DKS 1603 Manual

Installation/Owner’s Manual

1603

Barrier Gate Operator with Auto Spike System

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

1603-065-K-12-20

THIS PRODUCT IS TO BE INSTALLED AND SERVICED BY A TRAINED GATE SYSTEMS TECHNICIAN ONLY.

Visit www.dkslocator.com

to find a professional installing and servicing dealer in your area.

CAUTION: Installation and use of traffic control spike unit in areas that are subject to freezing weather with the potential of snow and ice accumulation is not recommended.

The unit may freeze in the up position and cause unintended injury or damage due the inability of the spikes to retract.

CONFORM

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In gle wo od, CA

Moving Gate Can Cause

Serious Injury or Death

KEE without prior warning.

Do not let

Pedestrians ve at any time e or play trance.

Y

DoorKing 8080-057 Retr o-r eflectiv e phot ocell sold separ ate ly

A WALKWA

OT

Date Installed:

Installer/Company Name:

Phone Number:

Leave Manual with Owner

Circuit Board

Serial Number and Revision Letter:

Y

Copyright 2020 DoorKing ® , Inc. All rights reserved.

Conforms To UL STD 325

Certified To CSA STD C22.2 # 247

Copyright 2009 DoorKing, Inc. All rights reserved.

UL 325 Entrapment Protection

UL 325 Classifications

Authorized

Personnel ONLY or parking areas associated with a residence of one-to four single families.

Class III - Industrial/Limited Access

Vehicular Gate Operator

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 accessible by or intended to service the general public.

STATE PRISON

Class II - Commercial/General Access


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 buildings accessible by or servicing the general public.

Class IV -

Restricted Access


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.

Gate Operator Category

Effective January 12, 2016

Horizontal Slide, Vertical Lift, Vertical Pivot Swing, Vertical Barrier (Arm)

Entrapment Protection Types A, B1*, B2* or D A, B1*, B2*, C or D

Type A - Inherent entrapment protection system.

Type B1 - Non-contact sensor (photoelectric sensor or the equivalent).

Type B2 - Contact sensor (edge device or equivalent).

Type C - Inherent force limiting, inherent adjustable clutch or inherent pressure relief device.

Vertical Barrier Note: Barrier gate operators (arm) that is not intended to move toward a rigid object closer than 16 inches (406 mm) are not required to be provided with a means of entrapment protection.

Type D - Actuating device requiring constant pressure to maintain opening or closing motion of the gate.

* B1 and B2 means of entrapment protection must be MONITORED.

2 Safety - 1 1603-065-K-12-20

Safety Information for Vertical Barrier Arm and Spikes

A Y WA KW LK LK AL

A

WA WA A A W A T OT NO

Separate Pedestrian

Walkway

Located so pedestrians cannot come in contact with the barrier arm.

G

C

N O T A W A L K W A Y

Pedestrian Alert

Warning

“NOT A WALKWAY” pavement marking facing both directions, permanently painted WHITE on pavement.

Hazard Stripes

NO stopping or standing “Hazard

Stripes”. Permanently painted

WHITE on pavement under the arm.

E

F

A

In-Ground Loop(s)

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

B

Warning Signs

Permanently mounted on operator and arm and easily visible.

Speed Bump

Helps increase distance and time between vehicles.

G

B

WARNING

MOVING ARM can serious injury or death.

STAY CLEAR of arm at all times.

NO: Pedestrians

Bicycles

Motorcycles



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.

Contact Sensor Note: A reverse edge is NOT to be used as a replacement, or in lieu of, in-ground loops or non-contact sensor (photocell) that protect vehicles passing underneath the barrier arm. A moving vehicle coming in contact with a downward moving barrier arm WILL result in damage to the vehicle and the barrier arm/reversing edge if NOT using in-ground loops or non-contact sensor (Photocell).

E

H B

WARNING

MOVING ARM can serious injury or death.

cause vehicle damage, of arm STAY CLEAR at all times.

NO: Pedestrians

Bicycles

Motorcycles

D

C

F

SPEED

LIMIT

5

5 MPH

DO NOT

BACK UP

Severe Tire Damage!

No Pedestrians in Traffic Lane

Photo Beam no higher than 27.5” above grade.

21” is typical for most installations.

A

1603-065-K-12-20







C

Non-Contact Sensor

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

D

Contact Sensor

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

E

Spike Warning and Illumination

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

F

Speed Limit Sign

Helps control traffic.

G

Traffic Red/Green Light

Helps control traffic.

H

Arm LED Lights

Helps with arm’s visibility and position.

Safety - 2 3

Safety Information for Vertical Barrier Arm and Spikes

Reduce the risk of injury or death, read and follow all instructions.

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

AR

NIN

AR

MOV ser

NIN

NO cau

STA

NO

ING A se v

inj ll ti

Bic

Mo ll ti

Bic

Mo

RM

or ycle torc me de ycle can dea ian le d jur stri an ycle r d age of a rm with out in t he prio gate are r w ing

Y

947GHT4

NOT A WALKWA

NOT A WALKWA







Y

Important: Barrier gate operator CANNOT sense a person under the raised arm.

This scenario is VERY DANGEROUS and MUST NEVER OCCUR!!

• Make sure all warning signs are on operator and arm and are easily visible.

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

• Spike Warning.

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

vehicles and the spike area is well illuminated.

• Speed limit through barrier area is 5 MPH.

Install speed bumps, warning signs and hazard stripes where visible in the area

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

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

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

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

•

Automotive traffic only - No bicycles or motorcycles.

Pedestrians MUST be provided with separate access.

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

• Security features should be installed to avoid unauthorized use.

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

further away from the operator than 50 ft. If the installed hardware is in violation of these restrictions remove the operator

from service immediately and contact your service dealer.

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

controls. Any activity in the entrance and exit lanes should be monitored to ensure a safe operation when opening or closing

the barrier gate. The motion of the barrier boom must be directly observable by the person operating the barrier. While the

barrier boom is in motion NO pedestrian and NO vehicle shall be in the immediate vicinity of the barrier.

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

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

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

any maintenance or repairs.

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

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

4 Safety - 3 1603-065-K-12-20

QUICK GUIDE: Terminal Descriptions

NC NO

Input LEDs:

The LED that is above the terminal wiring input will light when that terminal input gets activated.

#6 #7 #8 #9

Input LEDs

#10 #11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Relay Contacts

Terminal #5 Note:

Exceeding 250 mA of power from this terminal may cause the circuit board transformer to overheat, causing intermittent problems.

DANGER

HIGH VOLTAGE!

6

Function is dependent on the setting of programming SW 1, switch 6.

When switch 6 is OFF , this input will cause the operator to rotate the arm to the up position. If the arm is in the down cycle, this input will reverse the arm to the up position. If this terminal has a constant input, the arm will remain in the up position regardless of any down input or timer command to rotate down.

When switch 6 is ON , this input will cause the operator to rotate the arm to the up position when it is down, and will cause the operator to rotate the arm to the down position when it is up. If the auto timer is turned

ON (Not recommended if switch 6 is ON), this input will override the timer and rotate the arm to the down position. If the arm is in the down cycle, this input will reverse the arm to the up position.

SW 1


When switch 8 is ON , the function of this input is identical to terminal 6.

When switch 8 is OFF , this terminal becomes the logic output of the up loop detector.

SW 1

7

Function is dependent on the setting of programming SW 1, switches 1 and 4.

With switch 1 OFF and switch 4 ON , activation and then deactivation of this input will rotate the arm to the down position, provided that the deactivation of the input happens while the arm is in the full up position. This input will override the auto timer if it is turned ON . If the arm is in the down position, traveling in the down cycle, or traveling in the up cycle, activation and deactivation of this input has no effect on the arm.

With switches 1 and 4 are ON , activation and then deactivation of this input will rotate the arm to the down position after it reaches the full up position regardless of when the deactivation of the input occurred.

When switch 4 is OFF , this input is identical to the reverse input, terminal 9.

SW 1

See page 7 for terminal wiring.

8

12

13


When switch 5 is OFF , activation of the down loop will activate the relay.

When switch 5 is ON , activation of the UP loop will activate the relay.

SW 1

Relay contacts can be set for Normally Open (NO) or Normally

NO

Closed (NC)

NC operation.

Contact rating is 1 amp maximum at 24 Volts.

11

This input is used when sequencing the

1603 with a slide or swing gate operator in

PAMS applications. This input is only active after a MOMENTARY UP input is received.

Activation of this input will rotate the arm to the up position or reverse an arm in the down cycle to the up position.

9

10



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

When the arm is in the down position, activation of this input has no effect.

When the arm is in the up position, activation of this input will prevent the arm from rotating to the down position. If the arm is in the down cycle, activation of this input will reverse the arm to the up position.

5

1603 SPECIFICATIONS

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

Type of wiring to be used on ALL external devices:

A) Type CL2 , CL2P , CL2R , or CL2X .

B) Other cable with equivalent or better electrical, mechanical, and flammability ratings.

15.74”

1603 Housing

15.26”

Class of Operation

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

Type of Gate

Single Traffic Lane Vehicular Barrier Gate Only

Arm Types

Aluminum – Straight or Folding Arm

Max Arm Length

CONFORMS TO

ANSI/UL-325

53382

CERTIFIED TO

CAN/CSA C22.2 NO. 247

VEHICULAR GATE OPERATOR

CLASS HP

MODEL

SERIAL

VOLTS

AMPS

MAX GATE LOAD

PHASE

60 Hz

DoorKing, Inc., Inglewood, CA

6

Max Spike Length

9 Ft. (Three 3-ft spike sections)

Gate Cycles

Speed

90° in approximately 1.5 seconds

Pedestrian Protection

Inherent entrapment sensing system (Type A)

Provision for connection of a non-contact sensor

(Type B1) and/or contact sensor (Type B2)

38.5”







13”

43.6”

Model #

1603

1603

Convenience

Open

Horsepower - Volts

No

Yes

1/2 HP - 115 VAC

1/2 HP - 115 VAC

Amp

5.7

5.7

Note: 208/230/460/575 VAC input voltage can be connected to the operator by installing an “Optional”

High Voltage Kit (P/N 2600-266).

Drawings not to scale

1603 Aluminum Arm

Folding arm assembly can be installed for low headroom application.

Round Aluminum Arm (No LEDs)

Choose

14 Ft 1-Piece Aluminum Arm Only P/N 1601-516

14 Ft 2-Piece Aluminum Arm Only P/N 1601-524

Arm Hardware Kit (Required) P/N 1601-242

Round Aluminum FOLDING Arm (No LEDs)

Aluminum FOLDING Arm Kit (With Arm) P/N 1601-610

1603 Auto Spike System

Up to 3 spike sections can connect together.

Operator Extension Section

P/N 1603-168

Required

Spike Section

P/N 1603-165

Round Aluminum LED Arm

14 Ft Aluminum LED Arm Only P/N 1601-518


Aluminum LED Arm Wire Harness Kit (Required) P/N 1601-535

Round Aluminum FOLDING LED Arm

Aluminum LED FOLDING Arm Kit (With Arm) P/N 1601-600

Contact Sensor Note: A reverse edge is NOT to be used as a replacement, or in lieu of, in-ground loops or non-contact sensor (photocell) that protect vehicles passing underneath the barrier arm. A moving vehicle coming in contact with a downward moving barrier arm WILL result in damage to the vehicle and the barrier arm/reversing edge if NOT using in-ground loops or non-contact sensor (Photocell).

Octagon Reversing Edge Arm (No LEDs)

Extension Section

Choose

14 Ft 1-Piece Octagon Arm Only P/N 1601-555


Octagon Arm Hardware Kit (Required) P/N 1601-235

Reversing Edge (Required) P/N 8080-080

P/N 1603-170

Optional

End Cap

P/N 1610-240

Octagon Arm (No reversing edge or LEDs)

Choose




Rubber Bumper P/N 8080-089

Octagon Reversing Edge/Red-Green LED Arm

Choose




Reverse Edge + Red/Green LED (Required) P/N 8080-096

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

1603-065-K-12-20

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION

QUICK GUIDE - TERMINAL DESCRIPTIONS

SPECIFICATIONS FOR 1603

SECTION 1 - INSTALLATION OF OPERATOR

1.1

1.2

Operator Positioning and Conduit Requirements

Concrete Pad Requirements

1.4 Dual Operator Installation (Primary/Secondary)

SECTION 2 - WIRING

2.1

2.2

2.3

High Voltage Wire Runs

High Voltage Terminal Connections

Main Terminal Description

SECTION 3 - INSTALLATION OF AUTO SPIKE SYSTEM

3.1

3.2

3.3

3.4

Connect Sections Together on Concrete Pad

Test Spikes when Operator Positioned on LEFT side

Test Spikes when Operator Positioned on RIGHT side

Secure EACH Section to Concrete

SECTION 4 - LOOP DETECTOR LANE SETUPS

4.1

4.2

4.3

4.4

4.5

Entry Lane Only

Exit Lane Only

2-Way Traffic Lane

Ticket Spitter Entry Lane

Operator Timer ON Entry Lane (No Down Loop)

SECTION 5 - ARM INSTALLATION

5.2 Mounting Aluminum Arm

SECTION 6 - ADJUSTMENTS

6.1

6.2

6.3

6.4

6.5

1601 Circuit Board Description and Adjustments

DIP-Switch SW 1 and SW 2 Settings

Magnetic Limit Adjustment

Reverse Sensor Adjustment

Manual Operation of Arm and Spikes

SECTION 7 - OPTIONAL CONVENIENCE OPEN SYSTEM

7.1

7.2

Circuit Board Settings and Descriptions

DC System Wire Schematic

SECTION 8 - OPTIONAL ACCESSORIES INSTALLATION

8.1

8.2

Contact Sensor Installation (Reversing Edge)

Additional “Optional” Accessories

SECTION 9 - TECHNICAL INSTRUCTIONS

9.3 Troubleshooting

9.4 Accessories Parts List

Operator Wiring Schematics

Wiring Traffic Light AND Ocatgon Reverse Edge/LED Arm

Wiring Traffic Light AND Round Aluminum LED Arm

1603-065-K-12-20

Safety-1-3

Quick Guide-1

Previous Page

2

3

4

2

3

5

6

7

5

5

8

10

11

8

9

18

18

19-21

22

22

23

17

17

17

12

12

13

14

15

16

24

24

25

26

26

27-28

29

29

30

30-31

32

33-34

35

36

1

SECTION 1 - INSTALLATION OF OPERATOR

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

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

1.1 Operator Positioning and Conduit Requirements

Operator Mounted on

LEFT

Side of Traffic Lane

Preferred (Factory Set)

Conduit Runs

Operator Mounted on

RIGHT

Side of Traffic Lane

Traffic Direction

DO NOT install operator or spikes on asphalt.

Conduit Runs

Traffic Direction

2

The spike’s drive chain MUST be reversed so spikes rotate in correct direction when operator is on HT side, , see section 3.3.

WARNING

MOVING ARM can cause vehicle damage, serious injury or death.


NO: Pedestrians

Bicycles

Motorcycles

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

WARNING


of arm STAY CLEAR at all times.

NO: Pedestrians

Bicycles

Motorcycles

STOP

DO NOT

BACK UP

Severe Tire Damage!

CONFORMS TO

ANSI/UL-325

CAN/CSA C22.2 NO. 247 CERTIFIED TO

53382


CLASS HP

MODEL

SERIAL

VOLTS

AMPS

PHASE

60 Hz

MAX GATE LOAD



Conduit Area Photocell mounts directly under arm for safety, see safety pages in front of manual.

See page 7 to wire photocell. Sold separately P/N 8080-057.

Photocell Note: DO NOT mount photocell to the operator cabinet. Cabinet can flex or vibrate during operation which may cause misalignment of the beam.

Conduit Area







Sign Sold

Separately

P/N 1615-081

Inside

Operator

Primary/Secondary Interconnection Cable (Dual Operator Application Only)

Control and/or P.A.M.S. Wires (Low Voltage wire insulation)

Loop Lead-In Wires (Low Voltage wire insulation)

AC Input Power (High Voltage wire insulation)

Illuminated Sign AC Input Power

(High Voltage wire insulation)

•

•

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

application may vary from this depending on your specific needs.

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

difficult and can cause damage to wire insulation.

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

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

Sweep

YES

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

Elbow

NO

1603-065-K-12-20

1.2 Concrete Pad Requirements

The operator and auto spike system must ONLY be installed on a concrete pad with a minimum 6 inch depth. The concrete pad must be

FLAT and LEVEL (Check local building codes for restrictions).

Reinforced concrete recommended.

Note: Operator shown mounted on the LEFT side of traffic lane

(preferred).

CA

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ICU

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SS

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2.2

LA

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TIF

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ATE

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HP SER IAL

VO

LTS

AM

PS

MA X G

ATE

Doo rKin

LO g,

AD

Inc ., In

PH

60 H

AS gle wo od, CA

Moving

Serious Injury or

Gate Can Ca

KEE

P

Do not le in the g

This ent ate area.

Pede rance

Gate may n ope strians must use is for

Deat move rat e th h separate ent

or play rance

Note: Operator extension section REQUIRED to connect to operator.

VEH

R G

ATE ATO

60 H nglew

Mo

Ser

EP

no

This

Ped ving

CL out t le

en estr s In

EA r w te a ce is for s m

Ga

R! G arn en ust te C ate op

ve use

m ay te th hicle par an C

m s o ate eath

at ate nly.

aus

or p e any

tim lay

en tran ce.

It is recommended that the

“Spike” sections not exceed

9 feet (Three 3-Ft spike sections) for proper operation.

1

DO NOT install operator or spikes on asphalt.

2

Concrete length:

3 spike sections 160.5”

3

6”

15.5”

IMPORTANT: A barrier gate operator installed

WITHOUT any external safety sensors CANNOT sense a person under the raised arm and can strike them while the arm is lowering.

DoorKing recommends installing an external photo sensor directly under the arm. See safety pages in front of this manual for more information.

P/N 8080-057

18”

36”

Concrete length: 2 spike sections 124.5”

Embedded Wire M

36”

1.3 Mount Operator

Remove breather pin from gear reducer AFTER the operator has been secured in place.

CONFORMS TO

ANSI/UL-325

CERTIFIED TO

CAN/CSA C22.2 NO. 247

53382


CLASS HP

MODEL

SERIAL

VOLTS PHASE

AMPS

MAX GATE LOAD

60 Hz


WARNING

MOVING ARM cause vehicle damage, serious injury or death.

STAY CLEAR at all times.

NO: Pedestrians

Bicycles

Motorcycles

Inside Operator

esh







7”

6”

Secure the operator to the concrete pad with the mounting flange using

1/2” x 3” minimum sleeve anchors

(not supplied).

Traffic Direction

6”

20”

6”

32” Minimum and spik

of co ncrete pad.

32”

Min

6” Minimum

1/2

Sleeve Anchor

Approximate position of conduit runs.

Sections MUST lay flat and level to operate properly!

Conduit

Sleeve Anchors

Embedded Wire Mesh

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

DO NOT secure sections at this time.

1603-065-K-12-20 3

1.4 Dual Operator Installation (Primary/Secondary)

For use in areas needing more than three 3-Ft spike sections (9 ft. of spikes) in a traffic lane.

Up to six 3-Ft spike sections (18 ft. of spikes) can be used with dual operators.

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

• There are no end cap sections used for the spikes.

• RIGHT side operator spike’s drive chain will need to be reversed , see section 3.3.

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

• Each operator requires AC power.

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

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

Primary Operator

Circuit Board

TIME

DELAY

Secondary Operator

Circuit Board

TIME

DELAY

UP

LOOP

Settings using

Down Loop

UP

LOOP

Primary

Operator

DOWN

LOOP

1601

REVERSE

SENSITIVITY

POWER

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

SW 1

SW 1, switch 4 is ON .

SW 1, switch 5 is OFF .


Set other DIP-switches based on gate operation preferences.

DOWN

LOOP

1601

REVERSE

SENSITIVITY

POWER

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Jumper

Wire

Jumper

Wire

Yellow

Brown

Gray

Orange

Primary/Secondary

Interconnection Cable

Yellow

Sold separately from DoorKing.

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

Brown

Gray

Orange

4

When using Reverse Loops:

DIP-Switch settings: SW 1, switch 4 is OFF. SW 1, switch 5 is OFF. SW 1, switch 8 is OFF. Set other DIP-switches based on gate operation preferences. See page 16 for reverse loop wiring.

Interconnection cable: The BROWN wire must be connected to SECONDARY TERMINAL #9 along with the

GRAY wire . All other terminal wire connections are the same as shown above.

IMPORTANT: The barrier gate operators installed WITHOUT any external safety sensors CANNOT sense a person under the raised arms and can strike them while the arms are lowering. DoorKing recommends installing an external photo sensor directly under the arm. See safety pages in front of this manual for more information.

P/N 8080-057

Secondary

Operator

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

Each operator controls two 3-ft spike sections.

1603-065-K-12-20

SECTION 2 - WIRING

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

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

THIS GATE OPERATOR MUST BE PROPERLY GROUNDED!!

2.1 High Voltage Wire Runs

The distance shown in the chart is measured in “Feet” from the operator to the power source. If power wiring is greater than the maximum distance shown, it is recommended that a service feeder be installed. When large gauge wire is used, a separate junction box must be installed for the operator connection. The wire table is based on stranded copper wire. Wire run calculations are based on the NEC recommended maximum 3% voltage drop on the power line, plus an additional 10% reduction in distance to allow for other losses in the system.

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

Model

Type

1603 1/2 HP

Voltage

Required

115

Amps

Required

5.7

12 AWG

170

Wire Size / Max Distance in Feet

10 AWG

275

8 AWG

460

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

6 AWG

690

“Optional” Heater Installation Note: When installing a heater, refer to the “high voltage AC power wire size and distance limitations” table on the instruction sheet with the specific heater kits (115, 208/230, 460 VAC) for AC power wire run limitations.

“Optional” High Voltage Kit Installation Note: When installing the high voltage kit for 208/230/460/575 VAC input power, refer to the “high voltage AC power wire size and distance limitations” table on the instruction sheet with the high voltage kit (P/N 2600-266) for AC power wire run limitations.

2.2 High Voltage Terminal Connections

Chassis

Ground

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

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

Be sure to color code all wiring.

• It is recommended that a surge suppressor be installed on

the high voltage power lines to help protect the operator

and circuit board from surges and power fluctuations.

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

115 VAC

AC Power Terminal

Neu Hot

White - Neutral

Black - 115 VAC Hot

Green - Chassis Ground

High Voltage

AC Power Wire

DANGER

HIGH VOLTAGE!

Note: “Optional”

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

Keep wire clear of all moving parts.

1603-065-K-12-20

DO NOT

power up and cycle the operator until the “ DIP-Switches” have been set for the 1603 model (See pages 18 and 19).

The operator will not function properly unless the switches have been correctly set.

AC POWER

ON

External Power

Disconnect

Switch

Note: A separate power disconnect switch may be needed in your area. Check local building codes before installation.

OFF

5

6

2.3 Main Terminal Description

Input LEDs:

The LED that is above the terminal wiring input will light when that terminal input gets activated.

NC NO

#6 #7 #8 #9

Input LEDs

#10 #11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Relay Contacts

Terminal #5 Note:

Exceeding 250 mA of power from this terminal may cause the circuit board transformer to overheat, causing intermittent problems.

DANGER

HIGH VOLTAGE!

6


When switch 6 is OFF , this input will cause the operator to rotate the arm to the up position. If the arm is in the down cycle, this input will reverse the arm to the up position. If this terminal has a constant input, the arm will remain in the up position regardless of any down input or timer command to rotate down.

When switch 6 is ON , this input will cause the operator to rotate the arm to the up position when it is down, and will cause the operator to rotate the arm to the down position when it is up. If the auto timer is turned

ON (Not recommended if switch 6 is ON), this input will override the timer and rotate the arm to the down position. If the arm is in the down cycle, this input will reverse the arm to the up position.

SW 1

12

13


When switch 5 is OFF , activation of the down loop will activate the relay.

When switch 5 is ON , activation of the UP loop will activate the relay.

SW 1

Relay contacts can be set for Normally Open (NO) or Normally

NO

Closed (NC)

NC operation.

Contact rating is 1 amp maximum at 24 Volts.


When switch 8 is ON , the function of this input is identical to terminal 6.

When switch 8 is OFF , this terminal becomes the logic output of the up loop detector.

SW 1

7

Function is dependent on the setting of programming SW 1, switches 1 and 4.

With switch 1 OFF and switch 4 ON , activation and then deactivation of this input will rotate the arm to the down position, provided that the deactivation of the input happens while the arm is in the full up position. This input will override the auto timer if it is turned ON . If the arm is in the down position, traveling in the down cycle, or traveling in the up cycle, activation and deactivation of this input has no effect on the arm.

With switches 1 and 4 are ON , activation and then deactivation of this input will rotate the arm to the down position after it reaches the full up position regardless of when the deactivation of the input occurred.

When switch 4 is OFF , this input is identical to the reverse input, terminal 9.

SW 1

8

11



PAMS applications. This input is only active after a MOMENTARY UP input is received.

Activation of this input will rotate the arm to the up position or reverse an arm in the down cycle to the up position.

9

10



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

When the arm is in the down position, activation of this input has no effect.

When the arm is in the up position, activation of this input will prevent the arm from rotating to the down position. If the arm is in the down cycle, activation of this input will reverse the arm to the up position.

1603-065-K-12-20

2.4 Control Wiring for Single/Primary Operator

UP

LOOP

DoorKing Access Control System (Model 1833, 1835, 1837 or

1838) tracker system can be connected.

This system can keep track of gate operator cycle count, shorted inputs, loop detector problems, any forced entry attempts, if the gate has struck anything during the open or close cycle, power interruptions, etc.

For more detailed information refer to the Tracker Installation and

Wiring Manual, DoorKing P/N 2358-010.

Gat e

Tracker

(Quad Box

Shown)

Terminal 6 required only if the tracker board will activate the gate operator. Refer to the manual 2358-065 for detailed information.

Gate Operator

Data Terminal

1601

POWER Type of wiring to be used on ALL external devices:



nic

Electro

Box Assembly

TIM

DE

E

Y

LA

TIME

DELAY

REVERSE

SEN Y

UP

LOOP

Antenna mounted outside operator housing.

Coax Antenna Kit

P/N 1514-073

115 VAC

Convenience

Outlets

Power safety and opening devices that require 115

VAC power.

DO WN

LOOP

PO

WE R

RSE

RE

VE

SE

NSITIV

ITY

NC

NO

DOWN

LOOP

NC NO

DANGER

HIGH VOLTAGE!

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1. Com

3-Wire Radio Receiver

3. 24 Volt

2. Relay

Up-Inputs

Down-Inputs

Terminal #5 Note: Exceeding 250 mA of power from this terminal may cause the circuit board transformer to overheat, causing intermittent problems.

HOLD OPEN

Manual Gate Control Toggle

P/N 1200-017

OPEN

WARNING

User MUST make sure gate area IS CLEAR before manually operating gate arm.

Up toggle position: User toggles switch up to hold gate open.

Center toggle position: Is neutral for normal operation.

ROUND Aluminum Arm Contact Sensor ONLY

See page 26

WARNING

MOVING ARM


can serious injury or death.

of arm

NO: Pedestrians

Bicycles

Motorcycles

2-Wire 6ft Reversing Edge

P/N 8080-071

4-Wire 6ft Reversing Edge

P/N 8080-091

Non-Contact Sensor (Always Reverses)

21” Typical Beam Height.

27.5” Max. Beam Height.

24 Volt

DoorKing P/N-8080-057

Photocell power supply

(Sold separately)

WARNING



NO: Pedestrians

Bicycles

Motorcycles







Relay

Contact and Non-Contact Sensors Note: Helps minimizes the potential of the arm lowering on vehicular or other traffic that loops cannot sense.

Non-Contact Sensor Installation Note: DO NOT mount photocell to the operator cabinet. Cabinet can flex or vibrate during operation which may cause misalignment of the beam.

1603-065-K-12-20 7

SECTION 3 - AUTO SPIKE SYSTEM INSTALLATION

The operator and auto spike system must be installed on a flat and level concrete pad with a minimum 6 inch depth (Check local building codes for restrictions). Reinforced concrete recommended. It is recommended that the “Spike” sections not exceed

9 feet (Three 3-Ft spike sections) for proper operation.

3.1 Connect Sections Together on Concrete Pad

Snap all sections together using socket connectors with spikes aligned in UP position.

DO NOT anchor them to the concrete at this time.

CA

CLAS

CON

AN

N/C

VEHI

FO

SI/U

C2

CUL

RM

L-3

25

2.

S TO

CER TIF

IED

TO

47

TE OP

MO DE

2 N

AR

GA

O. 2 533

HP

ERA TOR

SER IAL

VO

LTS

AM

PS

MA X G

ATE LO

Doo rKin g, In

AD c., Ing

PH

AS

60 H lewo od, CA

Mo

Serious Inju

KEEP

Do not

Th let ch

Pedestr arni ng.

ma ance ea.

ians is for

vehi n Caus ath he gate e me cles onl y.

or pl ay ance.

Operator

Section

Note: Operator extension section with torsion shaft

REQUIRED to connect to operator.

Operator

Torsion Shaft to Spikes Connection

(REQUIRED)

Align Spikes

Sections MUST lay flat, even, straight and centered on concrete.

Socket

Connector

Spike to Spike Connection

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


Socket

Connector

Extension to Spike Connection

(Optional)

8


UP Position

RETRACTED Position

CORRECT Spike Positions

The spikes will retract towards oncoming traffic.

1603-065-K-12-20

3.2 Test Spikes when Operator positioned on LEFT side

Note: If operator is positioned on RIGHT side, see next page.

CA N/C

VEH

CLA

SS

MODE

CO

NF

CER

SA

OR

SI/U

C22

ICU

LAR

MS

IED

.2 N

TO

25

TO

O.

GAT

24

E O PER

SER IAL

VO

LTS

AM

PS

MA X GA

Doo rKin

LO

AD g,

In c., Ing lew

PH

AS

60 H ood , C

5338

HP

ATOR

Movi

Se ng G wi in tho

This

Ped no

CL ut prio gate en r wa tranc ildren ea e is

mu

op

for te may

mo era

ve te th hicle ve ath at an e g ate e y tim e or p lay e e ntran ce

DO NOT anchor the sections to the concrete until the spikes have been tested and they operate smoothly. If spikes are not in the correct UP and RETACTED positions during operation as shown on previous page, some adjustment will be required

(See below).


Turnbuckles

1603-065-K-12-20

Lower Sprocket

Spike Adjustment

With operator in the spikes UP position, loosen both turnbuckles on crossed chain inside the operator to release chain from the lower sprocket....

....spikes can now be adjusted to the correct UP position as shown.

Correct UP Position


....replace the chain back onto lower sprocket and tighten both turnbuckles after spikes have been adjusted to the correct position.

9

3.3 Test Spikes when Operator positioned on RIGHT side

When operator is mounted on the RIGHT side as shown, the chain MUST be reversed (See below).

Moving wi EP tho

no

Th

Pe des

CL t le e g

EA t ch ate tria nc

R!

ild e is jury or Deat

Gat rnin

for e may g.

t us era te

m e sepa ove s onl y.

at the gat h e

an y tim e o y e e ntra nc e.

e


DO NOT anchor the sections to the concrete until the spikes have been tested and they operate smoothly. If spikes are not in the correct UP and RETACTED positions during operation, some adjustment will be required (See below).

Reverse Chain

Use the master links to disconnect the spike’s drive chain and reverse it so spikes will rotate in the correct direction. The spikes can also be adjusted to the correct position at this time (see below)

Master

Links

10

Spike Adjustment


RETRACTED Position

Correct UP Position

Adjust spikes as shown.

1603-065-K-12-20

3.4 Secure EACH Section to Concrete

Extreme force is exerted on the sections every time a vehicle drives over them. It is important that they have enough anchors in them to keep them securely in place.

After you have tested the spikes and are satified with the way they perform, without moving the sections , secure EACH section in place with sleeve anchors (8 sleeve anchors are located inside the spike sections. The ramps will need to be unbolted to gain access to the mounting holes). After ALL sections have been secured to the concrete, mount the end cap in place.

Maintenance Tip: It is important to check the sections every so often to make sure all the sleeve anchors have not loosened up.

The spikes will NOT function well with loose sleeve anchors.

Ramp

3/8

Secure sections and end cap to concrete with 3/8” x 3” minimum sleeve anchors (Not supplied).

CA

N/C

VEH

CO NF

AN

ICU

CLA SS

OR

CERT

SA

C2

MS

L-3

IFIE

TO

MO DE

SER

IAL

VO

LTS

AMP

2.2

D T

LA R G

NO

. 2

ATE

47 533

OP ER

HP

ATO

R

Doo

E L

OA rKin g, In

PH

60 H

AS c., I ngle wo od , CA

Mov

Se

KE wi

EP

Do n

Ped ing G

CL ut p e g entr estri

EA rior t ch ate

R! Ga warn ild are ans

mu ren a.

st

op for ve

Can Cause

or te may era hicle se

De

mo te th s o ve

at e g ath any ti

or pa rate nly

en tran ce me pla y

Cut off excess threads flush with top of nut on the sleeve anchors that will come in contact with tires.

Tunnel

Note: Section illustrated without spike rod and white plastic supports to better show sleeve anchor mounting holes.

Traffic Direction End

Cap

Cleaning the Spikes

The ramps will have to be unbolted and the tunnel will need to have the debris cleaned out every so often to keep the spikes in good working condition. The sleeve anchors mounted inside the tunnel will also need to be checked for looseness and repaired when necessary.

1603-065-K-12-20 11

SECTION 4 - LOOP DETECTOR LANE SETUPS

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

Loop detector wiring shown is for DoorKing model 9409 Dual Channel and 9410 Single Channel plug-In loop detectors only.

If using other loop detectors refer to the separate Loop Information Manual for installation instructions, loops/preformed loops and wiring diagrams. All inputs to the main terminal are NORMALLY OPEN.

4.1 Entry Lane Only




TIME

DELAY

A

SW 1


SW 1, switch 7 is

OFF (Timer). The arm will rotate down after the vehicle clears the down loop. See timer note below.

UP

LOOP

NO

Com

A

SW 1

1601

POWER

SW 2

A Y WA LK LK KW AL WA A A W A T OT NO

1 Ft. Minimum Distance

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

9409

Dual Channel Main Terminal

1 2 3 4 5 6 7 8 9 10 11 12 13 14


12

If the arming loop is not used, then a single channel loop detector can be used (9410) in the down loop port.

Connect the down loop to loop 1 on this detector. Connect the access control device directly to main terminal 6 and 14.

NO

Arming Loop Note: The arming loop only allows the access control device to function when a vehicle is on the loop, otherwise it will not function. This prevents pedestrians from gaining access through the vehicular gate.

Timer Note: The timer can be used with a down loop. When timer is ON with a down loop, it will start countdown when the arm has fully raised.

Activation of the down loop will cancel timer countdown. Useful when an access control device has been activated but vehicle does not move forward to activate the down loop. The arm will remain UP.

Timer will time out and lower the arm without the down loop being activated.

Com

Access

Control

Device

Arming Loop for Access

Control Device

(Optional)

Speed Bump


1603-065-K-12-20

4.2 Exit Lane Only

Single Channel

UP

LOOP

A

SW 1


SW 1, switch 7 is OFF (Timer). The arm will rotate down after the vehicle clears the down loop.

See note below.

TIME

DELAY




9410

A

SW 1

1601

POWER

SW 2

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

9410

Single Channel

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Speed Bump


A Y WA KW LK LK WA AL W WA

Automatic

A A T A

Exit Loop (Free Exit)

OT NO



Down Loop

O T A W A L K W A

1603-065-K-12-20

Note: The timer can be used with a down loop. When timer is ON with a down loop, it will start countdown when the arm has fully raised.

Activation of the down loop will cancel timer countdown. Useful when the automatic exit loop has been activated but vehicle does not move forward to activate the down loop. The arm will remain UP.


13

4.3 Two-Way Traffic Lane

When a vehicle enters , the down loop will be overridden by the automatic exit loop which will continue to hold the arm up. When the interior down loop has been cleared by the vehicle, the arm will lower.

When a vehicle exits , the automatic exit loop will raise arm and when the down loop is cleared, the arm will lower. The interior down loop is inoperative for exiting vehicles.

Single Channel

TIME

DELAY




A

SW 1


SW 1, switch 7 is OFF (Timer). The arm will rotate down after the vehicle clears the down loops.

See timer note below.

UP

LOOP

NO

Com

9410

A

SW 1

1601

POWER

SW 2

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

9409


1 2 3 4 5 6 7 8 9 10 11 12 13 14

Down loops wired in series.

14

Non-Contact Sensor Note:

DoorKing highly recommends installing a non-contact sensor (photocell) directly under the arm for safety.

If the arming loop is not used, then a Single Channel Loop Detector can be used (9410) in the down loop port.

Connect the down loops to loop 1 on this detector. Connect the access control device directly to main terminal 6 and 14.


NO

Timer Note: The timer can be used with down loops. When timer is ON with a down loop, it will start countdown when the arm has fully raised. Activation of the down loop will cancel timer countdown. Useful when the access control device or automatic exit loop has been activated but vehicle does not move forward to activate the down loop. The arm will remain UP.


Interior

Down Loop

Y

Spacing between loops is critical when using this configuration. Be sure that the loops are spaced as shown in the diagram.

WA LK

Exit Loop

(Free Exit)

A T NO




Down Loop

Com

Access

Control

Device


Control Device

(Optional)

Speed Bump


1603-065-K-12-20

4.4 Ticket Spitter Entry Lane

UP

LOOP

A

SW 1


SW 1, switch 7 is OFF (Timer). The arm will rotate down after the vehicle clears the down loop.

See note below.




TIME

DELAY

NO

Com

A

SW 1

1601

POWER

SW 2

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

9409


1 2 3 4 5 6 7 8 9 10 11 12 13 14

Y WA LK A T NO



Com

NO

Ticket Eject

Loop

1603-065-K-12-20

Note: The timer can be used with a down loop. When timer is ON with a down loop, it will start countdown when the arm has fully raised.

Activation of the down loop will cancel timer countdown. Useful when the ticket spitter has been activated but vehicle does not move forward to activate the down loop. The arm will remain UP.


Speed Bump


1 5

A

4.5 Operator Timer ON Entry Lane (No Down Loop)

SW 1


SW 1, switch 7 is ON (Timer). The arm will rotate down after the timer has timed out.

B

TIME

DELAY

Adjust from 1 second

(full counter clockwise) to approximately 59 seconds (full clockwise).

1 59




B

TIME

DELAY

UP

LOOP

NO

Com

A

SW 1

1601

POWER

SW 2

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

9409


1 2 3 4 5 6 7 8 9 10 11 12 13 14

Reverse loops wired in series.

Y WA

Reverse Loop

LK WA A T NO

1 Ft.

Min

Note: Make sure that a vehicle can NOT fit in the area between the reverse loops.


Reverse Loop

1 Ft.

Min

16

If the arming loop is not used, then a Single Channel Loop Detector can be used (9410) in the down loop port.

Connect the reverse loops to loop 1 on this detector. Connect the access control device directly to main terminal 6 and 14.

NO


Reverse Loop Note: The reverse loops will prevent the arm from closing on a vehicle remaining in the arm’s pathway. The timer will restart the countdown any time the reverse loop gets activated.

Com

Access

Control

Device


Control Device

(Optional)

Speed Bump


1603-065-K-12-20

SECTION 5 - ARM INSTALLATION

The 14 ft. aluminum arm mounts on the same side of the operator as oncoming traffic (either straight or folding arm).

5.1 Mounting Hub

Operator in the Down position.

2

53

38

CONFORM

AN

SI

/UL

S TO

-3

25

TO

IFI

ED

2 NO.

CE C22.

247

OP

ERA

TOR

CA

N/

A

CS

LA

R

GA

TE

VE

HICU

CL

S

AS

HP

MODE

L

PHA

SE

SE

RI

AL

60 Hz

VOL

TS

S

D

AMP

MA

X

GA

TE LOA c., g,

In

In gle

CA wo od,

Do orKin ca n

,

WA

RNING mage

death.

MOVING ARM seri

ST

inj ous

AY at all

NO:

CLE

AR

.

arm

Pe es

Bi cycl cycl es

Motor

5.2 Mounting Aluminum Arm

Refer to instruction sheet that comes with YOUR CHOSEN ARM to install arm. Arm options are on the 1603 specifications page in front of this manual.

Note: Make sure Warning decals are on BOTH sides of arm.

Ca n C

De au se ath me ma y m ove at any ti or play

Seriou rni ng.

ild ren operate the gate

KEEP CLEAR! Gate in the gat ust use separate entrance.

ance is for vehicles only.

This entr

Pedestrians m

W

ARNING Ocatgon Arm

MO caus ser

ST

VI

NG

AR

M

AY CLEAR at al

NO e v l ti

: ehi

inj

Pe

Bic cle ur me s.

de yc

Moto rcy da can ma r d strian les cle ge, eath.

m of ar s s

HUB

HUB

Horizontal

Bolt

Locking

Plate

Screw

Arm is DOWN when

Spikes are UP

Arm is UP when

Spikes are DOWN

Test hub UP and DOWN positions before installing arm.

1603-065-K-12-20

Cover

Note: Helpful wiring diagrams on pages 35-36 if installing a octagon reverse edge/LED arm OR round aluminum LED arm AND a traffic light.

17

1 8

SECTION 6 - ADJUSTMENTS

The switch settings and adjustments in this chapter should be made after your installation and wiring to the operator is complete. Whenever any of the programming switches on the circuit board are changed, power must be shut-off, and then turned back on for the new setting to take effect.

6.1 1601 Circuit Board Description and Adjustments

Gate Tracker

Activity LED

An automatic sensor system that senses entrapment of a solid object and is incorporated as a permanent and integral part of the operator.

Single Channel Loop Detector

Gate Operator

Data Terminal

Operator status reporting; cycle count, shorted inputs, loop detector problems, power interruptions, etc.

See page 7.

DoorKing Plug-In

Loop Detectors

(Sold separately)

UP

LOOP

Auto Close Timer

Auto close timer (when turned on) SW 1, switch 7.

Adjust from 1 second (full counter clockwise) to approximately 59 seconds

(full clockwise).

TIME

DELAY

SW 1

How LEDs Function

Illuminated LEDs Indicates that low voltage power is being applied to the circuit board.

Input LEDs should be OFF and will only illuminate when the input is activated.

Limit LEDs will only illuminate when the respective limit sensor has been activated.

Self Test

1 59

Self test (when turned on) SW

1, switch 2.

Up Limit LED

Down Limit LED

Limit

Sensor

See page

22.

DIP-Switches

Set the DIP-switches on the circuit board to the desired setting. See switch settings information on the next 3 pages.

SW 1

SW 1

SW 1

DOWN

LOOP

Power

1601

REVERSE

SENSITIVITY

SW 2

Note: SW 2, switch 1

MUST be set for the correct model operator that has been installed.

SW 2

Arm Relay Contacts

(C – NC – NO) This relay can be used for a variety of purposes and is typically used to signal when the arm is up or down.

9409

Dual Channel Loop Detector

Reverse Sensor

Adjust reversing sensitivity for the

DOWN direction of arm.

See page 22.

Min Max

Input LEDs

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Dry Relay Contact

N.C.

N.O.

Relay activation is dependant on setting of SW 1, switch 5.

SW 1

Dry relay contacts (terminals 12-13) 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. See page 6 and next page.

1603-065-K-12-20

6.2 DIP-Switch SW 1 and SW 2 Settings

The two DIP-switches located on the circuit board are used to program the operator to operate in various modes and to turn on or off various operating features. Whenever a switch setting is changed, power to the operator must be turned OFF and then turned back on for the new setting to take affect. Check and review ALL switch settings prior to applying power to the operator.

SW 1 (Top 8 Switches)

Switch Function Setting

1

Down Active when arm is full up.

Down Active when arm is moving up or is up.

OFF

ON

Description

Activation and then deactivation of the down loop or down / reverse input will cause the arm to rotate down ONLY if the deactivation occurred after the arm reached the FULL UP position.

Activation and then deactivation of the down loop or down / reverse input will cause the arm to rotate down AFTER reaching the FULL UP position regardless of when the deactivation occurred.

Normal setting.

Self-test is turned off.

2 Self-Test

OFF

ON

OFF

Run self-test.

Normal setting.

Operator uses 360° of gearbox. Extends wear life of gearbox.

3

Gear Box Travel

ON Operator uses 180° of gearbox.

4

5

Down / Reverse

Loop and Input

Relay 1 Activation

OFF

ON

OFF

ON

Down / Reverse loop and input will function as a REVERSE loop and REVERSE input.

Normal setting.

Down / Reverse loop and input will function as a down input and cause the arm to rotate down upon deactivation of the input. See SW 1, switch 1 for additional information.

Normal setting.

Relay activates when the DOWN loop detector (DoorKing plug-in detector only) senses a vehicle presence.

Relay activates when the UP loop detector (DoorKing plug-in detector only) senses a vehicle presence.

6

7

8

Up Input Function

Timer

Up Loop Port Input

OFF

ON

OFF

ON

OFF

ON

Up Input will raise arm and/or reset the down timer. Input will not lower the arm.

Up Input will raise arm if it is down, or will lower arm if it is up.

Timer to lower arm is OFF.

Timer to lower arm is ON. Set from 1 to 59 seconds for close time delay. Timer can be used as a secondary closing command for a down loop. Timer countdown starts when arm has fully raised.

Down loop activation will cancel timer and lower arm OR arm will lower when timer has timed out.

Output of the loop detector plugged into the UP loop port is switched to terminal 7 for connection to other input terminals.

Normal setting.

Output of the loop detector plugged into the UP loop port will raise arm when activated.

SW 2 (Bottom 8 Switches)

Switch Function Setting

1

2

Model 1603

Multiple Input Memory

ON/OFF Switch

OFF

OFF

ON

Description

Switch must be OFF for model 1603 barrier gate operator.

Normal setting.

Operator will respond to a single UP command, then require a DOWN command.

Operator will not accept multiple Up commands.

Operator will not accept the next UP command until the previous DOWN command is in progress.

Turns ON the multiple input memory option 1 or 2 (See switch 3). SW 1, switch 4 must also be on.

3

4

5

6

7

8

Multiple Input

Memory Options

(SW2, Switch 2 must be ON)

(SW1, Switch 4 must be ON)

Option 1

(OFF Position)

Option 2

(ON Position)

Override a DOWN command – When the arm is in the up position for a vehicle passing through and the next vehicle’s UP command is received, the operator will hold the arm up and wait for the next vehicle to clear the down loop before lowering the arm. The operator will not count multiple UP commands.

Distance between access control device and barrier operator is a factor when using this option. Remote transmitters recommended for this option. See next page for more information.

Override Mulitlpe DOWN commands – The operator will count multiple UP commands received during an UP command and require a matching number of DOWN commands before lowering the arm.

Distance between access control device and barrier operator is a factor when using this option. Remote transmitters NOT recommended for this option. See page 21 for more information.

OFF

Stop Arm Function

Reverse Delay

Arm Rotation Direction

Spare

Spare

ON

OFF

ON

OFF

OFF

OFF

Normal setting.

Arm will NOT stop DURING the down cycle.

Stop Arm Function – Arm will stop DURING the down cycle if a vehicle activates the down loop.

An UP command will raise the arm, or the arm will continue down AFTER the down loop is cleared.

Arm reversal is delayed approximately .5 seconds when a reverse input from terminal 9 is received during the down cycle. (eg. non-contact sensor beam is blocked). Limited application use.

Normal setting. Instant Reverse – Arm reversal is delayed approximately .1 second when a reverse input from terminal 9 is received during the down cycle. (eg. non-contact sensor beam is blocked)

Normal setting.

Leave in OFF position.

Normal setting.


Normal setting.


1603-065-K-12-20 19

Option 1 - Override a DOWN Command

SW2, Switch 3 OFF

Remote transmitters are recommended for this option.

1 Valid UP command given.

Access Control Device

12 Ft. Maximum Distance

Basic operator UP/DOWN cycle:

A.

Valid UP command from the access control device will raise arm.

B.

Vehicle activating and clearing the down loop will lower the arm.

1st Car

Option 1 CANNOT be used at distances OVER 12 feet.

This allows multiple vehicles in this area which Option 1 WILL NOT keep track of.

See Option 2 on next page.

2 Operator will raise arm.

Note: Operator will NOT accept another valid UP command until

“1st Car” activates down loop.

1st Car

Next Car

3 1st Car activates down loop.

1st Car

4 While 1st Car is on down loop, the next UP command is given.

5

Operator will override “1st Car’s”

DOWN command.

Arm will remain up and wait for the “Next Car’s” down loop to be activated.

Next Car

1st Car

20

Note:

If an UP command is given while the arm is lowering, the arm will raise.

6 When “Next Car” activates then clears down loop, arm will lower.

1603-065-K-12-20

Option 2 - Override Multiple DOWN Commands

SW2, Switch 3 ON

Basic operator UP/DOWN cycle:

A.

Valid UP command from the access control device will raise arm.

B.

Vehicle activating and clearing the down loop will lower the arm.

1

5

This option allows the access control device and the barrier gate operator to have multiple vehicles in the area between them. The operator will count all the valid

UP commands received and require a down loop activation for each one. The arm will lower only after the last vehicle activates then clears the down loop.

Remote transmitters are NOT recommended for this option because one vehicle’s remote can accidently be pressed multiple times which will get counted by the operator as multiple vehicles.

Y WA LK WA

Down Loop

A T NO Y WA LK WA

Down Loop

A T NO Y WA LK WA

Down Loop

A T NO


2

Operator will raise arm

2


4

Operator will override multiple

DOWN commands.

Arm will remain up while counting the vehicles activating the down loop.

5


Operator will lower the arm

ONLY after the last vehicle activates then clears the down loop.

3

4

Note:

If an UP command is given while the arm is lowering, the arm will raise.

1 Valid UP command given

Access Control Device

1

3

5

1603-065-K-12-20 21

6.3 Magnetic Limit Adjustments

The operator has been preset at the factory to rotate 90°. No adjustments are necessary when used in a normal 90° setup.

If the arm needs to rotate less than 90°:

1

2

Turn operator power OFF .

Set the DIP-switch SW 1, switch 3 to ON .

This changes the rotation of the gearbox from 360° to 180° allowing the gearbox to rotate the arm less than 90°.

UP

LOOP

3

Note: The arm will always cycle to 90° open with the 360° gearbox setting.

SW 1

Loosen magnet limit assembly nuts and slide the assemblies to the desired UP and DOWN positions.

Tighten nuts when desired positions are achieved.

1601

TIME

DELAY

UP Limit LED

DOWN Limit LED

Magnetic Limit

Sensor

Magnet

Limit

Assembly

3

Magnet Limit

Assembly

DOWN

Limit

UP

Limit

3

Arm Shaft

22

6.4 Reverse Sensor

Reverse sensitivity adjustment will cause the barrier arm to reverse direction of travel should an object be encountered during the down cycle. The amount of force required for the arm to reverse direction depends on the reverse sensitivity potentiometer.

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

TIME

DELAY

While operator has AC power:

UP

AUTO

DOWN

UP

LOOP

1

2

3

Turn control switch to UP . Arm will rotate UP.

Turn control switch to DOWN . While arm is traveling down, rotate reverse sensor clockwise until the reverse LED lights up and the arm reverses direction. Rotate reverse sensor back counterclockwise approximately 1/8 turn.

Repeat the adjustment as needed to find a satisfactory setting.

UP

AUTO

DOWN

REVERSE

SENSITIVITY

1601

POWER

SW 1

SW 2

REVERSE

SENSITIVITY

DOWN

LOOP

Min Max

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1603-065-K-12-20

6.5 Manual Operation of Arm and Spikes

1 Unlock and remove access door.

2 Remove crank tool from inside access door.

3 Flip interlock assembly door up, ALL power will be disabled from operator, including battery back-up power on convenience open models.

4 Insert crank tool into motor pulley as shown.

5 Rotate crank tool to manually move operator arm and spikes up or down.

Access Door ool

Crank T

Storage

Interlock

Assembly

Door

38

2

CONFORM

AN

SI

/UL

S

TO

-3

25

TO

CE

RTI

A

CS

FIED

C2

2.

2 NO.

VE

HICU

LA

R GA

24

7

TE

OP

HP

TOR

ERA

CL

MODE

L

SE

RI

AL

PHA

60

SE

Hz

VOL

TS

S

AMP

MA

X

GA

TE

Door

Ki ng

, I

AD

LO nc

.,

Ing lew oo d,

CA

G ca n

M mage

,

WA

RNIN

MOVING AR ser

AR

death.

y or of ar m

ST

AY at al l tim

Pe de

NO: strians es

Bi cycl cyc les

Motor au se e

Moving Gate C ove at any tim or play

Serious Injury or D

ope rate the gate only.

Do not let chi in the gat must use separate entrance.

This entr

Pedestrians

1603-065-K-12-20 23

SECTION 7 - OPTIONAL CONVENIENCE OPEN SYSTEM

The optional convenience open system installed in your vehicular gate operator is designed as a convenience enhancement only.

It is not designed or intended to provide continuous gate operation during a power outage. Its sole purpose is to provide a method to open the vehicular gate to allow unimpeded traffic flow when the gate and access control system is without power. If your access control system requires 100% power backup and continuous operation when primary (AC) power has failed, a power inverter / backup system, such as DoorKing’s Model 1000 is required.

• The convenience open system cannot provide continuous gate operation during a power outage.

•

This system cycles the arm to the open position one time only after AC power failure.

• The convenience open system requires testing on a monthly basis to insure the batteries are fully charged and that the

system is operational.

• The convenience open system uses two 12-volt, 3.0 amp-hour gel-cell batteries. These batteries should be replaced

every two years on average, or sooner if required.

• Batteries are affected by temperature. Cold temperatures will reduce the effectiveness of the batteries. High temperatures

will result in a shortened battery life.

• Batteries are not covered under warranty.

24

7.1 Circuit Board Settings and Descriptions

This convenience open system consist of a control board (1473-010), motor and power supply (batteries) providing a completely redundant drive system to open the barrier arm should a power outage occur. This system is not designed to maintain continuous barrier operation; rather it provides a convenient method to open the arm once during adverse conditions.

If continuous barrier and access control system operation is required, refer to the DoorKing Model 1000 Inverter / Backup

Power System.

DIP-Switches

1

3

6

DO NOT use

Run Timer

4

5

1473-010

ON

1 2 3 4

Switch

1

2

Function Setting

Auto Open

Operation

After Power

Outage

OFF

ON

Motor Dir

Motor Direction

OFF

Description

DO NOT USE. Manual Mode.

(Auto Mode) Apartment complexes, gated communities, etc.:

Arm will automatically raise to the operator’s UP limit position.

Set so that the arm opens to the UP direction upon loss of AC power.

2

3

AC on ACT

Restore Power

Operation

OFF

ON

DO NOT USE. Physical Input Required.

Auto: a 1-second pulse is automatically sent to the barrier gate operator input to restore normal operation again.

1 2 3 4 5 6 7 8 9 10

4

Timer-OFF

Limit-ON

Operator Type

Timer-OFF

Limit-ON

DO NOT USE. “Run timer” is used and MUST be adjusted.

Operator limits are used to stop arm at UP position.

1

HEART BEAT LED

Blinking: Indicates board is operating normally.

2

Battery LEDs

BATT STAT LED

2 Blinks: Replace

3 Blinks: Battery level is too low.

4 Blinks: Batteries are not connected.

5 Blinks: Bad

6 Blinks: Battery charge current exceeds maximum, possible shorted cell.

TRICKLE LED

Steady Green LED: Battery is fully charged and a trickle charge is being used to maintain a full charge.

CHARGE LED

Steady Yellow LED: Battery is being bulk charged.

Blinking Yellow LED: Battery is 90% of a full charge.

STAT LED

3 Blinks: Extreme temperature, charging suspended.

3

Reset Button

Press to reset board.

4

Clear Stat Button

Press and hold the CLEAR STAT button for 4 secs clears the battery replacement reminder counter and resets the beeper. LEDs will also indicate battery status.

5

Beeper

A beep every 20 seconds indicates that battery replacement is needed. Press and hold the

CLEAR STAT button to reset the battery reminder beeper and clear the counter. LEDs will also indicate battery status.

6

Run Timer

DO NOT USE .

Operating Note: Arm will cycle to UP position automatically (DIP-Switch 1

ON ) during an AC power failure.

Operator’s DC limit sensor will stop and hold the arm in the UP position

(DIP-Switch 4 ON ). Operator will automatically return to normal operation once AC power has been restored (DIP-Switch 3 ON) .

Initial Power Up Convenience Open Note:

The DC power is not present on the main circuit board until the first initial cycle.

1603-065-K-12-20

7.2 DC System Wire Schematic

Run Timer Not Used

Batteries

1473-010

Red

ON

1 2 3 4

Arm Rotation Assembly in UP Position

1 2 3 4 5 6 7 8 9 10

DC Magnet

Limit Assembly

(Adjusted at Factory)

DC Limit

Sensor

Arm will cycle to UP position automatically during an AC power failure. DC limit sensor will stop and hold the arm in the UP position.

DC ON/OFF

Power Switch

Black/White

Red/White

Orange

Yellow

TIME

DELAY

UP

LOOP

SW 1

1601

POWER

SW 2

REVERSE

DOWN

LOOP

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

2 5 1603-065-K-12-20

26

SECTION 8 - OPTIONAL ACCESSORIES INSTALLATION

8.1 Contact Sensor Installation (Reversing Edge)

In addition to the electronic reversing device (ERD) an optional electric reversing edge may be installed on Round Aluminum arm ONLY offering additional protection. P/N 8080-071 - 2-wire 6 ft. P/N 8080-091 - 4-wire 6 ft.

1

Turn operator power OFF . Remove Cover.

Contact Sensor Note:

A reverse edge is NOT to be used as a replacement, or in lieu of, in-ground loops or non-contact sensor (photocell) that protect vehicles passing underneath the barrier arm. A moving vehicle coming in contact with a downward moving barrier arm WILL result in damage to the vehicle and the barrier arm/reversing edge if NOT using in-ground loops or non-contact sensor (Photocell).

Round Aluminum Arm OR W ood Arm

Mounting Channel

2-Wire Reversing Edge

5338

2

5

CONFORM

ANSI/UL-32

IFIE

D TO

NO. 247

CE

RT

SA C22.2

TE OPER

HP

CAN/C

AT

OR

VE

HICULAR GA

CLASS

MODEL PHASE

SERIAL

VO

LT

S

60 Hz

TE

LOA

D

Ingl

Inc., ewood

MAX

Doo rKing,

, C

A

M ca n

,

W

ARNING

MOVING AR cause vehicle damage

.

ST

AY

NO s cycle

Motor s

Mounting Channel

4-Wire Reversing Edge

2

Position the mounting channel at the end of the barrier arm and secure to the bottom of the arm using self-tapping metal screws (not supplied). Slide the reversing edges into the mounting channels.

3

Drill a 1/4-inch hole on the side of the operator housing

DELAY the internal components.

UP

LOOP

time

4

Install a plastic grommet (Not supplied) in the 1/4” hole to protect the wire from chaffing on sharp metal edges.

on ly.

5

without prior warni

Do not let st use s eparate entrance.

Secure the wire to the arm and hub using wire ties (not supplied).

Pedes leave a wire loop to allow the arm to rotate freely. Make sure wire does not rub against the cover when cycling.

DOWN

LOOP

SW 1

2-Wire Edge P/N 8080-071

POWER

SW 2

REVERSE

SENSITIVITY

1601

Wire T ies

4-Wire Edge P/N 8080-091

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

SER

IAL

TS

53 38

MS

TO

I/UL

-325

CE

CA

N/ CS

ANS

RT

IFI

A

C2

ED

2.

CU

LA

TO

2 N

O.

247

R

GA

HP

TO

R

TE O

PE

RA

HI

VE

S

CL

AS

L

DE

MO PHA

SE

60 H z

VOL

PS

AM

X GA

MA

Do

TE LO

AD ing orK

, I nc

., Ing lew oo d,

CA

NIN

G ca n

W

AR rious

CL

EAR imes

.

tri ans cy cles

Mot or of ar m cause vehi se

AY

ST at al l t

NO

: Pedes cy cles th

Movi

Se rio te Can Cause ng

Ga

Inj ury or ve

at or play us

R!

ate may mo arni

6

he gate

KE

EP CLEA for vehicles only.

without prior w

Th

Pedestrians mu

Wire

Tie Plastic

Grommet

Wire

Loop

IMPORTANT:

Allow a loop in the wire for rotating arm.

4-Wire 6ft Edge P/N 8080-091

Cover

WARNING



NO: Pedestrians

Bicycles

Motorcycles

Reversing Edge Wires N.O.

Com

6

Connect wires to terminals 9 and 14 without interfering with any of the operator’s moving parts. Re-install cover.

2-Wire 6ft Edge P/N 8080-071

1603-065-K-12-20

8.2 Additional Optional Accessories

“Optional” accessories offering additional features, available from DoorKing.

Fan Kit

This kit is designed for the 1603 barrier gate operator. It is recommended for hot humid climates to prevent heat and moisture build-up inside the housing

(P/N 1601-093).

For further information about this, go to DoorKing’s web site at: www.doorking.com

Exhaust V ents

Air

Flow

Intake V ents

Heater Kits

These kits are designed for the 1603 barrier gate operator. For cold weather climates where temperatures routinely drop below 10°F (-12°C). A built-in thermostat will automatically control the temperature inside operator housing. There are different kits depending on the input power wire being used to power the barrier gate operator.

For further information about these, go to DoorKing’s web site at: www.doorking.com

Mount

F

OF

ON

Mountin

Plate g

F

OF

ON

Mounting

Plate

VA

VA

P/N 1601-092 - 115 VAC

P/N 1601-197 - 208/230 VAC

P/N 1601-198 - 460 VAC

1603-065-K-12-20

Heater

Mounting

Position

27

8.2 Additional “Optional” Accessories

“Optional” accessories offering additional features, available from DoorKing.

LED Traffic Light

This kit is designed for the 1603 barrier gate operator. The traffic signal is synchronized with the gate operator’s up/down cycle. The red light stays on and only changes to green when the operator’s arm is fully raised and spikes are down.

P/N 1603-221 - 6 Ft Cable with NO Post

P/N 1603-222 - 6 Ft Cable with 35” Post



WARNING



of arm

NO: Pedestrians

Motorcycles

CERTIFIED TO

CAN/CSA C22.2 NO. 247


CLASS

MODEL

HP

SERIAL

VOLTS

AMPS

MAX GATE LOAD

PHASE

60 Hz


53382

WARNING



Motorcycles







Lighted Warning Sign

This kit is designed for the 1603 barrier gate operator. The warning sign has a light sensor for automatic dusk to dawn illumination and a manual On-Auto/Off switch. P/N 1615-081


5 MPH

DO NOT

BACK UP

Severe T

No Ped ire Damage!

est rians i n T raffic Lane

2 8

5 MPH

DO NOT

BACK UP

Severe Tire Damage!


Front Panel

WRONG WAY

STOP

SEVERE TIRE

DAMAGE

NO PEDESTRIANS

IN TRAFFIC LANE

Back Panel

1603-065-K-12-20

SECTION 9 - 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.

9.1 Maintenance

When servicing the gate operator, always check any external reversing devices (loops, photo eyes, 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.

If replacing arm, make sure warning decal is on both sides of arm.

When servicing this gate operator, always turn power OFF!! If equipped with batteries, make sure battery power switch is OFF .

If gearbox requires oil, use only Mobil SHC-629 Synthetic Gear Oil. Do not completely fill gearbox with oil. Gearbox is full when oil completely covers inspection window.

Monthly Interval

Arm ( s )

Operator

Component

Auto Spike System

Drive Belt ( s )

ERD Reversing System

Batteries

(On select models)

Convenience Open System

(Not on all models)

Fire Dept.

Maintenance

Check for alignment, tightness and wear.

Check for shaft alignment, tightness of hardware and wear of spikes. Make sure all tunnel plates and ramps are securely fastened to concrete.

Check for alignment, tightness and wear.

Check that the arm reverses on contact with an object in closing cycle. Adjust the reversing sensor if necessary.

If operator is equipped with optional convenience open system, check the batteries for any leakage or loose connections.

Batteries should be replaced every two years.

If operator is equipped with optional DC open system, check to be sure the system opens the arm upon loss of AC power.

Operator should resume normal operation when AC power has been restored.

Check emergency vehicle access device for proper operation.

1 6 12

✓ ✓

✓

✓ ✓

✓ ✓

✓

✓ ✓ ✓

✓ ✓

Gearbox

Linkages

Loop(s)

Pulleys

External Reverse

Device(s)

Complete System

1603-065-K-12-20

Check oil level and fill if necessary. Do not overfill.

Check internal linkages for wear. Inspect bushing for wear.

Check all external ground loops for proper operation.

Check set screw for tightness.

Check electric reversing edges and photo-cells for proper operation.

Perform a complete system check. Include all reversing devices, loops, access system devices, Fire Dept. access devices, etc.

✓ ✓

✓ ✓

✓

29

9.2 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 terminal.

1.

Use caution when checking high voltage areas: terminals 1 through 6, the motor capacitor and the motor.

2.

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 the arm up. Disconnect the keying devices one at a time until the LED goes OFF (see troubleshooting guide).

3.

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

4.

A malfunction in a loop or loop detector can cause the gate operator to hold the arm up, 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.

5.

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 arm, momentarily jumper across terminals 6 and 14 on the control board terminal. If the gate operator starts, this indicates that a problem exist with the keying device and not with the gate operator.

6.

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

9.3 Troubleshooting

30

Operator will not run.

Power LED is OFF.

• Check that power to the operator is turned ON.

• Check for 117 VAC with a voltmeter at control board terminals 1 and 2. If voltage measures 0,

check power supply to operator or check terminal strip. If voltage measures OK, replace control

board.

1603-065-K-12-20

9.3 Troubleshooting Continued

Operator will not run. Power LED is ON.

• Momentarily jumper terminal 6 to terminal 14. If input LED does not come ON, check terminal strip

or replace control board. If LED does come on, go to the next step.

Remove circuit board from the terminal strip and shutoff power to the operator:

1 Momentarily jumper terminal 2 to terminal 3 (Caution – High Voltage). Momentarily turn power ON.

The motor should run. Make sure power is OFF. Remove the jumper.

2 Momentarily jumper terminal 2 to terminal 4 (Caution – High Voltage). Momentarily turn power ON.

The motor should run. Make sure power is OFF. Remove the jumper.

• If motor does not run in either or both steps above, bad motor, motor capacitor or wiring to motor.

Arm rotates up, but will not rotate down.

• Check LEDs on terminals 6, 7 and 9. Any of these ON will hold the arm in the UP position. This

indicates a shorted input.

• Check the LEDs on the loop detectors. Any ON will hold the arm in the UP position. Possible loop or

loop detector problem.

• If auto timer is not used (SW1, switch 7 off ), check to be sure SW1, switch 6 is in the ON position.

This will cause terminal 6 to rotate the arm down when it is activated.

• Check to be sure SW1, switch 4 is ON. This will cause terminal 8 activation, then deactivation to

rotate arm down.

Down input / down loop will not rotate arm to down position.

• Check to be sure SW1, switch 4 is in the ON position.

• Down input must be activated, and then deactivated to cause arm to rotate down.

Loop detector LED is on continuously.

Loop detector LED never activates.

• Activate the reset switch on the loop detector.

• Decrease loop detector sensitivity.

• Check loop wire for resistance to ground with meg-ohm meter. Should be 100 meg-ohms or higher.

If less than 50 meg-ohms, replace loop wire.

• Be sure loop lead-in wire is twisted at least 6 turns per foot.

• Be sure all loop connections are soldered.

• Replace loop detector.

• Increase loop detector sensitivity.

• Check continuity of loop wire. Should be 0 ohms. If continuity check indicates anything other than

0 ohms, check all connections. Replace loop wire.

• Move loop detector board to the other loop detector port on the control board, and then check loop

operation. If loop detector still fails, replace loop board.

• If loop detector operates OK in the other loop port, replace control board.

Battery back-up system will not raise arm upon power outage.

• Check that the back-up system toggle switch is in the ON position.

• Check to be sure that the 1473-010 battery back-up control board switch settings are set as

described in SECTION 7.

• Check the batteries for proper voltage, replace if necessary.

• Replace the 1473-010 Back-up control board.

Operator has intermittent functionality problems that vary.

• The main terminal #5 250 mA power has been exceeded.

Check total amp draw of connected device(s).

1603-065-K-12-20 31

32

9.4 Accessories Parts List

The following accessories are available for the 1603 barrier gate operator.

Plug-In Loop Detector - Plug directly into ports on circuit board simplifying wiring.

P/N 9410-010 - Single channel detector.

P/N 9409-010 - Two channel detector.

P/N 9411-010 - Single channel detector with aux relay. Controls arm lowering for vehicles but NOT for pedestrians.

P/N 9416-010 - Single channel low power draw detector

P/N 9415-010 - Dual channel low power draw detector

Loop Wire - XLPE insulation is available in 500 and 1000 foot rolls, available in Black, Blue and Red insulation.

Loop Sealant - P/N 2600-771 Asphalt, P/N 2600-772 Concrete

Meg Ohm Meter - Checks the integrity of ground loops. P/N 9401-045

Reverse Edge Installs on the bottom of a ROUND aluminum arm ONLY .

P/N 8080-071 - 2-wire 6 ft.

P/N 8080-091 - 4-wire 6 ft.

Photo Cell - Prevents arm from lowering on vehicles or pedestrians.

DoorKing Model 8080-057 Retro-Reflective Photocell

Miller Edge Reflective-Guard Model RG

Miller Edge Prime-Guard Model PG

EMX Industries Model IRB-MON

EMX Industries Model IRB-RET

Omron Model E3K-R10K4

Seco-Larm Model E-936-S45RRGQ

Seco-Larm Model E-960-D90GQ

Time Clock - 7 clock, used to automatically open gate at pre-set time, fits inside operator.

P/N 2600-791 - 7 day clock

Surge Devices - Helps prevent circuit board failure caused by lightning strikes and power surges.

P/N 1879-080 - High Voltage

P/N 1878-010 - Low Voltage

Replacement Battery - Convenience open system. P/N 1801-009 (2 required)

Speed Bump - Prefabricated 6-foot speed bump reduces traffic speed through gate system. P/N 1610-150

115 VAC Heater Kit - Thermostatically controlled heater for cold environment.

Note: This heater kit only works with a 115 VAC Input power wire on the barrier gate operator. P/N 1601-092

208/230 VAC Heater with Fan Assembly Kit - Thermostatically controlled heater and fan for cold environment.

Note: This heater kit only works when installing a High Voltage Kit with 208 or 230 VAC Input power wire on the barrier gate operator.

460 VAC Heater with Fan Assembly Kit - Thermostatically controlled heater and fan for cold environment.

Note: This heater kit only works when installing a High Voltage Kit with 460 VAC Input power wire on the barrier gate operator. P/N 1601-198

Fan Kit - Thermostatically controlled fan for hot humid environments. P/N 1601-093

Manual Gate Control Toggle - Allows user to manually operate gate arm. Fits inside single-gang electrical box. P/N 1200-017

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

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

High Voltage Kit - Alter the input AC voltage on a 115 VAC 1603 to 208, 230, 460 or 575 VAC. P/N 2600-266

Gate Tracker™ - Optional control board allows the barrier gate operator to report activity to a companion 1833, 1835, 1837 or 1838 access control system.

Auto Spike System Parts

Operator Extension Section - 1.5 Ft torsion shaft, tunnel plate and ramp. P/N 1603-168

Extension Section - 1.5 Ft extension shaft, tunnel plate and ramp. P/N 1603-170

Spike Section - 3 Ft spike shaft, tunnel plate and ramp. P/N 1603-165

End Cap - P/N 1610-240

Lighted Auto Spike Warning Sign - Backlit spike warning sign with adjustable light for spike illumination. P/N 1615-081 - Auto Spikes

LED Traffic Light (Red, Green) - Manage the traffic flow with LED red-green lights. Bolts onto the 1601 or 1602 operator.

P/N 1603-221 - 6 Ft Cable with NO Post



Part numbers for 1603 arm kit “Options” are on the 1603 Specifications page.

1603-065-K-12-20

1/2 HP 115 VAC

UP

LOOP

Up Limit

Magnet

TIME

DELAY

Magnetic

Limit Sensor

Chassis Ground

NEU HOT

115 VAC

1601

POWER

REVERSE

SENSITIVITY

DOWN

LOOP

Current Sensor NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Black

Black

Com

Power

Neutral

Yellow

Orange

Ground

1603-065-K-12-20

AC Power UP/Auto/Down

33

1/2 HP 115 VAC / Convenience Open

1473-010

ON

1 2 3 4

UP

LOOP

Red

1 2 3 4 5 6 7 8 9 10

Up Limit

Magnet

TIME

DELAY

Magnetic

Limit Sensor

Black

Red

Black/White

Chassis Ground

Purple

Green

White

Orange

Yellow

115 VAC

NEU HOT

1601

POWER

REVERSE

SENSITIVITY

DOWN

LOOP

NC NO

Current Sensor

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Com

Black

Black

Power

Neutral

Purple

Blue

Red

34

Ground

AC Power DC Power UP/Auto/Down

1603-065-K-12-20

Wiring Traffic Light AND Octagon Reverse Edge/LED Arm




MAKE SURE ALL POWER IS TURNED OFF TO OPERATOR!

1603-065-K-12-20

UP

LOOP

1601-010

POWER

REVERSE

SENSITIVITY

TIME

DELAY

LED Traffic

Light Kits

Sold Separately

P/N 1603-223

11 Ft Cable/95” Post

P/N 1603-222


P/N 1603-221

6 Ft Cable/No Post

Traffic Light

Terminal

Red/

Brown

White

White

Octagon Arm

Reverse Edge/Red-Green LED Lights

Sold Separately

Choose




Reverse Edge + Red/Green LED (Required) P/N 8080-096

Keep wire harnesses clear of all moving parts.

Traffic

Light

Cable

Wire Guard

DOWN

LOOP

Arm Relay

Contacts

C NC NO

NC NO

NO - Open - GREEN Wire

NC - Close - RED Wire

C - Common - WHITE Wire (-)

BLACK Wire (+)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ON ON UP

OFF

AC POWER

OFF

DC POWER

DOWN

AUTO

115 VAC

Convenience

Outlet

NO - Open - GREEN Wire (Green LED)

NC - Close - ORANGE Wire (Red LED)

C - Common - WHITE Wire

Terminal 14 - Yellow Reverse Edge

Terminal 9 - Yellow Reverse Edge

Wire

Harness

(1601-345)

RED Wire (+)

BLACK Wire (-)

12 VDC

Connect RED and BLACK power wires from 1601-345 wire harness on the arm to the 2-Pin power terminal on the traffic light as shown (+ to + and - to -).

Both can be powered by ONE 12 VDC transformer.

+

2-Pin

Traffic

Light

Power

Terminal

12 VDC transformer

3 5

Wiring Traffic Light AND Round Aluminum LED Arm




MAKE SURE ALL POWER IS TURNED OFF TO OPERATOR!

36

UP

LOOP

TIME

DELAY

LED Traffic

Light Kits

Sold Separately

P/N 1603-223


P/N 1603-222


P/N 1603-221

6 Ft Cable/No Post

Traffic Light

Terminal

Red/

Brown

White

White

Round Aluminum LED Arm

Sold Separately

14 Ft Aluminum LED Arm Only P/N 1601-518


Aluminum LED Arm Wire Harness

Kit (Required) P/N 1601-535

1601-010

POWER

Keep wire harnesses clear of all moving parts.

REVERSE

SENSITIVITY

Traffic

Light

Cable

Wire Guard

DOWN

LOOP

Arm Relay

Contacts

C NC NO

NC NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ON ON UP

OFF

AC POWER

OFF

DC POWER

DOWN

AUTO

115 VAC

Convenience

Outlet

NO - Open - GREEN Wire

NC - Close - RED Wire

C - Common - WHITE Wire (-)

BLACK Wire (+)

Not Used

Black Wire

Red Wire

Wire Harness

(1601-535)

RED Wire (+)

BLACK Wire (-)

12 VDC

Connect RED and BLACK power wires from 1601-535 wire harness on the arm to the 2-Pin power terminal on the traffic light as shown (+ to + and - to -).

Both can be powered by ONE 12 VDC transformer.

+

2-Pin

Traffic

Light

Power

Terminal

12 VDC transformer

1603-065-K-12-20

1603-065-K-12-20 37

Installation/Owner’s Manual

Barrier Gate Operator with Auto Spike System

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

1603-065-K-12-20

THIS PRODUCT IS TO BE INSTALLED AND SERVICED BY A TRAINED GATE SYSTEMS TECHNICIAN ONLY.

Visit www.dkslocator.com

to find a professional installing and servicing dealer in your area.

www.doorking.com

DoorKing, Inc.

120 S. Glasgow Avenue

Inglewood, California 90301

U.S.A.

Phone: 310-645-0023

Fax: 310-641-1586

Copyright 2009 DoorKing, Inc. All rights reserved.

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