Sliding Gate Opener Model: DKC400Y Installation Manual WARNING Read and thoroughly understand all instructions before installing or operating this automatic gate opener. Failure to do so may cause serious injury or death. This gate opener produces a high level of force. Stand clear of the gate opener during operation and always be aware of the hazards associated with it. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 1 of 22
Table of Contents IMPORTANT READ THIS FIRST... 3 SAFETY... 3 PRELIMINARY CHECKS... 3 2. Main features... 4 3. Main technical parameters... 5 4. Working principle and main structure... 5 Installation... 6 Gate preparation... 6 Conduit Pipes... 6 Concrete pad... 7 Anchors... 7 Operator... 7 Installation of tracks (see Fig.3)... 8 Magnets for limit switch... 8 6. Connecting... 9 Wiring notes for control board... 11 Control... 13 Adding extra remote controls (Learn):... 14 Erase remote controls:... 14 Verify open direction... 15 Set auto-close function... 15 Cancel auto-close function:... 16 Pedestrian mode:... 16 Set width of pedestrian mode:... 16 Set auto-close function of pedestrian mode:... 17 Cancel both the width and the auto-close function of pedestrian mode:... 17 Cancel the width of pedestrian mode, but keep the auto-close function of pedestrian mode:... 18 Keep the width of pedestrian mode but cancel the auto-close function of pedestrian mode:... 18 Adjustment of the auto-reverse function:... 19 Check... 19 Maintenance... 20 Troubleshooting guide... 21 Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 2 of 22
IMPORTANT READ THIS FIRST WARNING This gate is dangerous if installed or used improperly. STAY AWAY FROM THE GATE WHILE IT IS OPERATING. The gate can crush hands, fingers or toes, knock over persons in the vicinity, and cause death if used improperly. KEEP CHILDREN AND ADULTS WITH MENTAL IMPAIRMENTS AWAY FROM THE GATE. Children and adults with mental impairments, who may not recognize the obvious dangers, are at particular risk and must be kept away from moving parts of this gate. Damage to the gate or improper installation or maintenance could cause additional hazards. NEVER USE THE GATE IF IT IS DAMAGED. SAFETY This booklet will offer you information you may need to install your gear motor and to safeguard your safety. However, caution is unquestionably indispensable and nothing is better than preventing accidents. WARNING: any repair or adjustment of working machinery is strictly prohibited unless all the necessary precautions (electrical supply disconnected and motor off) have been taken in order to avoid possible accidents. WARNING: any repair must be carried out by qualified people. WARNING: All moving mechanisms must be provided with suitable protections. WARNING: Keep the automatic controls out of the reach of children. WARNING: Command pulses must be given from positions where the gate is visible. WARNING: Use transmitters only if you can see the gate. Read carefully the instructions enclosed in this manual. Keep this booklet in a suitable place well known to all interested people. PRELIMINARY CHECKS The following gate characteristics should exist for the opener installation to be successful: The gate must be balanced You must be able to carry out manual closing and opening of the gate without any effort. Make sure that the gate has a solid structure and that there is no friction points in its movement. The weight of the gate should not exceed 600kg. Turn off all power to the gate opener until installation is completed. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 3 of 22
2. Main features The device is used to drive a sliding gate. Stop and reverse function if the gate is obstructed during operation. Supports up to 100 remote controls. User programmable and user erasable remote codes. Infrared terminal (N.C) is supplied to use. Auto-close function Pedestrian mode. Manual key release design for emergency purposes. Integrated control board for easier installation The gate opener can be integrated with an alarm lamp, photocell and other security devices. Soft start and soft stop functions to minimise wear and tear on your gate and gate hardware and ensure quiet and safe operation. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 4 of 22
3. Main technical parameters Model Name DKC400Y Power supply: 220V ~240V Motor speed: Gate moving speed (output gear 24 teeth) Gate moving speed (output gear 19 teeth) Output torque Max. gate weight Remote control range Remote control frequency Working temperature Limit switch Remote Control Auto Close Time Noise Working Time 1400r/min 14m/min 11m/min 14N.m 600kg 30m 433.92mHz -10 C ~ +55 C Magnetic or Spring limit switch Single Button Mode 0~45 sec less than 62dB 90 sec 4. Working principle and main structure The device is composed of a single-phase motor, worm and worm gear. The main shaft of the motor rotates the worm with the clutch engaged; the worm rotates the worm gear and output gear, which pushes the rack attached to the sliding gate, thus moving the gate. The device is equipped with a thermal protector; the thermal protector will switch off the motor automatically when the temperature exceeds 120 C and will switch on the motor when the temperature drops to around 85 C. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 5 of 22
Installation This gate opener is a rack driven operator which works by forcing a rack past the driving gear. An illustration is shown in Figure 1 below. The gate operator should be installed on the inside of the gate. Gate preparation Be sure the gate is properly installed and slides smoothly before installing the gate operator. The gate must be plumb, level, and move freely. Manually open and close the gate, checking for any friction points. Fig.1 Conduit Pipes PVC conduit pipes should be used to protect electrical cabling. Ideally, the conduit pipes should be set into the concrete when it is poured. Ensure that all cables are protected from sharp or rough objects to avoid any damage. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 6 of 22
Concrete pad The base of the unit should be installed on a concrete slab/pad to ensure proper stability. The concrete pad should be approximately 300mm x 200mm x 200mm deep to ensure proper operation. Anchors You can use the anchors, bolts, washers and nuts that are provided with the operator. These anchors must be set into the concrete when it is poured. You can also use other ground anchors such as Dynabolts to install in existing concrete. Operator In locations where frost occurs, mount the gate operator on an installation pad as shown in Fig.2. Check the operator and make sure it is lined up with the gate. Gate operator Gear Nut Spring washer Plain washer Nut Anchor Bolt Installation pad Conduit Wires Fig.2 Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 7 of 22
Installation of tracks (see Fig.3) Fix the three nuts (included with the metal tracks) on the rack element. Lay the first piece of track on the gear and weld the first nut on the gate. Move the gate manually, checking making sure the track isn t resisting movement at the gear, and weld the second and third nut. Place the second metal track near the first one. Move the gate manually and weld the three nuts as per the first track. Repeat until the gate is fully covered. When the rack has been installed, ensure that it rolls smoothly on the driving gear. The space between rack and gear should be about 1mm. Fig.3 Magnets for limit switch For added safety, it is recommended that limit devices such as a ground stop be placed at both ends of the gate to prevent the gate from sliding out of its rails. This is only a precaution; the gate operator actually uses a magnetic limit switch to control the open and closed positions of the gate. Install the magnet as shown in Fig.4 and Fig.5. Release the gear clutch and push the sliding gate manually to pre-determine the positions of the limit switch magnets. Fix the magnet brackets to the rack and tighten the gear clutch. The lower bracket is used as the opening limit switch and should be installed on the rack for the open position. Similarly, the higher magnet is for the closed position. Adjust the position of gate operator, the magnet should be 10~15mm away from the magnetic limit switch to work correctly. Now open and close the gates via the operator. Make final adjustments to the position of the magnets to ensure that your open and closed gate positions are correct. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 8 of 22
122mm DKC400Y AC Sliding Gate Installation Manual Magnet 10-15mm Magnetic limit switch inside Gate Nut Rack Gear Guide rail Fig.4 Fig.5 6. Connecting Make sure that the power is OFF before making any electrical connections. Perform the wiring (See Fig.6 and wiring notes for control board). Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 9 of 22
Fig.6 Control board scheme Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 10 of 22
Wiring notes for control board 1. Power switch: ON/OFF 2. Fuse: DKC400Y: 5A, Ø5x20 /DKC400UY: 10A, Ø5x20 3. Antenna: ANT 4. Beeper: DC12V 5. Dip-switch 6. Memory Card: 93C66 7. MCU: PIC 16C57C 8. Three button switch / single-button switch (keypad): Three-button switch (normally open, three-button mode): T (Stop), G (Close), K (Open), (Common) T G N.O. K OPEN CLOSE STOP MON Button switch K G T Control board terminal X10 Schematic diagram Wiring diagram Single-button switch / Keypad (normally open, single-button mode): T (Not used), G (Open priority), K (Open/stop/close), (Common) To install the keypad attach one lead of your keypad to K of terminal X10 and the other to the. The keypad will function in single channel mode. G NO com K NO com Not used Open Signal Com Button switch keypad T G K Control board terminal X10 Schematic diagram Wiring diagram Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 11 of 22
9. Limit switch: CL (Close limit), CO (Com), OP (Open limit),dc12v (Output power supply) CL CL OP N.O. (For N.O. limit switch) N.C. (For N.C. limit switch) OP Limit switch mode is adjustable by DIP-switch. (See table 1) Schematic diagram Motor wiring terminal RELEASE CLOSED OPEN SWITCH REED SWITCHES /U V MOTOR W Control board CL X9 OP U C V C W E Wiring diagram 10. Output power supply: +12V (DC +12V), (CO), DET (Loop detector), I.R. (Infrared N.C) GND +12V Out I.R +12V Terminal X8, No.10 AC24V Out I.R Terminal X8, No.10 AC24V Terminal X5,No.11 Infrared Control board Infrared Control board Infrared with DC input Infrared with AC input GND +12V Out DET +12V Terminal X8, No.10 AC24V Out DET AC24V Terminal X8, No.10 Terminal X5,No.11 Loop detector Control board Loop detector with DC input Loop detector Control board Loop detector with AC input Schematic diagram Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 12 of 22
11. Output power supply: AC24V 12. Power Indicator: LED 13. Learn button: AN 14. Force Adjustor (VR1): Clockwise +, Counterclockwise 15. Power Transformer: DKC400Y: 220V/12Vx2 / DKC400UY: 110V/12Vx2 16. Sampling Transformer: 110V/8.8V 4W 17. Alarm Lamp: DKC400Y:AC220V / DKC400UY:AC110V 18. Motor Capacitor 19. Motor: U (com), V (Positive direction), W (Opposite direction), E (grounding), Motor wiring terminal RELEASE CLOSED OPEN /U V W SWITCH REED SWITCHES MOTOR Control board CL OP U C V W E C X2 Wiring diagram 20. Power Input: E (Earth), L (Live), N (Neutral) DKC400Y: AC220 / DKC400UY: AC110V Control The remote control works in a single channel mode. It has four buttons. See Fig.7 remote control. The function of button 1, button 2, and button 3 are the same. With each press of the remote control button which has been programmed, the gate will close, stop, open or stop cycle. Button 4 is available for pedestrian mode. You can program/learn button 1, button 2 and button 3 individually. You also can program/learn two buttons or three buttons together, but you need repeat the program/learn process if you want to use more than one button. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 13 of 22
Button 1 Button 2 Button 4 Button 3 Fig.7 Remote control Adding extra remote controls (Learn): Press the button AN (See Fig.6 terminal 13) on the control board, then the LED2 will flash once, the beeper will ring for about 1 second. Then press the remote control button which you want to use, the LED2 will flash on and off again and the beeper will ring for about 2 seconds. The learning process is finished. Up to 100 remote controls may be used. Erase remote controls: To erase all existing remote controls, press and hold AN button, the beeper will ring, release the button once the beeper stops ringing. This indicates that all the remote controls have been erased completely. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 14 of 22
Verify open direction: If the gate does not move in the desired direction, then you will need to reverse the motor operating direction. Open the black plastic case and exchange wires V with W, and also exchange wires OP with CL. Table 1 DIP-switch (See Fig.6 terminal 5) Position DIP-switch Function 1 ON OFF Limit switch mode is NC. Limit switch mode is NO. 2 3 ON OFF ON OFF Auto-close function and auto-close function of pedestrian mode are available. Both Auto-close function and auto-close function of pedestrian mode are shut off. Programming / In this position the control board is in programming condition, DO NOT leave it in this position for normal operation. Normal / In this position the control board can be normally used. Set auto-close function This feature can be selected to make the gate stay open for some seconds before it automatically closes. The auto-close time can be adjusted to between 0 and 44 seconds Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press the remote control button (button 1, button 2 or button 3) that has been programmed to open the gate (see Verify open direction section). Stop the gate at any position by pressing the same button, pause for how long you want your gate to stay open before automatically closing. This is called the autoclose time. The range is between 0-44 seconds. Close the gate by pressing the same button. Press the button again to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 15 of 22
After this setup is complete, return DIP-switch 3 to OFF position immediately. The auto-close function has now been set. Cancel auto-close function: Please turn the second and the third DIP-switch (see Fig.6 terminal 5) to the ON position. Press the remote control button (button 1, button 2 or button 3) that has been programmed to open the gate (see Verify open direction section). Stop the gate at any position by pressing the same button, wait until the gate closes automatically (45 sec.). Press the same button to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. Thus the auto-close function has been canceled. Pedestrian mode: Pedestrian mode can be used to open the gate partially to allow pedestrian traffic to enter. Set width of pedestrian mode: Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press button 4 to open the gate (see Verify open direction section), Wait until the gate travels the distance you want to set for pedestrian mode (the range is between 0.3m-1.5m or 3-10 sec.) Then press the same button/button 4 to stop the gate, pause for a few seconds and close the gate by pressing the same button/button 4. Press the same button again to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. The width has been set for pedestrian mode. If you open the gate with button 4, the gate will stop at the position you have set above. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 16 of 22
Set auto-close function of pedestrian mode: Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press button 4 to open the gate (see Verify open direction section), wait between 3-10 seconds, then press the same button/button 4 to stop the gate. Now pause for however long you want your gate to stay open before automatically closing. This is called the auto-close time for pedestrian mode. The range is between 1-44 seconds. Close the gate by pressing the same button/button 4. Press the same button again to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. The auto-close function of pedestrian mode has been set Note: the new width of the pedestrian mode entry has been re-programmed in the device and replaced the original width you have set in the Set width of pedestrian mode section earlier. If you open the gate with button 4, the gate will stop at the position you have set, and after pausing for the time you have set, it will close automatically. Cancel both the width and the auto-close function of pedestrian mode: Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press button 4 to open the gate (see Verify open direction section). Wait for more than 15 seconds. Then press the same button/button 4 to stop the gate. Wait until the gate closes automatically (45 sec.). Press the same button/button 4 to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 17 of 22
Both the width and the auto-close function of the pedestrian mode have been erased. Cancel the width of pedestrian mode, but keep the auto-close function of pedestrian mode: Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press button 4 to open the gate (see Verify open direction section). Wait for more than 15 sec. Then press the same button/button 4 to stop the gate. Pause for how long you want your gate to stay open before automatically closing. The range is between 0-44 seconds. Then press the same button/button 4 to close the gate. Press the same button again to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. Note: the new auto-close time for pedestrian mode has replaced any auto-close time for pedestrian mode that you might have set earlier. Keep the width of pedestrian mode but cancel the auto-close function of pedestrian mode: Please turn the second and the third DIP-switch (See Fig.6 terminal 5) to the ON position. Press button 4 to open the gate (see Verify open direction section). Wait until the gate travels the distance you want to set for pedestrian mode (the range is between 0.3m-1.5m or 3-10 sec.) Press the same button/button 4 to stop the gate. Wait until the gate closes automatically (45 sec.). Press the same button again to stop the gate or let the gate stop at its closed position automatically if the limit switch is reached. After this setup is complete, return DIP-switch 3 to OFF position immediately. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 18 of 22
You are finished, the width for pedestrian opening has been preserved, but the autoclose function has removed. Note: the new width for pedestrian mode has replaced any previous pedestrian mode opening width which you might have set. Adjustment of the auto-reverse function: Rotate the VR1 knob (See Fig.6 terminal 14) with a screwdriver, the resistance can be increased (or decreased) by rotating clockwise (or counterclockwise). If you turn the variable resistor clockwise it will increase the sensitivity. If you turn the variable resistor counterclockwise, it will decrease the sensitivity. If the gate fails to top in the event of an obstruction, this means that the sensitivity has not been adjusted properly. For example if the gate fails to stop, the sensitivity might not be high enough to recognize that there is an obstruction. Note: Please exchange wires V and W if the auto-reverse direction is wrong. Exchange wires OP and CL if the limit direction is wrong. Check Check the power supply, grounding and wiring before running the device. Release the gear clutch with the release key to determine whether or not the gate can be moved manually. If everything is in good working order, tighten the clutch with the key. Switch on the power and run the device to ensure that the gate is sliding smoothly. Adjust the magnet position until the gate opens and closes properly at the intended positions. The motor is only designed to work for less than 5 minutes. If is runs continually for an extended period of time, a thermal protector shut off power to prevent damage. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 19 of 22
Maintenance Keep operator clean at all times. Ensure the operator is well earthed, and correctly terminated. Regularly grease the wheels and axles to ensure the gate moves smoothly. Ensure the power is switched off before removing the cover. Troubleshooting guide (next page) Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 20 of 22
Troubleshooting guide Trouble Possible causes Solutions Motor only runs in one direction. By pressing button 1(button 2 or button 3) which has been programmed to open the gate, press the same button again to stop the gate in required position, but the gate will automatically close immediately. When you use button 4 of remote control to open the gate, the gate doesn t open far enough When you use button 4 of remote control to open the gate, but the gate will automatically close immediately. The gate will not open or close. The wire connector terminal block has becomes loose. The limit switch wire connector terminal block has becomes loose. The electric component on the control board such as Q2, Q91 or Q92 may be damaged. The auto-close time is too short. The opening length set for pedestrian mode is not wide enough. The auto-close time of pedestrian mode is too short. The limit switch wire connector terminal block has becomes loose. Connecting wires or terminal blocks have become loose. The electric component on the control board such as Q2, Q91 or Q92 may be damaged. Power switch is OFF Check the wire connector terminal block make and sure it is plugged in terminal block 10, X8. Check the limit switch wire connector terminal block and make sure it is plugged in terminal block 9, X9. Check the limit switch mode. Replace the electric component Q2, Q91 or Q92 (BTA16/600) or replace the board. Reset the auto-close time. See Set auto-close function section. Reset the width for pedestrian mode. See Set width of pedestrian mode section. Reset the auto-close time for pedestrian. See Set auto-close function of pedestrian mode section. Check the limit switch mode (see table 1 DIP-switch). Check the connecting wires and terminal blocks. Replace the electric component Q2, Q91 or Q92 (BTA16/600) or replace the board. Make sure power switch is ON. Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 21 of 22
Remote control does not work When you open the gate by using button 1(button 2 or button 3) which has been programmed, the gate will stop in mid way or reverse before reaching the fully open position The remote control operating distance is too short. The indicator light of remote control does not light. Remote control is not suitable for receiver. Broken receiver board The Force Adj. (VR1) (autoreverse function knob) is set too low, making it extremely sensitive Gate is obstructed. Signals are shielded by the gate. Check the batteries on your remote control After making sure the codes are correct, erase remote controls and then re-program the codes in the device. See Adding extra remote controls (learning) section. Replace receiver board. Check the Force Adj. (VR1). Adjust VR1 to decrease sensitivity. Remove the obstruction. Link a new antenna (1~1.2m BVR 0.75mm 2 ) to the old antenna. Then fix the antenna on the wall vertically, make sure the total height from the top of antenna to the ground is approx. 1.5m. COPYRIGHT 2009 SOLAVIS WWW.SOLAVIS..AU 2/28 ASSEMBLY DRIVE TULLAMARINE VICTORIA 3043 Copyright 2008 SOLAVIS Doc: DKC400Y Installation Manual v1.1 page 22 of 22