Smart Chock™ Models SC0650 thru SC0654

Smart Chock™
Models SC0650 thru SC0654
A Product of
340 Gateway Park Drive
North Syracuse, NY 13212
Phone: 315-463-7348
Toll Free: 866-235-7468
Fax: 315-463-8559
Email: sales@dlmanufacturing.com
www.dlmanufacturing.com
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 1
INTRODUCTION
This manual is used for all 650 Series Smart Chock™ model types. The control board is
programmed for each model’s function. The description explains the differenced between
model types.
Model #
Part #
650
SC0650
651
SC0651
652
SC0652
Description
Standard Smart Chock™
No options: No outlets or interlocks
Powers & controls one outlet for dock light
Dock light turns off when door is closed
Powers & controls two outlets
Dock light & fan turn off when door is closed
Powers & controls two outlets & interlocks
Electric/Hydraulic leveler
653
SC0653
Dock light and fan turn off when door is closed
Leveler will not run when door is closed
Powers & controls two outlets & interlocks
Pneumatic leveler
654
SC0654
Dock light and fan turn off when door is closed
Leveler will not run when door is closed
Fan turns off when leveler runs
ELECTRICAL RATINGS:
INPUT VOLTAGE
120 VAC
INPUT FREQUENCY
60 HZ
MAXIMUM INPUT CURRENT
12 A
INPUT CURRENT WITH NO OUTLET(S) OR LEVELER LOAD
<.5 A (MODEL 650)
MAXIMUM OUTLET(S) CURRENT
12 A
MAXIMUM LEVELER LOAD CURRENT (J7 OR J8)
12 A
OUTSIDE LIGHT BOX VOLTAGE
12 VDC
MAXIMUM OUTSIDE LIGHT BOX LOAD CURRENT
1.25 A (12 V POWER SUPPLY CURRENT LIMIT)
SENSOR VOLTAGE (J2, J3, J4 & J16)
12 VDC
MAXIMUM SENSOR CURRENT (J2, J3, J4 & J16)
.2 A (J2, J3 & J4 PROTECTED BY PTC THERMISTOR)
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 2
Smart Chock™
---Sequence of Operations--Testing
POWER ON – Smart Chock enters a startup routine that turns the LED’s and Relays on and off a few times. The
startup routine runs for approximately 20 Seconds.
Loading Dock Door is Closed, Wheel is Unchocked
Inside Red Light is on
Outside Green Light is flashing
Wheel gets Chocked and after a 0 to 5 Second Delay
Outside Red Chock Icon turns on
Inside light changes from red to green “CHOCKED”
Outside Green Light turns off
Door Open
Outside top Red Light starts flashing
Interlocks turn on – the outlets for a fan and dock light are enabled
(1)
See note for Optional Sensor information
Door closes and after a
(2)
5 to 15 Second Delay
Outside flashing Red Light turns off
Interlocks turn off – the outlets for a fan and dock light are disabled
Driver Removes Chock
Outside Red Chock Icon turns off
After a 5 to 15 second delay, Outside Green flashing light turns on
Inside light changes from green “CHOCKED” light to Red Light
Safety Situations
*** Chock Pulled Prematurely with Door Open (After a
(2)
3 to 15 Second Delay)***
Inside light changes from green “CHOCKED” light to Red Flashing Light
Versa Light® Dock Light flashes and Inside Audible Alarm Sounds for 5 minutes, fan outlet is disabled
Interlocks are disabled
Outside Red Chock Icon turns off, outside red stay on
Outside Alarm turns on for 10 minutes
***Door opens without a truck wheel chocked***
Versa Light® Dock Light flashes and Inside Audible Alarm Sounds for 5 minutes, fan outlet is disabled
Interlocks are disabled
Outside Red Chock Icon turns off, outside red stay on and Outside Alarm comes on for 10 Minutes
***Chock Cable gets Cut or Disconnected from Chock***
Inside lights alternately flash from green to red, on board yellow system LED comes on
Outside Red comes on and if wheel was chocked, Chock Icon turns off and Outside Alarm comes on for 10 Minutes
Interlocks are disabled
Inside Alarm turns on and does not turn off until power is turned off or cable is plugged back in
(1)
An Optional Second Sensor can be connected to the Control Board at J3 or OPT2 (See page 12 for connection
information). The Optional Second Sensor negates the actions caused by the Door Sensor when the Door is Open. The
Outside Red Light, Interlocks and Outlets are turned off.
(2)
At the core of the Smart Chock Control Board is an embedded microcontroller. Under preprogrammed control, the
Smart Chock Time delays, Light Outputs and Relay Outputs can be modified to suit any Customers individual needs. For
example, the Time Delays could be preprogrammed anywhere from 3 to 15 seconds.
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
WARNING!!!!
Page 3
Do not use in hazardous or corrosive environments!
REQUIRED TOOLS
 Drill bits, masonry bit for tap-con / wood bits 3/16” for pilot hole in dock seal
 Tape measure
 Hammer Drill
 Wire strippers
 Drill screw gun
 Hammer
 Precision flat blade screwdriver 1/8” wide
 Felt tip marker
 Wire labels
 9/16” Wrenches for Chock Handle Assy.
INDEX
YEARLY
MAINTENANCE
Description
Page
COVER
-
INTRODUCTION / ELECTRICAL RATINGS
1
SEQUENCE OF OPERATIONS
2
GENERAL INFO / INDEX / REQUIRED TOOLS
3
Inspect mounting bolts for
tightness
INSTALLER SUPPLIED HARDWARE & FASTENERS
4
Clean unit with compressed air
CHOCK HANDLE ASSEMBLY INSTRUCTIONS
5
Clean Photo Sensor Lenses
INSIDE LIGHT BOX MOUNTING
6
INSIDE LIGHT BOX MOUNTING CONTINUED
7
Inspect chock cable for
damage or wear
PHOTO EYE INSTALL – TYPICAL & MxV DOOR
8
PHOTO EYE INSTALL – ROLLING STEEL DOOR
9
EXTERNAL BOX INSTALLATION
10
CONTROL BOARD WIRING OVERVIEW / INDEX
11
WIRING DIAGRAM J1 & J2
12
WIRING DIAGRAM J6, J7 & J8
13
INSIDE TO OUTSIDE BOX WIRING DIAGRAM J15 & J16
14
BOLLARD MOUNTING BRACKET (OPTIONAL)
15
MODEL 650 SYSTEM WIRING DIAGRAM
16
651 SYSTEM WIRING DIAGRAM
17
652 SYSTEM WIRING DIAGRAM
18
653 SYSTEM WIRING DIAGRAM
19
654 SYSTEM WIRING DIAGRAM
20
OUTSIDE LIGHT BOX / CHOCK WIRING DIAGRAM
21
DL MANUFACTURING TERMS/CONDITIONS/WARRANTY
22
7/19/2011
Inspect inside connections for
any damage
Check chock handle for
damage
SC9143 Rev A
Smart Chock™ Installation Guide
Page 4
Installer-supplied hardware & fasteners
Mounting Surface
Inside Light Box
Outside Light Box
Cement Block
(4) ¼” x 1¼” Tapcon
(4) #10 x 1” Tapcon
Tip up concrete panel
(4) ¼” x 1¼” Tapcon
(4) #10 x 1” Tapcon
Sheet Metal
Sheet metal walls are not
thick enough to hold inside
box
Sheet metal walls are not
thick enough to hold outside
box
Steel
(4) ¼” x ¾” self-drilling
screws
4) ¼” x ¾” self-drilling screws
Bollard
Use DL Manufacturing
supplied fasteners
Pole Bracket /
(4) 3/8 Dia. Concrete Anchors
Chock Hanger
Also needed:
Wiring the inside and outside
box together
7 conductor 18 gauge wire
½” flexible conduit with
connector for 7/8 knockout
Field Notes:
FOR SERVICE ASSISTANCE CALL DL MANUFACTURING TOLL FREE 866-235-7468
Smart Chock Model #:
Smart Chock Serial #:
(LOCATED LOWER PORTION OF CONTROL BOARD)
Door Location:
Customer:
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 5
MOUNTING OF HANDLE ASSEMBLY TO CHOCK
1. Remove the Nuts and Bolts from the Handle Assembly.
2. Attach the Handle Assembly to the Chock as shown below using the Hardware from
Step 1.
Hardware & Handle orientation
- Parts removed for clarity
Chock after assembly
CHOCK HANDLE ATTACHMENT
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 6
SMART CHOCKTM INSTALLATION
WALL MOUNTED STYLE
INTERNAL
(YELLOW BOX)
NOTE:
TM
Install internal Smart Chock
measuring 66” from the dock
floor to the top of the yellow box.
Use (4) ¼” x 1¼” Tapcons
INSIDE LIGHT BOX MOUNTING
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 7
SEE PAGE 4 FOR
FASTENER USAGE
INSIDE LIGHT BOX MOUNTING CON’T.
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 8
PHOTO EYE MOUNTING KIT
(FOR TYPICAL LOCATIONS & MxV DOOR)
SEE PAGE 9 FOR MOUNTING BRACKET LOCATION ON A ROLLING STEEL DOOR
STEP 1
1
2
MEASURE 18” ABOVE THE
DOOR (START AT THE TOP OF
DOOR JAMB) TO INSTALL
PHOTO SENSOR
STEP 2
2
2
DRILL 2 HOLES IN ROLLER
TRACK. USE 17/64” DRILL BIT
1
1
REFER TO PAGE 12 FOR
WIRING INSTRUCTIONS
NOTE:
PHOTO SENSOR HAS A RANGE
OF 1/2” TO 3-1/2”.
2” TO 3” IS RECOMMENDED.
ITEM #
QTY.
PART#
DESCRIPTION
1
1
CP5016
MOUNTING BRACKET KIT
2
1
CP3268
PHOTO SENSOR NUT KIT
DETAIL A
SCALE 1 : 20
PHOTO EYE INSTALL – TYPICAL SECTIONAL DOORS
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 9
PHOTO EYE MOUNTING KIT
(FOR ROLLING STEEL DOOR)
SEE PAGE 8 FOR MOUNTING BRACKET LOCATION ON A SECTIONAL DOOR
STEP 1
TO LOCATE THE MOUNTING BRACKET
POSITION, OPEN THE DOOR ALL THE WAY.
STEP 2
POSITION THE TOP OF THE BRACKET SO
THAT IT LINES UP JUST BELOW THE BOTTOM
SECTION OF THE DOOR AND MARK HOLES.
STEP 3
DRILL 2 HOLES IN ROLLER TRACK. USE
17/64” DRILL BIT.
STEP 4
LOCATE THE PHOTO SENSOR OPERATING
ADJUSTMENT (SEE FIGURE BELOW). SET
THE PHOTO SENSOR FOR LIGHT OPERATE.
STEP 5
ATTACH THE PHOTO SENSOR TO THE
MOUNTING BRACKET USING THE NUTS AND
WASHERS SUPPLIED WITH SENSOR.
BOTTOM OF
DOOR WHEN
FULLY OPEN
STEP 6
ATTACH THE MOUNTING BRACKET TO THE
TRACK RAIL USING HARDWARE SUPPLIED
WITH MOUNTING KIT.
REFER TO PAGE 12 FOR WIRING
INSTRUCTIONS
PHOTO EYE INSTALL – ROLLING STEEL DOORS
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 10
INSTALLATION OF OUTSIDE COMPONENTS
7”
[177.8]
4.5”
[114.3]
See Page 7 for Mounting
Instructions.
BOX MUST BE SECURELY FASTENED TO
WALL SO CABLE, WHEN PULLED, SNAPS OUT
OF SOCKET BEFORE BOX PULLS OFF WALL.
Pole Attachment
RED LED LIGHT
21 9/16”
[548.13]
GREEN LED LIGHT
CHOCK ICON – TURNS
RED WHEN WHEEL IS
CHOCKED
1. Attach Pole Mounting Bracket to wall using 3/8”
anchors. Top of bracket should be 46” off the
ground.
2. Attach Pole sections together and tighten set screw
in the Coupling.
3. Slide bottom of Pole (with black tubing) into
Mounting Bracket until it bottoms out. Pole is held in
place by the black rubber tubing.
Pole
Coupling
90”
POLE MTG BRACKET
Open end is always up.
46”
INSTALLATION OF OUTSIDE COMPONENTS
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
 REMOVE POWER BEFORE
SERVICING. MUST BE
INSTALLED BY QUALIFIED
ELECTRICIAN 
Page 11
WIRING OVERVIEW / INDEX
J5
Not
Used
MODEL 654 LEVELER
BUTTON
SEE PAGE 13 FOR
CONNECTIONS
RED LED STRIP
DO NOT APPLY
VOLTAGE TO J6
TERMINALS, FOR
SWITCH ONLY
OPTIONAL TERMINAL
BLOCK JUMPERS FOR OPT2
& OPT 3
Refer to Instructions that come
with Replacement PC Boards
J3-3 OR J4-3, COMMON GND
J3-2 OR J4-2, INPUT SIGNAL
J3-1 OR J4-1, +12 VDC, .2A
MAX
OPTIONAL SENSOR
SEE INSTRUCTIONS
THAT OPTIONAL
SENSOR COMES WITH
J3-3, COMMON GND
J3-2, SENSOR SIGNAL
J3-1, +12 VDC, .2A MAX
J6-1, 8.2 VDC, 3 mA MAX
J6-2, COMMON GND
OUTSIDE LIGHT BOX
SEE PAGE 14 FOR
CONNECTIONS
DockLogic OPTION
RS485 CONNECTION
5 VDC, 60 mA MAX
9100 bps
GRN LED STRIP
J15-1, +12 VDC, 1.25 A MAX
J15-2, RED LIGHT
J15-3, NO CONNECTION
J15-4, GREEN LIGHT
J10-3, COMMON GND
J10-2, CHANNEL A
J10-1, CHANNEL B
PHOTO SENSOR
SEE PAGE 12 FOR
CONNECTIONS
SC8864 ALARM BOARD
CHOCK
SEE PAGE 14 FOR
CONNECTIONS
J16-1, 8.2 VDC, 3mA max
J16-2, COMMON GND
J16-3, CHOCK SIGNAL
J2-3, COMMON GND
J2-2, SENSOR SIGNAL
J2-1, +12 VDC, .2A MAX
1 AMP SLO-BLO 250V
FUSE UNDER FUSE
COVER
Switching Relays for J7, J8,
Versa Light Outlet and Fan
Outlet are Rated 120 VAC,
12 A .75 Power Factor
.
REPLACE WITH ONLY
SAME TYPE AND
RATING
FOR BEST RESULTS
WHEN REPLACING
FUSE, PLACE FUSE IN
COVER, THEN PLACE
COVER OVER CLIPS
AND THEN SNAP FUSE
INTO CLIPS
J17
NOT
USED
MODEL 653 & 654 LEVELER
INTERLOCK
12 AMP BREAKER
FOR SWITCHED
VERSA LIGHT AND
FAN OUTLETS ONLY
120 VAC INPUT
120 VAC, 12 A MAX
60 HZ
SEE PAGE 12 FOR
CONNECTIONS
J1-1, 120 VAC LINE
J1-2, 120 VAC NEUTRAL
J1-3, GROUND
7/19/2011
ASSEMBLY NUMBER
& REV. LABEL
120 VAC, 12A MAX 60 HZ
J7-1 & 2 CONNECTED TO K3
ISOLATED RELAY CONTACTS
REFER TO PAGE 13
MODEL 653 & 654 OPTIONAL
ALTERNATE CONTACTS
MODEL
653 & 654
GND
WIRING OVERVIEW / INDEX
120 VAC, 12 A MAX 60 HZ
J8-1 & 2 CONNECTED TO K4
ISOLATED RELAY CONTACTS
REFER TO PAGE 13
SC9143 Rev A
Smart Chock™ Installation Guide
Page 12
SMART CHOCKTM FIELD WIRING DIAGRAM
INCOMING POWER
INTERNAL (YELLOW BOX)
1
2
3
J1
BLACK (120 VAC, 12 A MAX, 60Hz)
GND WIRE FROM
CHASSIS GND IS
PRE-INSTALLED ON
MODELS 653 & 654
WHITE (120 VAC NEUTRAL)
GREEN (GND) - ALL MODELS EXCEPT 653 & 654
GREEN (GND)
- MODELS 653 & 654 ONLY
MUST BE
INSTALLED
BY QUALIFIED
ELECTRICIAN
ON MODELS 653 & 654
USE CHASSIS GND
CONNECTION
(NOT USED ON OTHER MODELS)
DOOR PHOTO SENSOR
PHOTO SENSOR IS 12 VDC. DO NOT RUN IN SAME CONDUIT WITH 120 AND HIGHER VOLTAGE.
TRANSIENTS CAN DAMAGE CONTROL BOARD
DOOR
J2
3
2
1
BLUE -COM
BLACK
BROWN +12 VDC, .2A MAX
SENSING REVERSAL
ROTATE ADJUSTMENT 3/4 TURN TO CHANGE
OPERATION FROM (N/O TO N/C OR N/C TO N/O)
NORMALLY SET FOR DARK OPERATE OR N/C
WHEN LOCATED ABOVE PANELED DOOR OPENING
LED
Dark Op
Light Op
WIRING DIAGRAM J1 & J2
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 13
SMART CHOCKTM FIELD WIRING DIAGRAM
MODEL 654 LEVELER CONTROL SIGNAL
FX LEVELER
BUTTON
J6-1, 8.2 VDC, 3mA MAX
DO NOT
APPLY ANY
EXTERNAL
VOLTAGE TO
J6 TERMINALS
J6-2, COMMON GND
NOTE:
WHEN LEVELER SWITCH IS ACTIVATED, THE CONTROL SIGNAL WILL LET THE MICRO
PROCESSOR KNOW TO SHUT THE FAN OFF. IT WILL THEN TURN ON THE LEVELER (J7)
AND OPT1 (J8) AFTER A 2 SECOND DELAY. FAN WILL TURN ON WHEN LEVELER STOPS.
MODEL 654 LEVELER INTERLOCK / OPT1
J8 (OPT1) CONTACTS CLOSE
WHEN J7 (LEVELER) CLOSE.
CONTACTS CONNECTED TO
J7 & J8 ARE RATED 120 VAC
12 A,
.75 POWER FACTOR.
CONTACTS CONNECTED
TO J7 & J8 ARE DRY
CONTACTS (ISOLATED
FROM INTERNAL
CONTROL BOARD
CIRCUITRY).
TO LEVELER MOTOR
120 VAC LINE, 12 A MAX, 50 / 60 HZ
MODEL 653 LEVELER INTERLOCK / OPT1
J8 (OPT1) CONTACTS CLOSE
WHEN J7 (LEVELER) CLOSE.
CONTACTS CONNECTED TO
J7 & J8 ARE RATED 120 VAC
12 A,
.75 POWER FACTOR.
CONTACTS CONNECTED
TO J7 & J8 ARE DRY
CONTACTS (ISOLATED
FROM INTERNAL
CONTROL BOARD
CIRCUITRY).
(1)
CONNECT LEVELER INTERLOCK FROM
LEVELER CONTROL BOX TO J7-1 AND J7-2.
120 VAC, 12A MAX, 60 HZ
(1)
SEE MANUFACTURERS’ DOCK LEVELER
INSTRUCTIONS FOR INTERLOCK CONNECTIONS
WIRING DIAGRAM J6, J7 & J8
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 14
SMART CHOCK™ FIELD WIRING DIAGRAM
OUTSIDE LIGHTS
(YELLOW BOX) CONTROL BOARD CONNECTIONS
J15
BROWN - +12VDC, 1.25A MAX.
1
2 OUTSIDE
3 LIGHTS
4
RED – TOP RED LEDS
ORANGE – CHOCK ICON
YELLOW – GREEN LEDS
WHITE – LOOP BACK
J16
1
2
3
BLUE – CIRCUIT COMMON
BLACK - SENSOR SIGNAL
CHOCK
OUTSIDE (BLACK BOX) CONNECTIONS TO
J2 OF PCB ASSEMBLY SC8863 (CHOCK ICON)
J2
TO
CONTROL
BOARD J15
TO
CONTROL
BOARD J16
{
{
J2
CHOCK ICON PC BOARD
TERMINAL BLOCK
(OUTSIDE LIGHT BOX)
BROWN
RED
YELLOW
ORANGE
WHITE
BLACK
BLUE
1
2
3
4
5
6
7
NOTE: WIRING SEQUENCE AT
CHOCK ICON BOARD IS
DIFFERENT FROM THE INSIDE
LIGHT BOX – SEE BELOW
+12VDC
RED
GRN
CHK’D
LPBK
SEN
COM
J15
OUTSIDE LIGHTS
TERMINAL BLOCK
(INSIDE LIGHT BOX)
J16
CHOCK
TERMINAL BLOCK
(INSIDE LIGHT BOX)
WIRING DIAGRAM – INSIDE TO OUTSIDE BOX
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 15
OPTIONAL BOLLARD BRACKET
7/19/2011
SC9143 Rev A
1
2
3
P1
J7
LEVELER
K3
2
1
J4
OPT3
J3
OPT2
1
2
3
R
E
2
1
J18
Inside Red LEDs
BLU
BRN
HDR2
J1
AC INPUT
POWER
SUPPLY
OPT1
K4
J8
GRND
3
2
1
BLK
Audible Alarm
Inside Green LEDs
PHOTOSEN
J12
(-)
(-)
J14
CONTROL BOARD
J17
FAN
K2
5
4
3
2
1
1
2
3
HDR1
J11
(+)
(+)
J13
1 A
F1
BRKR1
12A
NEUTRAL
LINE
P2
J15
J2
DOOR
J6
2
1
1
2
3
1
2
3
4
RS232
J9
1
2
3
2
3
J10
1
RS485
LEV CNTRL
CHOCK
J16
OUTSIDE LIGHTS
VERSALITE
K1
5
4
3
2
1
1
2
3
7/19/2011
1
2
3
4
5
6
7
MODEL 650 WIRING DIAGRAM
CNTRL BOARD CONN.
12DC
RED
GRN
CHKD
LPBK
SEN
COM
J11
CHOCK ICON
PCB ASSEMBLY
J19
BLACK
OUTSIDE
LIGHT
ASSEMBLY
1
2
3
GROUND
GREEN
GREEN
GREEN
GREEN
Green LEDs10 paralleled
Resistor/LED
Circuits
RED
BLK
WHT
BLU
J3-1
J3-2
J3-3
J3-4
RED
RED
RPTC1
RED
RED
GD
GD
TM
A
S
RT
LT
S
CHOCK
CABLE
TM
RT
LT
RED & GREEN
PCB ASSEMBLY
RED
RED
RED & GREEN LED BOARD ASSEMBLY
Chock Icon15 paralleled
Resistor/LED
Circuits
J20
1 +12 V
2
3
RED
RED
Red LEDs15 paralleled
Resistor/LED
Circuits
BLU
JMPR
WHT
BLK
BLU
PROG
BRN ULT SON SENSOR
+12 V
CIRCUIT COMMON
SIGNAL
WHEEL CHOCK
ASSEMBLY
Smart Chock™ Installation Guide
Page 16
SC9143 Rev A
1
2
3
P1
J7
LEVELER
K3
2
1
J4
OPT3
J3
OPT2
1
2
3
R
E
2
1
J18
Inside Red LEDs
BLU
BRN
HDR2
J1
AC INPUT
POWER
SUPPLY
OPT1
K4
J8
GRND
3
2
1
BLK
Audible Alarm
Inside Green LEDs
PHOTOSEN
J12
(-)
(-)
J14
CONTROL BOARD
J17
FAN
K2
5
4
3
2
1
1
2
3
HDR1
J11
(+)
(+)
J13
1 A
F1
BRKR1
12A
NEUTRAL
J15
J2
DOOR
J6
2
1
1
2
3
1
2
3
4
RS232
J9
1
2
3
2
3
J10
1
RS485
LEV CNTRL
CHOCK
J16
OUTSIDE LIGHTS
VERSALITE
K1
P2
LIGHT
LINE
5
4
3
2
1
1
2
3
7/19/2011
1
2
3
4
5
6
7
MODEL 651 WIRING DIAGRAM
CNTRL BOARD CONN.
12DC
RED
GRN
CHKD
LPBK
SEN
COM
J11
CHOCK ICON
PCB ASSEMBLY
J19
BLACK
OUTSIDE
LIGHT
ASSEMBLY
1
2
3
GROUND
GREEN
GREEN
GREEN
GREEN
Green LEDs10 paralleled
Resistor/LED
Circuits
RED
BLK
WHT
BLU
J3-1
J3-2
J3-3
J3-4
RED
RED
RPTC1
RED
RED
GD
GD
TM
A
S
RT
LT
S
CHOCK
CABLE
TM
RT
LT
RED & GREEN
PCB ASSEMBLY
RED
RED
RED & GREEN LED BOARD ASSEMBLY
Chock Icon15 paralleled
Resistor/LED
Circuits
J20
1 +12 V
2
3
RED
RED
Red LEDs15 paralleled
Resistor/LED
Circuits
BLU
JMPR
WHT
BLK
BLU
PROG
BRN ULT SON SENSOR
+12 V
CIRCUIT COMMON
SIGNAL
WHEEL CHOCK
ASSEMBLY
Smart Chock™ Installation Guide
Page 17
SC9143 Rev A
1
2
3
FAN
P1
J7
LEVELER
K3
2
1
J4
OPT3
J3
OPT2
1
2
3
R
E
2
1
J18
Inside Red LEDs
BLU
BRN
HDR2
J1
AC INPUT
POWER
SUPPLY
OPT1
K4
J8
GRND
3
2
1
BLK
Audible Alarm
Inside Green LEDs
PHOTOSEN
J12
(-)
(-)
J14
CONTROL BOARD
J17
FAN
K2
5
4
3
2
1
1
2
3
HDR1
J11
(+)
(+)
J13
1 A
F1
BRKR1
12A
NEUTRAL
J15
J2
DOOR
J6
2
1
1
2
3
1
2
3
4
RS232
J9
1
2
3
2
3
J10
1
RS485
LEV CNTRL
CHOCK
J16
OUTSIDE LIGHTS
VERSALITE
K1
P2
LIGHT
LINE
5
4
3
2
1
1
2
3
7/19/2011
1
2
3
4
5
6
7
MODEL 652 WIRING DIAGRAM
CNTRL BOARD CONN.
12DC
RED
GRN
CHKD
LPBK
SEN
COM
J11
CHOCK ICON
PCB ASSEMBLY
J19
BLACK
OUTSIDE
LIGHT
ASSEMBLY
1
2
3
GROUND
GREEN
GREEN
GREEN
GREEN
Green LEDs10 paralleled
Resistor/LED
Circuits
RED
BLK
WHT
BLU
J3-1
J3-2
J3-3
J3-4
RED
RED
RPTC1
RED
RED
GD
GD
TM
A
S
RT
LT
S
CHOCK
CABLE
TM
RT
LT
RED & GREEN
PCB ASSEMBLY
RED
RED
RED & GREEN LED BOARD ASSEMBLY
Chock Icon15 paralleled
Resistor/LED
Circuits
J20
1 +12 V
2
3
RED
RED
Red LEDs15 paralleled
Resistor/LED
Circuits
BLU
JMPR
WHT
BLK
BLU
PROG
BRN ULT SON SENSOR
+12 V
CIRCUIT COMMON
SIGNAL
WHEEL CHOCK
ASSEMBLY
Smart Chock™ Installation Guide
Page 18
SC9143 Rev A
1
2
3
FAN
LEV MOTOR
T3
P1
TYPICAL
HYDRAULIC
LEVELER
WIRING
DIAGRAM
J4
OPT3
J3
OPT2
J7
LEVELER
K3
R
E
PHOTOSEN
J12
(-)
(-)
J14
CONTROL BOARD
J17
FAN
K2
J8
J18
POWER
SUPPLY
OPT1
K4
GROUND
BLU
BRN
BLK
Audible Alarm
Inside Green LEDs
HDR2
J1
AC INPUT
HDR1
J11
(+)
(+)
J13
1 A
F1
BRKR1
12A
NEUTRAL
MOT CONTACTOR COIL
LEVELER BUTTON
O/L
Inside Red LEDs
CIR BRKR
2
1
480/120
2
1
T2
3 PH MOT CONTACTOR
1
2
3
G R ND
3
2
1
T1
5
4
3
2
1
1
2
3
LINE
J2
DOOR
2
1
1
2
3
1
2
3
4
RS232
J9
1
2
3
2
3
J10
1
RS485
LEV CNTRL
J6
J16
J15
CHOCK
OUTSIDE LIGHTS
VERSALITE
K1
P2
LIGHT
5
4
3
2
1
1
2
3
7/19/2011
1
2
3
4
5
6
7
CNTRL BOARD CONN.
12DC
RED
GRN
CHKD
LPBK
SEN
COM
J11
CHOCK ICON
PCB ASSEMBLY
J19
BLACK
OUTSIDE
LIGHT
ASSEMBLY
1
2
3
480 3 PH
GREEN
GREEN
GREEN
GREEN
Green LEDs10 paralleled
Resistor/LED
Circuits
RED
RED & GREEN
PCB ASSEMBLY
RED
RED & GREEN LED BOARD ASSEMBLY
RED
BLK
WHT
BLU
J3-1
J3-2
J3-3
J3-4
RED
RED
RPTC1
RED
RED
Chock Icon15 paralleled
Resistor/LED
Circuits
J20
1 +12 V
2
3
RED
RED
Red LEDs15 paralleled
Resistor/LED
Circuits
GD
MODEL 653 WIRING DIAGRAM
GD
TM
A
S
RT
LT
S
CHOCK
CABLE
TM
RT
LT
BLU
JMPR
WHT
BLK
BLU
PROG
BRN
CIRCUIT COMMON
SIGNAL
+12 V
ULT SON SENSOR
WHEEL CHOCK
ASSEMBLY
Smart Chock™ Installation Guide
Page 19
SC9143 Rev A
1
2
3
FAN
FAN
K2
P1
J7
LEVELER
K3
2
1
J4
OPT3
J3
OPT2
R
E
J8
J18
GROUND
Inside Red LEDs
BLU
BRN
HDR2
J1
AC INPUT
POWER
SUPPLY
OPT1
K4
2
1
BLK
Audible Alarm
Inside Green LEDs
PHOTOSEN
J12
(-)
(-)
J14
CONTROL BOARD
J17
M
1
2
3
GRND
3
2
1
LEVELER MOTOR
5
4
3
2
1
1
2
3
HDR1
J11
(+)
(+)
J13
1 A
F1
BRKR1
12A
NEUTRAL
J15
J2
DOOR
J6
2
1
1
2
3
1
2
3
4
RS232
J9
1
2
3
2
3
J10
1
RS485
LEV CNTRL
CHOCK
J16
OUTSIDE LIGHTS
VERSALITE
K1
P2
LIGHT
LINE
5
4
3
2
1
1
2
3
7/19/2011
1
2
3
4
5
6
7
MODEL 654 WIRING DIAGRAM
CNTRL BOARD CONN.
12DC
RED
GRN
CHKD
LPBK
SEN
COM
J11
CHOCK ICON
PCB ASSEMBLY
J19
BLACK
OUTSIDE
LIGHT
ASSEMBLY
1
2
3
TYPICAL
PNEUMATIC
LEVELER
WIRING
DIAGRAM
GREEN
GREEN
GREEN
GREEN
RED
BLK
WHT
BLU
J3-1
J3-2
J3-3
J3-4
RED
RED
RPTC1
RED
RED
RED
RED
GD
GD
TM
A
S
RT
LT
S
CHOCK
CABLE
TM
RT
LT
RED & GREEN
PCB ASSEMBLY
Green LEDs10 paralleled
Resistor/LED
Circuits
RED
RED & GREEN LED BOARD ASSEMBLY
Chock Icon15 paralleled
Resistor/LED
Circuits
J20
1 +12 V
2
3
RED
Red LEDs15 paralleled
Resistor/LED
Circuits
BLU
JMPR
WHT
BLK
BLU
PROG
BRN ULT SON SENSOR
+12 V
CIRCUIT COMMON
SIGNAL
WHEEL CHOCK
ASSEMBLY
Smart Chock™ Installation Guide
Page 20
SC9143 Rev A
Smart Chock™ Installation Guide
Page 21
OUTSIDE LIGHT BOX / CHOCK WIRING DIAGRAM
BLACK
OUTSIDE
LIGHT
ASSEMBLY
CHOCK CABLE PLUG
AND SOCKET TERMINAL
IDENTIFICATION
Red LEDs15 paralleled
Resistor/LED
Circuits
RED
RED
S
RED
1+12 V
2
3
GD
GD
LT
LT
LOOKING
INTO
SOCKET
Green LEDs10 paralleled
Resistor/LED
Circuits
J1
A
RT
RED & GREEN
PCB ASSEMBLY
SS8023
J1
TM
TM
RED
GREEN
GREEN
GREEN
GREEN
S
A
RT
LOOKING
AT END
OF PLUG
123
Chock Icon15 paralleled
Resistor/LED
Circuits
CHOCK ICON
PCB ASSEMBLY
SC8863
RED
RED
RED
RED
RPTC1
WHEEL CHOCK
ASSEMBLY
J3-1
RED
LT
J3-2
BLK
RT
J3-3
WHT
J3-4
BLU
CHOCK
CABLE
+12 V
LT
BRN ULT SON SENSOR
RT
S
A
TM
S
GD
TM
SIGNAL
BLK
PROG
BLU
JMPR
WHT
BLU
J2
GD
1234567
CIRCUIT COMMON
J15-2
RED
J15-1
+12 V
J15-3
CHOCK
LEDS
J15-4
GRN
J16-3
CHK SIG
J16-1
LP BK
J16-2
CNTRL
COM
WIRES TO INSIDE CONTROL BOARD
OUTSIDE LIGHT BOX / CHOCK WIRING DIAGRAM
7/19/2011
SC9143 Rev A
Smart Chock™ Installation Guide
Page 22
DL Manufacturing
Terms / Conditions/ Warranty
Shipping Times
~ Orders for stock items received by 3:00pm EST will be processed for shipment the next day. Orders requesting
nd
2 Day Air or Overnight Air received by 1:00pm will be processed for same day shipment.
Shipments / Freight
~ All DL Manufacturing orders will ship directly from our facility in North Syracuse, NY.
~ All parts will be shipped via UPS Ground unless you authorize a different service. UPS shipments are prepaid
and the charges are added to your invoices.
~ For orders shipping by common carrier, the freight will be FOB, North Syracuse, NY. When “best way” is the
preferred shipping method on your order, DL Manufacturing will choose the carrier, unless otherwise stated, for the
orders shipping from this facility. No adjustments will be made after the order has shipped.
Returns
~ DL Manufacturing will issue a Returned Material Authorization (RMA) number for any product, parts and
accessories. Products should not be returned without an RMA number.
~ Replacement parts will be invoiced at the time of shipping. Invoices will be credited upon receipt and inspection
of Returned Material Authorization (RMA).
~ Freight for returns is paid for by the shipper unless otherwise specified by DL Manufacturing.
~ A restocking fee of 25% of net price or a minimum $20.00 is charged for returns.
~ All replacement parts are warranted for a period of 90 days from shipment.
Cancellation Fees
~ Cancellation charges may be incurred on orders cancelled with DL Manufacturing. Please contact DL
Manufacturing to discuss each situation.
Warranty Policy
~ All Products (excluding bulbs) manufactured by DL Manufacturing are warranted to be free from defects for a
period of 12 months from the date of shipment, excluding doors, which have a warranty period of 12 months from
date of installation or 18 months from shipment, whenever occurs first.
This warranty does not cover unreasonable/improper use or use beyond rated conditions, improper storage,
negligence or accident; damage because of incorporated use of equipment with Goods, after Customer has or
reasonably should have, knowledge of any defect; or improperly installed by any other Person that is unauthorized
by DL Manufacturing.
This warranty is subject to customer covenants to inform all subsequent buyers of the Goods of the limitation on
and exclusive of warranties provided for herein. Customer hereby indemnifies and agrees to hold DL
Manufacturing harmless from and against all losses, costs and expenses, including reasonable attorney’s fees
incurred by DL Manufacturing as a result of any third party claim relating to the purchase, sale or use of, or
otherwise relating to, the Goods covered by this Agreement.
In no event shall DL Manufacturing be required to repair, replace or reimburse Customer for more than the part or
material that is found to be defective and DL Manufacturing’s liability shall in such event be no greater than the
invoiced price of the item and shall not include labor, shipping or other costs incurred in connection with the
reshipment of defective Goods to DL Manufacturing or the reinstallation of such Goods after any repair or
replacement. The remedy set forth in this paragraph is expressly agreed to be the sole and exclusive remedy for
any breach of warranty. This warranty is exclusive and in lieu of all other warranties expressed or implied, including
but not limited to any warranty of merchantability or of fitness for a particular purpose.
Limitation of Liability - In no event as a result of breach of contract, warranty or negligence shall DL Manufacturing
be liable for special, or consequential damages including but not limited to loss of profits or revenues, loss of any
equipment, cost of capital, cost of substitute equipment, facilities or services, downtime costs or claims of
purchasers of the Customer for such damages. Additionally, DL Manufacturing will not be liable for any delay in
the performance of contracts and orders, or in the shipment and delivery of goods, or for any damage suffered by
the Customer by reason of delay, when such delay is, directly or indirectly, caused by force majeure, including war,
Government interference, strikes, embargoes, shortage of labor, fuel, fires, floods, or any other cause or cause
whether or not similar in nature to any of those herein before specified beyond DL Manufacturing’s control.
7/19/2011
SC9143 Rev A
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