Installation/Owner’s Manual 1603 Barrier Gate Operator with Auto Spike System Use this manual for circuit board 1601-010 Revision V or higher. 1603-065-N-7-11 Date Installed: Installer/Company Name: Circuit Board Serial Number and Revision Letter: Phone Number: Leave Manual with Owner Copyright 2011 DoorKing, Inc. All rights reserved. TM UL 325 Compliant Copyright 2009 DoorKing, Inc. All rights reserved.
1603 SPECIFICATIONS Use this manual for the Model 1603 operators with circuit board 1601-010 Rev V or higher ONLY. Class of Operation Model 1601 - UL 325 Class II, III, IV – ETL Listed Type of Gate Single Traffic Lane Vehicular Barrier Gate Only Arm Types Aluminum – Straight or Folding Arm Max Arm Length 14 Ft. Max Spike Length 12 Ft. Gate Cycles High Cycle Speed 90° in approximately 1.5 seconds Primary Entrapment Protection 38.
TABLE OF CONTENTS SPECIFICATIONS Safety Information for Vertical Barrier Arm UL 325 Entrapment Protection SECTION 1 - INSTALLATION OF OPERATOR 1.1 1.2 1.3 1.4 Operator Positioning and Conduit Requirements Concrete Pad Requirements Mount Operator Dual Operator Installation (Primary/Secondary) SECTION 2 - WIRING 2.1 2.2 2.3 2.4 High Voltage Wire Runs High Voltage Terminal Connections Main Terminal Description Control Wiring SECTION 3 - INSTALLATION OF AUTO SPIKE SYSTEM 3.1 3.2 3.3 3.
Safety Information for Vertical Barrier Arm 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 • Do not install the operator in such a way that the arm moves within 2 feet of a rigid object.
UL 325 Entrapment Protection Class I Class II A vehicular gate operator (or system) intended for use in a home of one-to four single family dwelling, or a garage or parking area associated therewith. A vehicular gate operator (or system) intended for use in a commercial location or building such as a multi-family housing unit (five or more single family units) hotel, garages, retail store or other building servicing the general public.
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.
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. Sections can be connected in different configurations for specific applications. It is recommended that the “Spike” sections not exceed 12 feet (Four 3-Ft spike sections) for proper operation.
1.4 Dual Operator Installation (Primary/Secondary) For use in areas needing more than four 3-Ft sections of spikes (12 ft.) in a traffic lane. Up to eight 3-Ft spike sections (24 feet of spikes) can be used with dual operators. Primary Spike Shaft Primary Operator Install dual operators the same as installing two single operators except for: • There are no end cap sections used. • For spike sections to align, secondary operator will be offset 3.5” from the primary operator.
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.
2.3 Main Terminal Description NC NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Low Voltage Common 7 ON Function is dependent on the setting of programming SW 1, switch 5. When switch 5 is OFF, activation of the down loop will activate the relay. When switch 5 is ON, activation of the UP loop will activate the relay. SW 1 Relay contacts can be set for Normally Open (NO) or Normally NO Closed (NC) C N operation. Contact rating is 1 amp maximum at 24 Volts.
2.4 Control Wiring for Single/Primary Operator TIME DELAY UP LOOP 1 2 3 4 5 6 7 8 ON Terminal 6 required only if the tracker board will activate the gate operator. Refer to the manual 2351-065 for detailed information. POWER 1 2 3 4 5 6 7 8 1601 Gate Tracker (Quad Box Shown) ON DoorKing Access Control System (Model 1833, 1835, 1837 or 1838) tracker system can be connected.
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. Spike shaft restraining guide. Operator shaft extends 1/2 the length of the connector shaft. Connector Shaft Tunnel Plate Extension Shaft Extension shaft is the same length as its tunnel plate and WILL slide back and forth for adjustment.
3.2 Assemble Shafts Operator must be in the Down arm position for the spikes to be UP 90°. tor ra pe O 4B A connector shaft must be installed between certain sections with 8 bolts as shown. Ext en Sh sion aft olt s 4B olt Sp Shike aft s Co nn Shector aft 8B Sp Shike aft olt s Nylon Guide 3.3 Test Spikes DO NOT anchor the tunnel plates to the concrete until the spikes have been tested and they operate smoothly.
3.3a Adjust Spikes If Necessary Spikes can now be adjusted to the vertical position. Replace the chain back into lower sprocket and tighten turnbuckle after spikes are vertical. Vertical With operator in the Down arm position, loosen turnbuckle on crossed chain to release chain from the lower sprocket. 3.4 Secure Tunnel Plates and Ramps to Concrete Sleeve Anchor (Cut off excess threads flush with top of nut).
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.
4.2 Exit Lane Only ON Single Channel 1 2 3 4 5 6 7 8 A SW 1, switch 4 is ON. SW 1, switch 7 is OFF (Timer). The arm will rotate down after the vehicle clears the down loop. See note below. SW 1 TIME DELAY UP LOOP 1 2 3 4 5 6 7 8 ON A 9410 SW 1 1 2 3 4 5 6 7 8 POWER ON 1601 Speed Bump SW 2 Helps increase distance and time between vehicles. REVERSE SENSITIVITY DOWN LOOP Automatic Exit Loop (Free Exit) NC NO 9410 Single Channel 1 Ft.
4.3 Two-Way Traffic Lane 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 ON A 1 2 3 4 5 6 7 8 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. SW 1, switch 4 is ON. SW 1, switch 7 is OFF (Timer).
4.4 Ticket Spitter Entry Lane ON 1 2 3 4 5 6 7 8 A SW 1, switch 4 is ON. SW 1, switch 7 is OFF (Timer). The arm will rotate down after the vehicle clears the down loop. See note below. SW 1 TIME DELAY UP LOOP 1 2 3 4 5 6 7 8 ON A SW 1 POWER 1 2 3 4 5 6 7 8 1601 Com ON NO SW 2 REVERSE SENSITIVITY DOWN LOOP Down Loop 1 Ft. Minimum Distance NC NO 9409 Main Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Com NO Note: The timer can be used with a down loop.
4.5 Operator Timer ON Entry Lane (No Down Loop) ON 1 2 3 4 5 6 7 8 A TIME DELAY SW 1, switch 4 is OFF. Adjust from 1 second (full counter clockwise) to approximately 59 seconds (full clockwise). B SW 1, switch 7 is ON (Timer). The arm will rotate down after the timer has timed out. 1 59 SW 1 TIME DELAY B UP LOOP 1 2 3 4 5 6 7 8 ON A SW 1 POWER 1 2 3 4 5 6 7 8 1601 Com ON NO Reverse Loop SW 2 1 Ft.
SECTION 5 - ARM INSTALLATION The 14 ft. aluminum arm mounts on the left side of the operator (either straight or folding arm). 5.1 Mounting Hub Vertical Operator in the Down position. Ho rizo nta l Bolt Screw Hu Locking Plate b CO N AN FOR SI/ MS UL- TO 32 CA CER 5 N/C TI SA FIED C22 TO VE .2 HIC NO 53 . 24 CLA ULA 38 2 7 R SS GA TE MO OP DEL ER AT SER OR HP IAL VO LT Le S AM PS MA XG AT ft S Doo rK E LO AD ing, ide Inc. , PH AS E 60 Hz Ingl ew oo of Op d, CA era tor 5.
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 An automatic sensor system that senses entrapment of a solid object and is incorporated as a permanent and integral part of the operator.
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. Switch Function 1 Down Active when arm is full up.
Option 1 - Override a DOWN Command Remote transmitters are recommended for this option. Basic operator UP/DOWN cycle: 1 Valid UP command given. Access Control Device A. Valid UP command from the access control device will raise arm. 12 Ft. Maximum Distance B. Vehicle activating and clearing the down loop will lower the arm. Down Loop 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.
Option 2 - Override Multiple DOWN Commands SW2, Switch 3 ON Basic operator UP/DOWN cycle: 1 A. Valid UP command from the access control device will raise arm. 5 B. Vehicle activating and clearing the down loop will lower the arm. Down Loop 2 2 Operator will raise arm 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.
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°: Magnet Limit Assembly 1 Turn operator power OFF. ON This changes the rotation of the gearbox from 360° to 180° allowing the gearbox to rotate the arm less than 90°. Note: The arm will always cycle to 90° open with the 360° gearbox setting. 1 2 3 4 5 6 7 8 2 Set the DIP-switch SW 1, switch 3 to ON.
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.
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.
7.2 DC System Description Do Not Adjust Timer Not Used Do Not Adjust Charging LED Arm Rotation Assembly in UP Position 12 V 3 Amp/Hr Red/White – + Batteries 2340 DIP-Switches 12 V 3 Amp/Hr – + DC Motor Red Red/White Black/White Red Black DC Motor Negative Output DC Motor Positive Output Battery Negative Input Battery Positive Input 24 VAC Common 24 VAC Input Activation Output Radio Power Not used.
SECTION 8 - OPTIONAL ACCESSORIES INSTALLATION 8.1 Contact Sensor (Reversing Edge) In addition to the electronic reversing device (ERD) an optional electric reversing edge (P/N 8080-016) may be installed offering additional protection to the arm, operator and obstruction. Mo un Re ver tin gC han nel sin gE dg e 1 Turn operator power OFF. 2 Center and secure the 6-foot mounting channel to the bottom of the barrier arm using self-tapping metal screws (not supplied).
8.2 Fan Kit Threaded Housing Studs (Existing) An optional fan kit (P/N 1601-093) is recommended in hot humid climates to prevent heat and moisture build-up inside the housing. 1 Shut off AC power to operator. Turn off DC power switch on certain models. Lock Nut Mo Tabuntin g Lock Nut Lock Nut 3 Route fan wires as shown. Use supplied threaded studs and lock nuts supplied. Slide mounting tabs over existing air duct.
8.3 Heater Kit To avoid the gearbox oil from freezing an optional heater kit (P/N 1601-092) is recommended in areas where temperatures routinely drop below 40°F (4°C). 1 Shut off AC power to operator. Washer 2 Mount heater with 2 lock nuts. Turn off DC power switch on certain models. Threaded Housing Stud (Existing) Place the 2 supplied washers between the operator wall and the heater to create an air gap. Lock Nut 3 Route heater wires as shown. Use supplied wire stays and existing wire restrainers.
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 secondary (external) reversing devices (loops, photo eyes, etc.) for proper operation.
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.
9.3 Troubleshooting Continued Symptom Possible Solution(s) 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. • Momentarily jumper terminal 2 to terminal 3 (Caution – High Voltage). The motor should run. • Momentarily jumper terminal 2 to terminal 4 (Caution – High Voltage). The motor should run in opposite direction of above.
9.4 Accessories Parts List The following accessories are available for the 1603 barrier gate operator. Loop Detector - Plug directly into ports on circuit board simplifying wiring. P/N 94010-010 - Single channel detector. P/N 9409-010 - Two channel 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.
1/2 HP 115 VAC Up Limit Magnet TIME DELAY UP LOOP 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ON POWER ON 1601 Down Limit Magnet (White Dot) Magnetic Limit Sensor REVERSE SENSITIVITY DOWN LOOP NC NO Ground Current Sensor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Chassis Ground Com Power NEU HOT 115 VAC Neutral Blue Red 1/2 HP Single Phase Purple Yellow Orange Ground 1603-065-N-7-11 AC Power UP/Auto/Down 35
TIME DELAY UP LOOP – + 12 V 3 Amp/Hr Batteries DC Motor 1 2 3 4 5 6 7 8 ON DC Magnetic Up Limit Sensor 1 2 3 4 5 6 7 8 POWER ON 1601 Down Limit Magnet (White Dot) Magnetic Limit Sensor Red DC Up Limit Magnet 12 V 3 Amp/Hr 2340 Up Limit Magnet Red/White – + 1/2 HP 115 VAC / Convenience Open REVERSE SENSITIVITY DOWN LOOP Red Black/White Ground Current Sensor NC NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Chassis Ground Com Power NEU HOT 115 VAC Neutral Purple Green White Orange Yellow
1/2 HP 230 / 460 VAC Up Limit Magnet TIME DELAY UP LOOP 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ON POWER ON 1601 Down Limit Magnet (White Dot) Magnetic Limit Sensor REVERSE SENSITIVITY DOWN LOOP NC NO Ground Current Sensor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Chassis Ground Com Power HOT HOT NEU NEU HOT 230 / 460 VAC Neutral Yellow Orange Purple Blue Red To Blue Blue 230 VAC Blue Ground AC Power 1603-065-N-7-11 Blue Black UP/Auto/Down Brown White Black/White To White Blue Black To Blue
TIME DELAY UP LOOP – + 12 V 3 Amp/Hr 1 2 3 4 5 6 7 8 ON DC Motor 1 2 3 4 5 6 7 8 POWER ON 1601 DC Magnetic Up Limit Sensor Down Limit Magnet (White Dot) Magnetic Limit Sensor Red Batteries DC Up Limit Magnet 12 V 3 Amp/Hr 2340 Up Limit Magnet Red/White – + 1/2 HP 230 / 460 VAC / Convenience Open REVERSE SENSITIVITY DOWN LOOP Red Black/White NC NO Ground Current Sensor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Chassis Ground Com Power HOT HOT NEU NEU HOT 230 / 460 VAC Neutral Purple G
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Installation/Owner’s Manual 1603 Barrier Gate Operator with Auto Spike System Use this manual for circuit board 1601-010 Revision V or higher. 1603-065-N-7-11 www.doorking.com DoorKing, Inc. 120 Glasgow Avenue Inglewood, California 90301 U.S.A. Phone: 310-645-0023 Fax: 310-641-1586 Copyright 2009 DoorKing, Inc. All rights reserved.
