1-ON

DIP-Switch

SW 1, switch 2-OFF

Primary Operator

Opens Counter-Clockwise

SW 1

Secondary Operator

Opens Clockwise

Open

Gate

Drive motors face the same direction in a dual gate installation.

Limit sensors are positioned according to the opening direction of the gate (See limit plates shown above).

Open

Gate

6400-065-D-4-09

SECTION 2 - INSTALL CONTROL BOX

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. Check local building codes prior to installing any permanent wiring to ensure all wiring and connections comply with local electrical code requirements..

2.1 Install Control Box

Position the control box on the wall, close enough to the operator so the primary operator cable can be easily routed inside the box. Secure the control box to the wall with appropriate hardware (not included). Control box has predrilled mounting holes. All power and control wires should be routed to control box in conduits with sweeps. Never run high voltage and low voltage wires in the same conduit, keep them in separate conduits.

• 3/4” conduit recommended. Use only sweeps for conduit bends and NOT elbow connectors. Elbows will make

wire pulls very difficult and can cause damage to wire insulation.

• Remove fragile components from control box to protect them during installation if necessary.

Coaxial Cable Antenna Kit

P/N 1514-073 (Sold separately)

Drain Pipe

Secondary Operator Conduit (Dual Operators)

2.2 Installation of Warning Signs

This DoorKing Swing Gate Operator is shipped with two warning signs. The purpose of the warning sign is to alert uninformed persons, and to remind persons familiar with the gate system, that a possible hazard exists so that appropriate action can be taken to avoid the hazard or to reduce exposure to the hazard.

Permanently install the supplied warning signs in locations so

that the signs are visible by persons on both sides of the gate.

• Use appropriate hardware such as wood or sheet metal screws

(not supplied) to install the warning signs.

6400-065-D-4-09

6002

6003

Actuator

Cable

Loops and/or

Control

Devices

Control

Box must be properly grounded.

AC Power

Sweeps

23

24

SECTION 3 - WIRING

Before attempting to connect any wiring to the control box, be sure that the circuit breaker in the electrical panel is in the OFF position. Permanent wiring must be installed to the control box 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 control box (both high and low voltage) complies with local code requirements.

GATE OPERATOR(S) MUST BE PROPERLY GROUNDED!!

3.1 Wiring Operator

(

s

)

Brown wire

Blue wire

Orange wire

Red wire

Yellow wire

Green wire

Green/Yellow wire

Not Used

Primary or Secondary Wiring

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

Secondary Operator

1

2

3

4

5

6

7

Primary Operator

6400 Secondary Wiring ONLY!

Blue wire

Brown wire

Orange wire

Red wire

Yellow wire

Green wire

Green/Yellow wire

Not Used

1

2

3

4

5

6

7

8

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Motor wires MUST be reversed for the 6400 Secondary operator ONLY.

Secondary

Operator

Primary

Operator

DoorKing interconnection cable (P/N 2600-75x) in underground conduit (Not supplied)

6400-065-D-4-09

3.2 Secondary Entrapment Protection Wiring

In addition to the inherent reversing sensor system, this operator has provisions for the connection of a non-contact (type B1) secondary entrapment protection device. This is required by UL 325 standards. DoorKing highly recommends installing loops and loop detectors to enhance this secondary entrapment protection.

Entrapment protection devices are required to reduce the risk of injury. Install sensors where the risk of entrapment or obstruction exists while gate is moving.

PHOTO OPEN (Photo Cell)

Stops gate movement in the open cycle. Gate resumes normal operation when the input (obstruction) is cleared.

PHOTO CLOSE (Photo Cell)

Stops the gate in the closing cycle. Gate resumes closing when the input (obstruction) is cleared.

Not used

Not used

COMMON

Terminal for the secondary entrapment device input.

COMMON

2

11

3

6

5

4

N.O.

Com

Secondary Entrapment Protection Terminal

Photo Cells

Closed Gates

Safety Protection

Safety Photo Cell

DIP-Switch Setting

SW 1

Switch 5 OFF

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

25 6400-065-D-4-09

3.3 Main Terminal Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

26

2

• When gate is closed, input will open gate.

• When gate is open and auto close timer SW 1, switch 4 is turned ON, input will re-set and hold timer.

• When gate is open and auto close timer SW 1, switch 4 is turned OFF, input will close gate.

• When gate is closing, input will reverse gate.

SW 1

• When gate is closed, this input has no affect on the gate operator.

• When gate is open and auto close timer SW 1, switch 4 is turned ON, input will re-set and hold timer.

• When gate is open and auto close timer SW 1, switch 4 is turned OFF, input will prevent gate from closing.

• When gate is closing, input will reverse gate if SW 1, switch 5 is OFF.

• When gate is closing, input has no affect on the gate operator if SW 1, switch 5 is ON (set for shadow input).

SW 1

SW 1

8

15

DC power is not present on the board until first initial cycle of gate.

12 Maglock:

Switch 3 ON,

1 sec. delay at start.

SW 2

10

11

Operation of relay is dependent on setting of

SW 2, switches 1 and 2. Relay contacts can be set for Normally Open (NO) or Normally

Closed (NC) operation. Contact rating is

1 amp maximum at 24 Volts.

NC

NO

• Switch 1 OFF, Switch 2 OFF:

Relay activates when gate is OPEN.

SW 2

• Switch 1 OFF, Switch 2 ON:

Relay activates when gate is OPEN,

OPENING or CLOSING.

• Switch 1 ON, Switch 2 OFF:

Relay activates when gate is OPEN or OPENING.

• Switch 1 ON, Switch 2 ON:

Relay activates when gate is OPENING or CLOSING.

4

• lf SW 1, switch 3 is ON, this input is identical to

Single Button Activation.

• lf SW 1, switch 3 is OFF, this terminal becomes the logic output of the EXIT loop detector.

SW 1

6400-065-D-4-09

3.4 Main Terminal Wiring

Controls must be far enough from the gate so that the user is prevented from coming in contact with the gate while operating the controls. Outdoor or easily accessible controls should have a security feature to prevent unauthorized use. When installing electrical equipment make certain all wiring complies with local code requirements. Do not power any control devices from the circuit board other than low voltage devices.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

4-Wire

Receiver

Reversing input on

Terminal 8 only functions while the gate is at the full open position or during the closing cycle. It should not be used as an input for a secondary entrapment protection device during the opening gate cycle.

Refer to Section 3.2

Secondary Entrapment

Protection Wiring.

3-Wire Receiver

Mount inside of control box door.

Telephone Entry

Switch 3 ON

SW 1

Note: Telephone entry device must use a separate power source.

6400-065-D-4-09

Com

N.O.

Magnetic Lock

Com

N.C.

Switch 3 ON

SW 2

Note: Circuit board provides 24 VDC to power maglock.

Connect optional control devices to the main terminal strip. Use 18 AWG wire for all low voltage wiring, maximum distance

3000 feet. Use a low voltage surge suppressor,

(DoorKing P/N

1878-010) if low voltage wire runs exceed 1000 feet.

All inputs to the terminal strip must be NORMALLY

OPEN.

Knox Box

(Dry contact)

Com

N.O.

Com

N.O.

Keypad

(Dry contact)

Switch 3 ON

Com

N.O.

Key Switch

(Dry contact)

SW 1

27

28

3.5 Loop Detector Wiring

To protect the operator from accidentally closing on vehicles in the gate’s path, DoorKing highly recommends that loops and loop detectors be installed. Loops are laid underneath, cut into asphalt or concrete driveways or buried beneath gravel and earth driveways. A loop detection system will sense a vehicle like a metal detector and send a signal to the gate operator preventing the gate from automatically opening or closing on a vehicle when it is in the gate’s swing path. Refer to the separate loop and loop detectors information manual (Located at Doorking’s web site) for further information. DoorKing recommends that a licensed installer perform this work.

Shadow Loop

The shadow loop is placed inside the gate’s swinging path to prevent the gate from closing on a vehicle in this area. It is only active when the gate is in the full

open position. Vehicles in the shadow area will activate it. It will not allow the gate to close unless this area is clear. After a closing cycle begins, the shadow loop will not reverse the gate. Reverse loops work in conjunction with the shadow loop and both should be used.

Auto mat ic Exit

Rev ers e

Reverse Loops

Reverse loops are placed just outside the gate’s swinging path to prevent the gate from closing on a vehicle in these areas. They will stop or reverse the cycling of the gate while a vehicle is in or near the gate’s swing pathway.

Reverse loops are wired in series.

Sha dow

Reve rse

Com

N.O.

9410

9409

Automatic Exit Loop

Automatically opens the gate for exiting vehicles without having to use a transmitter or keypad.

The exit loop can be placed 20-100 feet away from the gate so that the gate is open or partially open as you drive up to it.

Relay must be set to N.O.

NO

NC

Note: Loop detector wiring is shown for DoorKing plug-in loop detectors

P/N 9409-010 and P/N 9410-010 only. If other loop detectors are used, refer to the installation instructions supplied with those detectors for wiring instructions.

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Shadow Loop

DIP-Switch Settings

SW 1, switch 5 is OFF.

SW 1

SW 2

SW 2, switch 1 is ON and switch 2 is OFF.

6400-065-D-4-09

3.6 High Voltage Wiring and Battery Connection

CONTROL BOX MUST BE PROPERLY GROUNDED!!

Reset Button

CAUTION

Do not connect the battery to the circuit board until power is needed to test the operator.

Battery Connection

1

2

3

4

5

6

7

AC Power Switch

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

To Cycle Operator:

After power has been connected, activate the operator by pressing the key switch button.

Alarm

Reset

Button

Chassis

Ground

DANGER

HIGH VOLTAGE!

Important Power Note: To turn-off ALL power to the operator, the AC power switch must be turned off and the battery plug must be disconnected from the circuit board.

Connect 115 VAC input power wires (black and white) to black (Hot) and white (Neutral) transformer wires. Connect input green wire to chassis ground.

It is recommended that a surge suppressor be installed on the high voltage power lines.

6400-065-D-4-09 29

SECTION 4 - ADJUSTMENTS

The switch settings and adjustments in this section should be made after your installation and wiring to the operator(s) is complete. Whenever any programming or switch setting on the control board are changed, press the reset switch for new settings to take effect.

4.1 Circuit Board Adjustments

DIP-Switches

Loop Detector

9410 Single Channel

Loop Detector

9409 Dual Channel

Set DIP-switches on the circuit board to the desired setting.

See switch-setting charts on next 2 pages.

SW 1

SW 2

Reset Switch

Press reset switch to activate changed control board settings.

Self Test

Self Test

Mode

Self test mode is for bench checks only. The operator will continually cycle the gate.

Normal

Mode

The jumper must be set at normal mode to function.

Key Switch

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Auto Close Timer

• Auto close timer (when turned on) SW 1, switch 4.

Adjust from 1 second (full counter clockwise) to approximately

23 seconds

(full clockwise).

SW 1

TIME

DELAY

1 23

Cycles the operator when pressed.

30

Dry Relay Contact

Dry relay contacts (terminals 10-11) can be set for Normally Open (NO) or

Normally Closed (NC) operation by placing the relay shorting bar on the N.O. or N.C. pins respectively.

NO

NC

Secondary

Reverse Sensors

Adjust reversing sensitivity for:

PRIMARY (single) and

SECONDARY (dual) operators.

See 4.4 on pages 32 and 33.

Primary

Min Max

Sensitivity

6400-065-D-4-09

4.2 DIP-Switch Settings

Whenever any programming or switch setting on the control board is changed, press the reset switch for new settings to take effect.

Switch Function

1

Opening

Direction of

Primary

Operator

ON

Setting

OFF

6400

SW 1 (Top 8 Switches)

Description

OFF setting. Opens 6400 clockwise.

Drive

Motor

Orientation

Open

Limit

Close

Limit

Drive

Motor

Orientation

ON setting. Opens 6400 counter-clockwise.

OFF setting.

6002 or 6003

ON setting.

Close

Limit

Open

Limit

2

Opening

Direction of

Secondary

Operator

Same as primary operator above.

3

4

5

6

7

8

Exit loop

Logic Output

Auto-Close

Timer

Reverse

Shadow

Overlapping

Gates

Single

Dual

Spare

OFF

ON (normal)

OFF

ON

OFF (normal)

ON

OFF

ON

OFF

ON

OFF

Terminal 4 is output from exit loop detector.

Terminal 4 is open command.

Auto-close timer is OFF. Manual input required to close gate.

Auto-close timer is ON. Adjustable from 1-23 seconds.

Terminal 8 is a standard Reverse input.

Terminal 8 is a Shadow reverse input.

Both operatorss start at the same time.

Secondary operator starts 1-2 seconds before primary operator.

Switch must be OFF for single operator.

Switch must be ON when (dual) operators are used.

Leave in the OFF position.

Switch 1 Sets direction of the primary operator so that the operator cycles open upon initial power up and open command. If the operator begins to cycle close upon initial power up and open command, turn power off and change the setting on this switch.

Switch 2 Sets direction of the secondary operator so that the operator cycles open upon initial power up and open command. If the operator begins to cycle close upon initial power up and open command, turn power off and change the setting on this switch.

Switch 3 Determines if the output of the loop detector (DoorKing loop detectors only) plugged into the EXIT port will be sent directly to the microprocessor to open the gate, or if the output is directed to Terminal 4 where it can then be connected to other input terminals.

Switch 4 Turns the auto close timer on or off. Maximum time that the close timer can be set for is approximately 23 seconds.

Switch 5 This switch sets the input at Terminal 8 to act as a normal reverse input or to act as a shadow input. A shadow input will only hold the gate operator in the open position once it is in the full open position. A shadow input will not reverse the direction of the gate actuator once it begins its close cycle.

Switch 6 Turns the gate overlap feature on or off. When turned ON, the Secondary operator begins its cycle 1-2 seconds prior to the Primary operator, allowing the Primary gate to reach its full closed position 1-2 seconds before the Secondary gate. This feature is useful when a magnetic lock is used to secure the gates.

Switch 7 Sets up the circuit board for single or dual (Primary / Secondary) gate operation.

Switch 8 Spare switch. Leave in the OFF position.

Continued on next page.

6400-065-D-4-09 31

4.2 DIP-Switch Settings Continued

Whenever any programming or switch setting on the control board is changed, press the reset switch for new settings to take effect.

Switch Function

1 and 2

3

4

Setting

Relay

Operation

Maglock

DK Deadbolt Lock

Spare

1-OFF 2-OFF

1-OFF 2-ON

1-ON 2-OFF

1-ON 2-ON

ON

OFF

OFF

SW 2 (Bottom 4 Switches)

Description

Relay activates when gate is fully open.

Relay activates when gate is not closed.

Relay activates when gate is opening and open.

Relay activates when gate is opening and closing.

1 second delay to disengage maglock.

4-5 seconds delay to retract dead-bolt.

Leave in the OFF position.

Switch 1 and 2 These work in conjunction with each other and determine when the relay on the board will be activated. This relay can be used as a switch for various functions such as illuminating a warning light when the gate is moving, or turning on a green light when the gate is full open. This relay is not available for these uses if it is being used for the shadow loop function.

Switch 3 Used for a maglock or a DK deadbolt lock.

Switch 4 Spare switch. Leave in OFF position.

4.3 Limit Sensor Adjustments

The limit sensors must be adjusted to precisely set the full open and full closed position of the gate. This feature is especially useful in applications where the gate opens partially, such as on a curved driveway. Power to the circuit board must be ON when adjusting the limit switches.

A Manually release operator with key and remove cover with 3 or 4 screws.

B Manually move the gate to the desired open or closed position.

Loosen the limit nuts and slowly slide the limit assembly until the

LIMIT LED on the circuit board lights up.

6002 or 6003

Slow Down

B

C Tighten the limit nuts, re-lock operator with key and test the gate stopping positions. Repeat if necessary.

Limit Nut

6400

Lim it Nut

B

D Re-install the cover. Adjust the secondary operator limit sensors if dual operators have been installed.

Slow

Down

Note: 3 and 5 limit LEDs can be

Open or Close limits according to

SW 1, switch 1 and 2 settings.

Secondary

4.4 Inherent Entrapment Sensing Adjustment

32

This vehicular gate operator is equipped with an inherent adjustable reversing sensor (Type A) that is used as the primary entrapment sensing system according to the UL 325 standards. The gate will reverse direction upon encountering an obstruction in either the opening or closing gate cycle. For the reverse system to function correctly, the gate must be properly installed and work freely in both directions. A good set of roller bearing hinges is essential for proper swing gate operation.

The ideal adjustment will allow the operator to move the gate through its entire travel cycle without reversing, but

Primary will reverse upon contact with an obstruction with no more than 40 Lbs of force. This force can be measured with a gate scale, DoorKing P/N 2600-225. Continued on next page.

Min Max

Sensitivity

6400-065-D-4-09

The amount of force required for the gate to reverse direction depends on the reverse sensitivity potentiometer.

CAUTION: Keep pedestrians and vehicles clear of the gate while adjusting sensor!

While operator has AC power:

1 Press the Key Switch button to cycle the gate open.

Min Max

Sensitivity

2 While gate is opening, slowly rotate Primary reverse sensor clockwise until the reverse LED lights up and the gate reverses direction. Rotate reverse sensor back counter-clockwise approximately 1/8 turn.

Primary

3 Cycle the gate a few times to be sure that it cycles completely.

Note: Secondary operator must be individually adjusted if dual operators have been installed. Use the

Secondary reverse sensor.

Secondary

Test the operators reversing sensitivity:

Place an immobile object along the gate path, allowing the gate to strike it while in the open or

close cycle. The gate must reverse direction after striking the object. If it does not, increase

Min Max

Sensitivity

4.5 Shutdown Conditions

Under various entrapment conditions the operator will assume either a SOFT or HARD (alarm) shutdown. To determine what type of reset action is required, you will need to understand how the different entrapment conditions affect the gate operator.

Soft Shutdown

This occurs in various situations where the inherent or secondary entrapment protection devices have been activated.

In a soft shutdown condition, the operator will not respond to any input that was present when the entrapment protection device sensed or encountered an obstruction. If the gate stops at the open position, the operator will not respond to the automatic close timer and a “manual input” is required to close the gate.

Example 1 - A time clock keys the gate open in the morning and an entrapment protection device senses

an obstruction prior to the gate reaching the full open position. If the entrapment is sensed by the inherent

system, the gate will reverse and run back to the closed position. The time clock input is still present, but

the gate will not re-open.

Note: In some systems, the time clock input comes from the telephone entry system relay. This same relay may also provide open commands for a card reader, MicroPLUS transmitters and the visitor telephone entry. If so, these devices will also be disabled in a soft shutdown condition.

Example 2 - If the gate is closing and an entrapment protection device is activated, the gate will either stop or

reverse and run back to the open position, depending upon if the secondary or inherent device was activated.

The automatic close timer will not close the gate.

Example 3 - If a moving vehicle runs over a loop while the gate is cycling open and hits the opening gate, the

operator’s inherent entrapment protection is activated. The gate will reverse direction and run back to the

closed position. A soft shutdown condition does not occur and the loop provides an immediate reset of the

operator. Once the loop area is clear and another open command is given, the gate will cycle open.

Resetting a Soft Shutdown

In some conditions, a soft shutdown will reset as soon as the entrapment condition clears. For example, if a noncontact sensor (photo cell) is sensing an obstruction, the operator will stop the gate and assume a soft shutdown condition. When the photocell clears, the operator will return to normal operation.

6400-065-D-4-09

When the operator is in a soft shutdown, activation of any “intended input” will reset the operator. An “intended input” includes any command input device, any standard safety input device and any loop input. Activating any of these inputs will reset the gate. At that point the gate will return to normal operation. If the gate is open, the automatic close timer will then time out and close the gate.

33

4.5 Shutdown Conditions Continued

Hard Shutdown

A hard shutdown condition occurs when the inherent entrapment protection system has sensed two consecutive obstructions before the gate reaches the full open or closed position.

Example - The gate is closing and the inherent entrapment protection system senses an obstruction and

causes the gate to reverse direction. As the gate begins to run in the open direction, a second obstruction

is sensed prior to the gate reaching the full open position. Once the second obstruction has been sensed,

the operator will stop, the audio alarm will be activated and ALL standard inputs are shut down (including

open commands, safety commands, loop inputs, etc.).

Note: The audio alarm will remain activated for a maximum of five minutes, or until the operator receives a reset input.

The hard shutdown condition will remain in affect even if the audio alarm shuts off after five minutes.

• After 5 minutes, the audio alarm will “chirp” every 5 seconds. This indicates that the operator is in a hard

shutdown condition and the Reset Button or the Alarm Reset Button must be activated to reset the

operator and silence the alarm. See illustration below.

Resetting a Hard Shutdown

When the operator is in a hard shutdown condition (audio alarm activated or audio alarm “chirps” every 5 seconds), to reset the gate operator and return it to normal operation, activate the Reset Button or the Alarm Reset Button.

• Before resetting a hard shutdown, determine why the shutdown occurred. Inspect the gate for any

obstructions along its path that could have activated the inherent entrapment sensing system. Inspect

the gate and gate hardware.

Note: DoorKing operators have a built-in alarm reset push buttons on the circuit board and on the bottom of the control box for quick access. Activating either one of these buttons will return the gate operator to normal operation, but will not activate the gate operator.

Reset Button

4

5

6

7

1

2

3

4302

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Alarm Reset

Button

34

Once the gate has been reset, an open or close command is needed to start the gate operator. Most activating commands will cause the gate operator to cycle to the open position. This includes activation of a key switch or open command and activation of an open loop. Activation of a close command will run the gate to the closed position.

6400-065-D-4-09

SECTION 5 - MAINTENANCE AND TROUBLESHOOTING

Inspection and service of this gate operator by a qualified technician should be performed anytime a malfunction is observed or suspected. High cycle usage may require more frequent service checks.

5.1 Maintenance

When servicing the gate operator, always check any secondary (external) reversing devices (loops, photo cells, etc.) for proper operation. If external reversing devices cannot be made operable, do not place this operator in service until the malfunction can be identified and corrected.

Always check the inherent reversing system when performing any maintenance. If the inherent reversing system cannot be made operable, remove this operator from service until the cause of the malfunction is identified and corrected. Keeping this operator in service when the inherent reversing system is malfunctioning creates a hazard for persons which can result in serious injury or death should they become entrapped in the gate.

When servicing the gate operator, be sure that the 24 VAC input power and batteries are disconnected.

Alarm

Operator

Component

Batteries

Fire Dept.

Gate

Primary Reverse System

Loop(s)

Release

Secondary Reverse Device

Complete System

Maintenance

Monthly Interval

3 6 12

Activate the primary (inherent) reverse system by blocking the gate with a solid object. When the gate reverses, block the gate in the opposite direction prior to the limit being reached. The entrapment alarm should activate. Press the reset button to silence the alarm.

Check the batteries for any leakage or loose connections.

Batteries should be replaced every two years.

Check emergency vehicle access device for proper operation.

Inspect for damage. Check gate hinges for wear and grease if necessary.

Check that the gate reverses on contact with an object in both the opening and closing cycles.

Adjust the reversing sensor if necessary.

Check vehicular reverse and shadow loops for proper operation.

Check manual release for proper operation.

Check secondary (external) reverse device(s) stop or reverse the gate when activated.

Complete check of gate and gate operating system.

5.2 Diagnostics Check

Have the following diagnostic tools available: VOM meter with minimum voltage memory or min-max range to check voltage and continuity. Meg-ohm meter capable of checking up to 500 megohms of resistance to properly check ground loop integrity.

A malfunction can be isolated to one of the following:

• Gate Operator • Loop System • Keying Devices.

Disconnect all external inputs to the circuit board.

1. Check the input indicator LED’s. They should only come ON when a keying device (card reader, push button, etc.) is activated. If any of the input LED’s are ON continuously, this will cause the gate operator to hold open. Disconnect the keying devices one at a time until the LED goes OFF (see troubleshooting guide).

2. If the operator stops or holds open, check external secondary entrapment protection devices for any shorts or malfunction.

3. A malfunction in a loop or loop detector can cause the gate operator to hold open, or not detect a vehicle when it is present over the loop. Pull the loop detector circuit boards from the loop ports on the operator circuit board. If the malfunction persists, the problem is not with the loop system. For more information refer to the loop detector instruction sheet and the DoorKing

Loop and Loop Detector Information Manual. Continued on next page.

6400-065-D-4-09 35

5.2 Diagnostics Check Continued

4. Check that there are no shorted or open control wires from the keying devices to the gate operator. If a keying device fails to open the gate, momentarily jumper across terminals 1 and 2 on the control board. If the gate operator starts, this indicates that a problem exist with the keying device and not with the gate operator.

5. Check the supply voltage and batteries. A voltage drop on the supply line (usually caused by using too small supply voltage wires) will cause the operator to malfunction. Batteries should be fully charged for proper operation, replace batteries every two years on average.

5.3 Troubleshooting

Symptom

Operator(s) will not run. Power LED is

OFF.

Possible Solution

(

s

)

• Check that AC power to the operator is turned ON.

• Check battery power.

• Check for 24 VAC at terminals 19 and 20. If voltage measures OK, check the terminal strip or

replace the circuit board.

Operator(s) will not run. Power LED is

ON.

• Momentarily jumper terminal 1 to terminal 2. If the input LED does not come ON, check the terminal

strip or replace the circuit board. If LED does come ON, proceed to next steps.

• Check the fuses.

• Check Motor(s):

Remove the circuit board. With two 14 AWG insulated jumper wires, momentarily jumper the battery

terminals to the motor terminals (1, 2) of the Primary operator connector. The operator should run.

Swap the two wires at the terminal strip. The operator should run in the opposite direction. Repeat

these steps using the Secondary operator connector.

• If the operator(s) run in both directions in the step above, replace the control board. If the

operator(s) do not run, or run in only one direction, problem can be a bad operator, wire

connections from the control board to the operator(s) or a bad control board.

36

Gate opens a short distance, then stops and reverses.

• Check the reversing sensitivity.

• Check the secondary safety devices.

• Disconnect the gate from the gate operator and check that the gate swings freely without any

binding.

• Replace the circuit board.

Gate opens but will not close.

Gate closes but will not open.

• Check the input LEDs. Any ON will hold the gate open and indicates a problem with a keying device.

• Check the secondary safety devices. Any activated will hold the gate open and indicates a problem

with the safety device.

• Check the loop detectors. Any activated can hold the gate open and indicates a problem with the

loop detector or ground loop.

• Operator may be in a “soft shutdown.” Activate any keying device to determine if operator returns

to normal operation.

• If automatic close is desired, be sure SW 1, switch 4 is ON.

• Operator may be in a “soft shutdown.” Check input LEDs. If any are ON, momentarily disconnect,

then re-connect the wire going to the respective terminal. Operator should open.

• Check to be sure that the operator is running in the proper direction. Turn power OFF, and then back

ON. Activate a keying device. Operator should run in the open direction. If operator runs in the

close direction, turn power OFF and change direction switch SW 1, switches 1 and/or 2. Go to

above section if operator now opens but will not close.

• Be sure that the respective LED on the control board lights when the keying device connected to the

respective terminal is activated. If LED does not light, momentarily place a jumper wire from

terminal 1 to the input terminal being checked. If LED lights and gate opens, problem is with the

keying device. If LED does not light, replace control board.

• Check motor as described above “Operator(s) will not run. Power LED is ON”.

6400-065-D-4-09

5.3 Troubleshooting Continued

Symptom Possible Solution

(

s

)

Gate starts to close, then reverses to open.

• Disconnect the gate from the operator and check that the gate operates freely without any binding.

• Check the loop detector LED’s and input LED’s. Any that fl ash ON will cause the gate to reverse.

• If a shadow loop is used, check for proper wiring. A mis-wired shadow loop detector will cause the

gate to reverse.

• Replace the circuit board.

Gate closes and opens continously.

• Check for any input or loop detector LED’s that are ON.

• Check that the operator is running in the proper direction (see “gate closes but will not open”).

• Check the SELF TEST jumper, see page 30.

Alarm sounds for 5 minutes and then beeps once every 5 seconds. Operator will not run.

• Operator is in a “hard shutdown” condition. Reset switch must be activated to return operator to

normal operation, see Hard Shutdown Section 4.5, page 34.

5.4 Accessory Items

The following accessory items are available for the models 6002, 6003 and 6400 swing gate operators.

Photo Cell - Non-contact (photo-cells) sensors for use as a secondary entrapment protection device.

EMX Industries, Inc. Model IRB-325

MMTC, Inc. Model E3K-R10K4-NR

Loop Detector - Detectors plug directly into ports on circuit board simplifying wiring.

P/N 9410-010 - Single channel detector

P/N 9409-010 – Two-channel detector

Magnetic Lock - Magnetic Gate Lock Kit provides an excellent means to secure swing gates and is a fail-safe device allowing emergency vehicle access upon power outage.

P/N 1216-080 and P/N 1216-081

Interconnect Cable - Interconnect wire cable contains all the necessary wires to interconnect primary / secondary operators.

Cable length 30 feet. P/N 2600-755 Cable length 40 feet. P/N 2600-756 Cable length 50 feet. P/N 2600-757

Time Clock - 7 day and 365 day time clocks can be used to automatically open gate at pre-set time and days. Compact clock fits inside the control box.

P/N 2600-791 - 7 day clock

P/N 2600-795 - 365 day clock

Hinges - Heavy-duty ball bearing hinges provide easy swing gate operation.

P/N 1200-009 (Flange) , P/N 1200-019, P/N 1200-039. Two (2) required.

Surge Devices - High and low voltage surge suppressors help prevent circuit board failure caused by lightning strikes and power surges.

P/N 1876-010 - High Voltage

P/N 1878-010 - Low Voltage

Gate Scale - Use to test torque required to move gate. P/N 2600-225

Speed Bumps - Prefabricated six-foot speed bump reduces traffic speed through gate system. P/N 1610-150

Batteries - 12 Volt 3 Amp Hour. P/N 1801-009. Two (2) required.

6400-065-D-4-09 37

Control Box, Deluxe or Standard

Secondary Operator

Connector

1

4

5

6

7

2

3

Black

12 V

3 Amp/Hr

Battery

Red

Black

+

– +

Primary Operator

Connector

1

4

5

6

7

2

3

12 V

3 Amp/Hr

Battery

38

Deluxe Control Box

Convenience Outlets 115 VAC

AC Power

Black Hot

White

Neutral

Chassis

Ground

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Black

Red

Red

Transformer

Red

Red

Standard Control Box

Transformer

AC Power

Alarm

Reset

Button

115 VAC

Chassis

Ground

6400-065-D-4-09

Models 6002 , 6003 and 6400

6002

Yellow Brown

Limit Assembly

6003

Yellow Brown

Limit Assembly

Purple

Limit Assembly

Gray

White

Motor

Blue and Brown

A

(Motor) Brown 1

(Motor) Blue 2

(Limit) Gray 3

(Slow Down) Purple 4

(Limit) Yellow 5

(Slow Down) Brown 6

(Common) 4 White Wires 7

5

6

7

3

4

1

2

5

6

7

3

4

1

2

Purple

Limit Assembly

Gray

White

A

1 Brown

2 Blue

3 Orange

4 Red

5 Yellow

6 Green

7 Green/Yellow

Motor

Blue and Brown

A

6400

Yellow

Green

Brown

Blue

Red

Green/Yellow

Orange

6400-065-D-4-09

(Common) White

(Limit) Yellow

(Slow Down) Brown

(Common) White

(Motor) Brown

(Motor) Blue

(Slow Down) Purple

(Common) White

(Common) White

(Limit) Gray

39

Owner’s Manual

Standard or Deluxe Control Box for:

6002 * 6003 * 6400

Vehicular Swing Gate Operators

6400-065-D-4-09

DoorKing, Inc.

120 Glasgow Avenue

Inglewood, California 90301

U.S.A.

Phone: 310-645-0023

Fax: 310-641-1586 www.doorking.com

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