INSTALLATION AND OWNER’S MANUAL GATE STAR 4000 Model GS4000 - Heavy Duty Commercial Vehicular Swing Gate Operator 104950 Serial #: READ THIS MANUAL Date Installed: CAREFULLY BEFORE Your Dealer: New - Allstar’s CGA2K™ TECHNOLOGY! Meets all March 1, 2000 UL325 requirements.
TABLE OF CONTENTS Pre-Installation Notes................................................... 3 Operator Class Designation ................................... 3 Section A: Gate System Design/Installation ............. 4 Section B: Preparing the Site ..................................... 6 The Concrete Operator Pad.................................... 6 Placing the Vehicle Detector Loops ..................... 6 Electrical Power Requirements.............................. 8 Section C: Installing the Operator ....
PRE-INSTALLATION NOTES The Allstar Gate Star 4000 (GS4000) Vehicular Gate Operator will provide convenience and assurance to the ultimate users for many years. It is ruggedly built of the finest materials and has been thoroughly inspected and tested at the Allstar factory. It has many features that will aid in the installation and testing of the complete gate system. The GS4000 is certified to comply with UL Standard for Safety 325, as revised March 1, 2000. (115 Volt version only.
A: GATE SYSTEM DESIGN/ INSTALLATION WARNING! TO REDUCE THE RISK OF SEVERE INJURY OR DEATH: READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS AND GATE SYSTEM DESIGN PARAMETERS! 104949 GATE SYSTEM DESIGN AND INSTALLATION SAFETY CHECK LIST: • The GS4000 operator may be installed on a Class I, II, III, or IV Vehicular Swing Gate. See page 3 for an explanation of the different Class locations. See the last page of this manual for the operator specifications (voltage, maximum gate weight & length etc.).
A: GATE SYSTEM DESIGN INSTALLATION edge and the post to which the gate is mounted. It is recommended that the hinges be mounted so that this opening increases as the gate swings open. PROTECT THIS "PINCH POINT" SO THIS HAZARD IS AVERTED. See Figure 3. • CONSIDER ALL OTHER "PINCH POINTS" IN YOUR MOVING GATE CAN CAUSE SERIOUS INJURY OR DEATH DESIGN of the gate system. Observe the arm as it opens and the two arm pieces swing past each other. Use protective measures to reduce hazards at this location.
B: PREPARING THE SITE If mounting anchor bolts are to be installed prior to pouring the pad, pay particular attention to the bolt pattern and the location of the mounting holes with respect to the center line of the gate post. It is critical for the proper operation of the Arm that the center line of the shaft of the GS4000 MECHANICAL UNIT be located exactly as shown on the bolt pattern drawing, Figure 6. THE CONCRETE PAD The standard GS4000 is designed to operate a single leaf gate.
B: PREPARING THE SITE Figure 7: Loop Diagrams 104945 TERMINATION OF THE WIRE AT THE VEHICLE DETECTOR. Above ground splices may be used providing the wire is twisted, soldered and moisture sealed. For best long term results, do not use wire nuts anywhere in the loop system. Connect to the Vehicle Detector harness by soldering. VEHICLE DETECTOR LOOP BLANKING FOR SWING GATES The inside loop for a swing gate installation must be located at least 4 feet outside of the arc of the gate.
B: PREPARING THE SITE OTHER VOLTAGES AND 3 PHASE SYSTEMS. ELECTRICAL POWER REQUIREMENTS The GS4000 can operate at other voltages or on three (3) phase systems. To operate at 440 VAC it will be necessary to install an external step down transformer. The transformer should be located in a separate electrical box and protected by suitable circuit breaker and/or fusing. A 440 Volt rated switch should also be installed. Follow local electrical codes or the National Electrical Code.
C: INSTALLING THE OPERATOR TOOLS REQUIRED The following tools and materials are required for a proper installation of the GS4000. 1. Wire cutter, stripper and crimping tools. (For attaching accessory equipment to the control box barrier strip.) 2. A #2 Phillips Head screw driver for removing the screws to the High Voltage cover. 3. Medium standard straight blade screw driver for the terminal strip screws. 4. Very small blade screwdriver. (For adjusting the potentiometer on the Logic and Power board.) 5.
C: INSTALLING THE OPERATOR HARDWARE LEGEND 1 (1 EA) 1/2-13 X 2” BOLT & 1/2 FLAT WASHER 104961 2 (2 EA) 1/2-13 NYLOCK NUT & 1/2” FLATWASHER 3 (2 EA) 5/16-18 X 5/8L SQ HEAD SET SCREWS 4 (1 EA) 1/2-13 X 23/4” BOLT & 1/2 FLAT WASHER 5 (2 EA) 1/4 -20 X 1-1/2” BOLT & 1/4 FLAT WASHER 6 (2 EA) 1/4-20 HEX NUT, INT TOOTH LOCK WASHER, 1/4 FLAT WASHER ** HARDWARE NOT TO SCALE ** Figure 9: Arm Positions TO REVIEW: Make sure the correct position of the GS4000 MECHANICAL UNIT from the center line of the gate hinge piv
C: INSTALLING THE OPERATOR ELECTRICAL HOOK UP The GS4000 electrical connection is made at the Input Volts terminals in the CONTROL BOX, see Figure 11. You will need to drill holes as required on the bottom of the CONTROL BOX to permit conduit entry. Run a flexible water tight conduit from the service junction box to the GS4000 CONTROL BOX. Pull three #14 wires from the service junction box in this conduit to the GS4000 Control Box. If the GS4000 is wired for 115 Volts, pull a black, white and green wire.
C: INSTALLING THE OPERATOR lines. Effective protection requires that the surge current from the lightning strike be shunted to ground. This must be done without raising the potential of the circuitry in the GS4000, with respect to ground, to the levels that will damage the solid state circuitry. Lightning strikes generate enormous currents for very short periods of time. Unfortunately, the period of time is long enough to damage solid state components and many times, other components.
C: INSTALLING THE OPERATOR contact is closed. Now, a contact will be made to the limit switch input at the terminal board through both limit switch contacts. Both motors will be turned off. A wiring schematic of the Bi-Parting installation is shown in Figure 15, page 14. It is important this schematic be followed closely and that the color codes at the MECHANICAL UNITS and the CONTROL BOX be followed exactly.
C: INSTALLING THE OPERATOR 110092 Figure 15: Bi-Parting Installation Limit & Motor Wiring Diagram 14
C: INSTALLING THE OPERATOR CLOSE/OPEN PHOTO/EDGE (#s 9, 10, 12, & 13) can be continuous commands as noted on page 18. Labels identify the function of each of the terminals on the strip. See the TERMINAL STRIP Reference Chart on pages 17-19 related to each terminal number for an explanation of each of the inputs.
C: INSTALLING THE OPERATOR 110123 WIRING A KEYPAD, CARD READER OR TELEPHONE ENTRY SYSTEM These devices activate the GS4000 by a relay contact closure within the device. Typically, these devices will be used to open a gate with the Timer-To-Close feature automatically closing the gate. In general, two wires or terminals are provided by the device to operate the gate. Follow the manufacturers instructions on locating these connections.
C: INSTALLING THE OPERATOR WARNING! PRESETTING THE MOTOR OVERLOAD SENSITIVITY POTENTIOMETERS IMPROPER WIRING COULD CAUSE ELECTROCUTION OR DAMAGE TO CIRCUITRY. FOLLOW LOCAL BUILDING AND ELECTRICAL CODES. The GS4000 has independent adjustments for Open and Close Overload Sensitivity. The GS4000 is shipped from the Factory with the overload settings at their most sensitive setting.
C: INSTALLING THE OPERATOR TERMINAL STRIP REFERENCE CHART # NAME DESCRIPTION 7 CLOSE Momentary or continuous signal. On/ Off mode set by Switch #1 # NAME DESCRIPTION 12 OPEN EDGE Momentary or continuous signal. This input is active only when referenced to the opening direction, it has no effect on the gate when closing or about to close. If activated when the gate is opening the gate will stop, pause and reverse in the close direction for 1/2 second (approx. 2 inches) and stop.
D: STARTING THE OPERATOR the nut on the Limit Switch Cam. Snug the set screw on the cam against the output shaft to protect the cam from accidental movement. Open the gate to its FULLY OPEN position. Repeat this procedure for the upper Limit Switch and Cam. (See Figure 21.) TERMINAL STRIP REFERENCE CHART # NAME DESCRIPTION 18 OPEN LIMIT SWITCH Connection for Limit Switch Input — See page 13, Fig. 13 or page 14, Fig.
D: STARTING THE OPERATOR APPLYING POWER TO THE GS4000 110125 PRE-POWER CHECK LIST Before applying power to the GS4000 for the first time, go through the following check list to ensure that all is in order for the application of power. 1. Check that the GS4000 power switch is off. 2. Check that the breaker at the power panel is on. LOCATION OF AUTOCLOSE TIMER ADJUSTMENT 3.
D: STARTING THE OPERATOR 3. Connect to Terminal #17, Close Limit Switch: Close Limit Switch light is ON. 4. Connect to Terminal #18, Open Limit Switch: Open Limit Switch light is ON. 5. Connect to Terminal #4, Radio Open.: Radio Open light is ON, Motor Open light is ON. light comes ON and the Open Pushbutton light is ON. Remove the wire from terminal #6 and observe that the Open Pushbutton light goes OUT and the Motor Open light stay ON. 14.
D: STARTING THE OPERATOR - FINAL SETTINGS MECHANICAL LIMIT AND THE LIMIT SWITCH LIGHT DOES NOT COME ON, THE LIMIT CAM OR THE STOP WILL NEED TO BE READJUSTED. WARNING! RISK OF ENTRAPMENT OVERLOAD SENSITIVITY HAS NOT BEEN SET. DO NOT ALLOW ANYONE NEAR THE GATE AND DO NOT LEAVE GATE AND GS4000 UNATTENDED UNTIL FOLLOWING PROCEDURES HAVE BEEN COMPLETED. USE CAUTION DURING THIS FINAL ADJUSTMENT PERIOD.
E: INSTALLATION NOTES FOR AUXILIARY EQUIPMENT describe the gate system operation to the end user. Review the Gate Operator System Operation and Safety Guide in Section F of this manual with the end user. FINAL SETTING OF THE MOTOR OVERLOAD SENSITIVITY The motor overload sensitivity was preset for each direction before turning on the main power to prevent the operator from "selftripping" during the preliminary adjustment period. You are now ready to install and connect the ancillary equipment.
F: END USER INSTRUCTIONS GATE OPENER OPERATION & SAFETY GUIDE WARNING! IMPORTANT SAFETY INSTRUCTIONS. TO REDUCE THE RISK OF SEVERE INJURY OR DEATH: READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL! To the Owner/End User of Allstar’s GS4000: • • Thank you for choosing an Allstar product. We are confident you will have many years of use and satisfaction with your gate operator.
F: END USER INSTRUCTIONS GATE OPENER OPERATION & SAFETY GUIDE MAINTAIN THE GATE AND GATE HARDWARE: A damaged gate or one that cannot be easily opened and closed manually must be repaired before installing a gate operator. A poorly operating gate may cause the load sensing device of the operator to fail, causing a risk of entrapment. Never overtighten the clutch or load sensing device to compensate for a poorly swinging gate.
MECHANICAL UNIT EXPLODED VIEW 106359 1 3 2 4 5 7 6 8 20 9 19 18 10 17 11 16 14 15 13 12 Figure 27: GS4000 Mechanical Unit Exploded View 26
MECHANICAL UNIT PARTS LIST ITEM # PART # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 010291 104442 010279 010221 104452 010216 104479 010278 010172 010213 010220 010215 010436 010156 010219 010218 010217 010173 102735 010231 DESCRIPTION RAIN SEAL RUBBER RING RAINSEAL PLATE OPERATOR COVER ROLLER CHAIN OUTPUT SHAFT SPROCKET, 1-1/4 SHAFT ARM STOP PALL OPERATOR FRAME MOTOR PULLEY, 2 IN V BELT, 5/8 IN BORE V-BELT BEARING, 1-1/4 SFT ACTUATOR, LIMIT CAM LIMIT SWITCH PULLEY, 8 V-BELT, 5/8 BORE SPEED REDU
TECHNICAL SPECIFICATIONS DRIVE PHYSICAL DRIVE SYSTEM: 60:1 Gearbox PAD: 24W x 30D x 3H OVERHEAD CLEARANCE: 21 Inch Minimum TORQUE LIMITER: Mounted on Output Shaft, UNIT SIZE: 16-1/8 x 24-7/8 x 17-1/4 OUTPUT SHAFT: 1-1/4 Diameter Ball-Bearing Mounted FRAME: Welded steel, Coated to UL Standards LIMITS: Independent Open & Close; Displaced COVER: Molded Polyethylene Cam with Micro Switch SHIPPING WEIGHT: 150 lbs. CAPACITIES ELECTRICAL MAX. GATE WEIGHT: 1000 lbs.