DL Manufacturing Smart Chock SC0650 User manual

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Smart Chock™
Models SC0650 thru SC0654
340 Gateway Park Drive
North Syracuse, NY 13212
Phone: [phone]
Toll Free: 866-235-7468
Fax: [phone]
Email: [e-mail]
www.dlmanufacturing.com
A Product of

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Smart Chock™ Installation Guide
This manual is used for models SC650 through SC654 Series Smart Chock™ model types. Be sure
to check your smart chock model type before consulting or servicing. The control board is
programmed for each model’s function. The description explains the differenced between model
types. Each model is programed and configured specifically for desired functionality.
Model #
Part # Description
650 CS650
Standard Smart Chock
™
No options: No outlets or interlocks
651 SC0651
Powers & controls one outlet for dock light
Dock light turns off when door is closed
652 SC0652
Powers & controls two outlets
Dock light & fan turn off when door is close
653 SC0653
Powers & controls two outlets & interlocks
Electric/Hydraulic leveler
Dock light and fan turn off when door is closed
Leveler will not run when door is closed
654 SC0654
Powers & controls two outlets & interlocks
Pneumatic leveler
Dock light and fan turn off when door is closed
Leveler will not run when door is closed
Fan turns off when leveler runs
INTRODUCTION
ELECTRICAL RATINGS:
INPUT VOLTAGE 120 VAC to 240VAC
INPUT FREQUENCY 60 HZ /50HZ
MAXIMUM INPUT CURRENT 12 A
INPUT CURRENT WITH NO OUTLET(S) OR LEVELER LOAD <.5 A (MODEL 650)
MAXIMUM OUTLET(S) CURRENT 12 A
MAXIMUM LEVELER LOAD CURRENT (J7 OR J8) 12 A
OUTSIDE LIGHT BOX VOLTAGE 12 VDC
MAXIMUM OUTSIDE LIGHT BOX LOAD CURRENT 1.25 A (12 V POWER SUPPLY CURRENT LIMIT)
SENSOR VOLTAGE (J2, J3, J4 & J16) 12 VDC
MAXIMUM SENSOR CURRENT (J2, J3, J4 & J16) .2 A (J2, J3 & J4 PROTECTED BY PTC THERMISTOR)

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Smart Chock™
---Sequence of Operations---
Testing
POWER ON – Smart Chock enters a startup routine that turns the LED’s and Relays on and off a few times. The startup routine
runs for approximately 20 Seconds.
Loading Dock Door is Closed, Wheel is Unchocked
•Inside Red Light is on
•Outside Green Light is flashing
Wheel gets Chocked and after a 0 to 5 Second Delay
•Outside Red Chock Icon turns on
• Inside light changes from red to green “CHOCKED”
•Outside Green Light turns off
Door Open
•Outside top Red Light starts flashing
•Interlocks turn on –the outlets for a fan and dock light are enabled
(1) See note for Optional Sensor information
Door closes and after a (2) 5 to 15 Second Delay
•Outside flashing Red Light turns off
•Interlocks turn off –the outlets for a fan and dock light are disabled
Driver Removes Chock
•Outside Red Chock Icon turns off
•After a 5 to 15 second delay, Outside Green flashing light turns on
• Inside light changes from green “CHOCKED” light to Red Light
Safety Situations
*** Chock Pulled Prematurely with Door Open (After a (2) 3 to 15 Second Delay)***
• Inside light changes from green “CHOCKED” light to Red Flashing Light
•Versa Light® Dock Light flashes and Inside Audible Alarm Sounds for 5 minutes, fan outlet is disabled
•Interlocks are disabled
•Outside Red Chock Icon turns off, outside red stay on
•Outside Alarm turns on for 10 minutes
***Door opens without a truck wheel chocked***
•Versa Light® Dock Light flashes and Inside Audible Alarm Sounds for 5 minutes, fan outlet is disabled
•Interlocks are disabled
•Outside Red Chock Icon turns off, outside red stay on and Outside Alarm comes on for 10 Minutes
***Chock Cable gets Cut or Disconnected from Chock***
•Inside lights alternately flash from green to red, on board yellow system LED comes on
•Outside Red comes on and if wheel was chocked, Chock Icon turns off and Outside Alarm comes on for 10 Minutes
•Interlocks are disabled
•Inside Alarm turns on and does not turn off until power is turned off or cable is plugged back in
(1) An Optional Second Sensor can be connected to the Control Board at J3 or OPT2 (See page 12 for connection information). The Optional
Second Sensor negates the actions caused by the Door Sensor when the Door is Open. The Outside Red Light, Interlocks and Outlets are
turned off.
(2) At the core of the Smart Chock Control Board is an embedded microcontroller. Under preprogrammed control, the Smart Chock Time
delays, Light Outputs and Relay Outputs can be modified to suit any Customers individual needs. For example, the Time Delays could be
preprogrammed anywhere from 3 to 15 seconds.
Smart Chock™ Installation Guide

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Smart Chock™ Installation Guide
WARNING!!!! Do not use in hazardous or corrosive environments!
REQUIRED TOOLS
❑Drill bits, masonry bit for tap-con / wood bits 3/16” for pilot hole in dock seal
❑Tape measure Hammer Drill
❑Wire strippers Drill screw gun
❑Hammer Precision flat blade screwdriver 1/8” wide
❑Felt tip marker Wire labels
❑9/16” Wrenches for Chock Handle Assy.
INDEX
Description Page
COVER -
INTRODUCTION / ELECTRICAL RATINGS 2
SEQUENCE OF OPERATIONS 3
GENERAL INFO / INDEX / REQUIRED TOOLS 4
INSTALLER SUPPLIED HARDWARE & FASTENERS 5
CHOCK HANDLEASSEMBLY INSTRUCTIONS 6
VECTOR CHOCK ASSEMBLY INSTRUCTIONS 7
INSIDE LIGHT BOX MOUNTING 8
INSIDE LIGHT BOX MOUNTING CONTINUED 9
BOLLARD MOUNTING BRACKET (OPTIONAL) 10
PHOTO EYE INSTALL –TYPICAL & MxV DOOR 11
PHOTO EYE INSTALL –ROLLING STEEL DOOR 12
EXTERNAL BOX INSTALLATION 13
CONTROL BOARD WIRING OVERVIEW / INDEX 14
WIRING DIAGRAM J1 & J2 15
WIRING DIAGRAM J6, J7 & J8 16
INSIDE TO OUTSIDE BOX WIRING DIAGRAM J15 & J16 17
MODEL 650 SYSTEM WIRING DIAGRAM 18
651 SYSTEM WIRING DIAGRAM 19
652 SYSTEM WIRING DIAGRAM 20
653 SYSTEM WIRING DIAGRAM 21
654 SYSTEM WIRING DIAGRAM 22
OUTSIDE LIGHT BOX / CHOCK WIRING DIAGRAM 23
DL MANUFACTURING TERMS/CONDITIONS/WARRANTY 24
YEARLY MAINTENANCE
•Inspect inside connections for any damage
•Inspect mounting bolts for tightness
•Clean unit with compressed air
•Clean Photo Sensor Lenses
•Inspect chock cable for damage or wear
•Check chock handle for damage
•Clean chock & ensure of debris
•Check choc for corrosion of plug connections
•For chocks with yellow cords, be sure
connection is tight with channel-locks

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Smart Chock™ Installation Guide
Installer-supplied hardware & fasteners
Mounting Surface
Inside Light Box Outside Light Box
Cement Block (4) ¼” x 1¼” Tapcon (4) #10 x 1” Tapcon
Tip up concrete panel (4) ¼” x 1¼” Tapcon (4) #10 x 1” Tapcon
Sheet Metal Sheet metal walls are not thick
enough to hold inside box
Sheet metal walls are not thick enough
to hold outside box
Steel (4) ¼” x ¾” self-drilling screws 4) ¼” x ¾” self-drilling screws
Bollard Use DL Manufacturing supplied kit
Pole Bracket /
Chock Hanger
(4) 3/8 Dia. Concrete Anchors
Also needed:
Wiring –Outside Box to
Inside Box
7 conductor 18 gauge
wire
½” flexible conduit with
connector for 7/8 knockout
Field Notes:
FOR SERVICE ASSISTANCE CALL DL MANUFACTURING TOLL FREE 866-235-7468
Smart Chock Model #:___________________________________________
Smart Chock Serial #:
(LOCATED LOWER PORTION OF CONTROL BOARD)_______________________________________________________
Door Location:_________________________________________________
Customer:_____________________________________________________

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Smart Chock™ Installation Guide
OPTION 1: STANDARD CHOCK HANDLE MOUNTING INSTRUCTIONS
1. Remove the Nuts and Bolts from the Handle Assembly.
2. Attach the Handle Assembly to the Chock as shown below using the Hardware from Step 1.
Hardware & Handle orientation
- Parts removed for clarity
Chock after assembly
FOR CHOCKS WITH YELLOW CABLES- BE SURE CONNECTION
IS TIGHT! TIGHTEN CONNECTION WITH CHANNEL LOCKS!

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OPTION 2: VECTOR CHOCK HANDLE MOUNTING INSTRUCTIONS
Smart Chock™ Installation Guide
1) Remove the Nuts and Bolts from the Extractor Assembly and Insert Extractor into Chock (Figure A.)
2) Slide Handle over Extractor. Place Washer, Lock Nut, & Bolt in that Order as Shown (Figure A.).
Tighten Bolt with Torque Wrench to 96 lb-ft.
EXTRACTOR INSERT
CHOCK HANDLE
MOUNTING BOLT
CHOCK HANDLE
TIGHTEN BOLT
TO 96 IB-FT.
EXTRACTOR INSERT CABLE
FIGURE A
FIGURE B
FIGURE C
TIGHTEN WITH
CHANNEL LOCKS

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Smart Chock™ Installation Guide
INSIDE LIGHT BOX MOUNTING
SMART CHOCKTM INSTALLATION
WALL MOUNTED STYLE
INTERNAL
(YELLOW BOX)
NOTE:
Install internal Smart ChockTM
measuring 66” from the dock
floor to the top of the yellow
box. Use (4) ¼” x 1¼” Tapcons
DOCK FLOOR
6.0” [152.35]
14.06”
[357.19]
7.75”
[196.85]
6.5”
[165.1]
9.63”
[244.47]
6.5”
[1676.4]
8.0”
[203.18]

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Smart Chock™ Installation Guide
66.0”
[1675.73]
SEE PAGE 4 FOR
FASTENER USAGE
Inside Floor
Level
CONDUIT
HOLE
REF 26.0”
[1066.8]
CENTER OF
TOP RED
LIGHT
SHOULD BE
90” ABOVE
GROUND
LEVEL
HOLE FOR
CONDUIT
74” [1880.15]
Wall
Outside Floor
Level
Inside Floor Level
DETAIL A
SCALE 1:12
Ǿ7/8” [22.25]
Thru hole. Drill
thru to outside
box for conduit
SECTIOB B-B
SCALE 1:12
Smart Chock ™
(Black-outside box)
Smart Chock ™
(Yellow-Inside box)
Smart Chock- Mounting
(on concrete wall or block wall)
INSIDE LIGHT BOX MOUNTING CON’T.

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Smart Chock™ Installation Guide
BOLLARD BRACKET
PART # MK5027
BOLLARD BRACKET
Used on bollards 4 to 10 inch diameter.
(2) Hose clamps & 12 ¼-20 mounting
Bolts are included.
BOLLARD BRACKET
(mounting hardware
included) Floor
Line
66”
[1675.73]
From
The floor
Or
Contact
Factory
VERSA LIGHT ™
Hsc ¼-20X1/2
12 Places
(provided)
SMART CHOCK™
Hose Clamps

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Smart Chock™ Installation Guide
PHOTO EYE INSTALL - TYPICAL & MxV DOORS

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Smart Chock™ Installation Guide
MAGNETIC CONTACT INSTALL - ROLLING STEEL DOORS

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Smart Chock™ Installation Guide
INSTALLATION OF OUTSIDE COMPONENTS
7.0”
[177.8]
21 9/16”
[548.13]
RED LED LIGHT
GREEN LED LIGHT
CHOCK ICON –TURNS
RED WHEN WHEEL IS
CHOCKED
Pole Attachment
1. Attach Pole Mounting Bracket to wall using 3/8” anchors.
Top of bracket should be 46” off the ground.
2. Attach Pole sections together and tighten set screw in the
Coupling.
3. Slide bottom of Pole (with black tubing) into Mounting
Bracket until it bottoms out. Pole is held in place by black
rubber tubing.
BOX MUST BE SECURELY FASTENED TO
WALL SO WHEN CABLE IS PULLED, IT SNAPS
OUT OF SOCKET BEFORE BOX IS PULLED
OFF THE WALL.
See Page 7 for
Mounting Instructions.
INSTALLATION OF OUTSIDE COMPONENTS
90” from ground
to center of red
LED board.
Fastening
Holes
Use appropriate
fastening
methods to
fasten to
building wall

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Smart Chock™ Installation Guide
REMOVE POWER
BEFORE SERVICING. MUST
BE INSTALLED BY
QUALIFIED ELECTRICIAN 
MODEL 654 LEVELER BUTTON
DO NOT APPLY
VOLTAGE TO J6
TERMINALS, FOR
SWITCH ONLY
J6-1, 8.2 VDC, 3 mA MAX
J6-2, COMMON GND
OUTSIDE LIGHT BOX
J15-1, +12 VDC, 1.25 A MAX
J15-2, RED LIGHT
J15-3, CHOCK ICON
J15-4, GREEN LIGHT
CHOCK
J16-1, 8.2 VDC, 3mA max
J16-2, COMMON GND
J16-3, CHOCK SIGNAL
1 AMP SLO-BLO 250V
FUSE UNDER FUSE
COVER
REPLACE WITH ONLY
SAME TYPE AND
RATING
FOR BEST RESULTS
WHEN REPLACING
FUSE, PLACE FUSE IN
COVER, THEN PLACE
COVER OVER CLIPS
AND THEN SNAP FUSE
INTO CLIPS
12 AMP BREAKER FOR
SWITCHED VERSA LIGHT AND
FAN OUTLETS ONLY. MANUAL
PRESS TO RESTART.
120 VAC INPUT
120 VAC, 12 A MAX
60 HZ
J1-1, 120 VAC LINE
J1-2, 120 VAC NEUTRAL
J1-3, GROUND WIRING OVERVIEW / INDEX
OPTIONAL ALTERNATE
CONTACTS
MODEL 653 & 654 LEVELER
INTERLOCK
J7-1 J7-2
277 VAC, 30AC
J7-1 & 2 CONNECTED TO K3
ISOLATED RELAY CONTACTS
ASSEMBLY NUMBER &
REV. LABEL
Switching Relays for J7, J8,
Versa Light Outlet and Fan
Outlet are Rated 120 VAC, 12
A .75 Power Factor
PHOTO EYE DOOR SENSOR
J2-3, COMMON GND
J2-2, SENSOR SIGNAL
J2-1, +12 VDC, .2A MAX
RS485 CONNECTION
5 VDC, 60 mA MAX
9100 bps
J10-3, COMMON GND
J10-2, CHANNEL A
J10-1, CHANNEL B
OPTIONAL SENSOR
SEE INSTRUCTIONS THAT
OPTIONAL SENSOR COMES
WITH SAFETY STRAP
J3-3, COMMON GND
J3-2, SENSOR SIGNAL
J3-1, +12 VDC, .2A MAX
OPTIONAL TERMINAL
BLOCK JUMPERS FOR
OPT2 & OPT 3
Refer to Instructions that come
with Replacement PC Boards
J3-3 OR J4-3, COMMON GND
J3-2 OR J4-2, INPUT SIGNAL
J3-1 OR J4-1, +12 VDC, .2A
MAX

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Smart Chock™ Installation Guide
WIRING DIAGRAM J1 & J2
BLACK (120 VAC, 12 A MAX, 60Hz)
WHITE (120 VAC NEUTRAL)
GREEN (GND) -ALL MODELS EXCEPT 653 & 654
GREEN (GND) -MODELS 653 & 654 ONLY
ON MODELS 653 & 654
USE CHASSIS GND
CONNECTION
(NOT USED ON OTHER MODELS)
MUST BE
INSTALLED
BY QUALIFIED
ELECTRICIAN
DOOR PHOTO SENSOR
PHOTO SENSOR IS 12 VDC. DO NOT RUN IN SAME CONDUIT WITH HIGHER VOLTAGE WIRING.
TRANSIENTS CAN DAMAGE CONTROL BOARD OR AFFECT OPERATION.
3 BLUE -COM
2 BLACK - SIGNAL
1 BROWN +12 VDC, .2A MAX
SENSING REVERSAL
CAREFULLY ROTATE ADJUSTMENT 3/4 TURN TO CHANGE
OPERATION BETWEAN N/O OR N/C.
NORMALLY SET FOR DARK OPERATE OR N/C
WHEN LOCATED ABOVE PANELED DOOR OPENING
SMART CHOCK™FIELD WIRING DIAGRAM
INCOMING POWER
INTERNAL (YELLOW BOX)
GND WIRE FROM
CHASSIS GND IS
PRE-INSTALLED ON
MODELS 653 & 654
J2

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Smart Chock™ Installation Guide
SMART CHOCKTM FIELD WIRING DIAGRAM
MODEL 654 LEVELER CONTROL SIGNAL
FX LEVELER
BUTTON
J6-1, 8.2 VDC, 3mA MAX
J6-2, COMMON GND
DO NOT APPLY
ANY EXTERNAL
VOLTAGE TO J6
TERMINALS
ON MODEL 654 SMART CHOCKS –WHEN THE LEVELER BUTTON IS PRESSED, THE FAN
WILL POWER DOWN. AFTER A 2 SECOND DELAY, THE LEVELER (J7) WILL RUN. ONCE
THE LEVELER BUTTON IS RELEASED, THE FAN WILL TURN BACK ON.
MODEL 654 & 653 LEVELER INTERLOCK / OPT1
J8 (OPT1) CONTACTS CLOSE
WHEN J7 (LEVELER) CLOSE.
CONTACTS CONNECTED TO J7
& J8 ARE RATED 120 VAC 12 A,
.75 POWER FACTOR.
CONTACTS CONNECTED
TO J7 & J8 ARE DRY
CONTACTS (ISOLATED
FROM INTERNAL CONTROL
BOARD CIRCUITRY).
INPUT POWER TO LEVELER MOTOR
WIRING DIAGRAM J6, J7 & J8

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Smart Chock™ Installation Guide
SMART CHOCKTM FIELD WIRING DIAGRAM
OUTSIDE LIGHTS
1
2
3
4
5
6
7
J2
CHOCK ICON BOARD
TERMINAL BLOCK
(OUTSIDE LIGHT BOX)
J15
OUTSIDE LIGHTS
TERMINAL BLOCK
(INSIDE LIGHT BOX)
J16
CHOCK TERMINAL
BLOCK (INSIDE
LIGHT BOX)
IMPORTANT!!!
OUTSIDE ICON BOARD TERMINAL BLOCK CONFIGURATIONS FOR CONNECTOR J2 ARE
DIFFERENT FOR RED VS AMBER ICON BOARDS:
WIRING DIAGRAM –INSIDE TO OUTSIDE BOX
SC8863 RED ICON BOARD SC8078AMBER ICON BOARD
OUTSIDE (BLACK BOX) CONECTIONS TO J2
OF PCB ASSEMBLY SC8863 (CHOCK ICON)
BROWN
RED
YELLOW
OARNGE
WHITE
BLACK
BLUE 7 COM
6 SEN
5 LPBK
4 CHK’D
3GREEN
2 RED
1 +12VDC
BROWN -+12VDC
RED –TOP RED LEDS
YELLOW –GREEN LEDS
J15
OUTSIDE
LIGHTS
OARNGE –CHOCK ICON
J16
CHOCK
WHITE –LOOP BACK
BLUE –CIRCUIT COMMON
BLACK –SENSOR SIGNAL
1
2
3
4
1
2
3
INSIDE (YELLOW BOX) CONTROL
BOARD CONNECTIONS
J2
7 6 5 4 3 2 1

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Smart Chock™ Installation Guide
MODEL 650 WIRING DIAGRAM

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Smart Chock™ Installation Guide
MODEL 651 WIRING DIAGRAM
VERSALIGHT

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Smart Chock™ Installation Guide
MODEL 652 WIRING DIAGRAM
VERSALIGHT