HySecurity HRG 220 ST Manual

Hy
HyHy
Hy-
--
-Security
SecuritySecurity
Security
Gate Operators
Gate OperatorsGate Operators
Gate Operators
HYDRAULIC
HYDRAULICHYDRAULIC
HYDRAULIC
SWING GATE
SWING GATESWING GATE
SWING GATE
Operators
OperatorsOperators
Operators
With Smart Touch Controller
With Smart Touch ControllerWith Smart Touch Controller
With Smart Touch Controller
Installation and Maintenance Manual
Installation and Maintenance ManualInstallation and Maintenance Manual
Installation and Maintenance Manual
HRG 220 ST, HRG 222 ST
and
DC Battery UPS version
Revision: ___
Hy-Security Gate Operators
Phone: [phone]
FAX: [phone]
Internet: www.hy-security.com
INSTR# 108
Email: [e-mail] Date 04/01/02

Installation and Maintenance Manual
Hy-Security Hydraulic Swing Gate Operator
ii
Hydraulic Swing Gate Operator
With Smart Touch Controller
©Copyright 2001 Hy-Security Gate Inc.
All rights reserved. No part of this manual may be reproduced by any means:
photocopier, electronic or mechanical, without the express written permission of Hy-
Security Gate Inc. Additionally, Hy-Security Inc. makes no representations or warranty
with respect to this manual. We also reserve the right to make changes in the products
described without notice and without any obligation to notify any persons of any such
revision or change.

Installation and Maintenance Manual
Hy-Security Hydraulic Swing Gate Operator
iii
Table of Contents
Introduction.......................................................................................................................v
Warranty Registration .....................................................................................................vi
Available Models and Features ................................................................................... 1-2
I. Safe Gate Design
Important Information .....................................................................................................3
Install an Automatic Operator only When: ...................................................................4
Important Information for Gate System Owners & Users ............................................5
I. Installation
Scope and Planning of Installation ............................................................................ 6-8
Technical Drawings................................................................................................... 9-11
Inside the HRG Swing Operator ...................................................................................12
Installation Preparations and Installation.............................................................. 13-18
Adjustment of Flow Regulating Valve .........................................................................18
Manual Operation Hand Pump .....................................................................................19
II. Smart Touch Set up
Basics of Using the Smart Touch Controller ..............................................................20
Installation Configuration for Smart Touch Controller ..............................................21
Wiring Control Inputs to the Smart Touch Controller ......................................... 22- 23
Connecting a Master/Slave Pair ...................................................................................24
Table of User and Installer Menu Functions ........................................................25 - 26
User Menu: Description Functions Available..............................................................27
Installer Menu: Description Functions Available.................................................28 - 29
Correctional Facility / Interlocked Pair / User Optional Wiring..................................30
Options for User Programmable Output Relays .........................................................31
Clock Functions.............................................................................................................32
III. Entrapment Protection
Entrapment Protection Schematic...............................................................................33
UL 325 Standard Requirements for Entrapment Protection Devices........................34
Placement and Use of Secondary Pedestrian Entrapment Sensors.........................35
Installing Gate Reversing Edge (Contact Type) Sensor.............................................36
Installing Photoelectric (Non-Contact) Sensor ....................................................37 - 38

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Hy-Security Hydraulic Swing Gate Operator
iv
Table of Contents, continued
IV. Detectors and Loops
Loop and Detector Installation Guide...................................................................39 - 40
Loop Layouts ..........................................................................................................41 - 42
Vehicle Detector Options..............................................................................................43
Hy-Security Hy-5A Vehicle Detector Installation ........................................................44
Standard 11 Pin Vehicle Detector installation.............................................................45
Vehicle Detector & Loop Fault Diagnostics ................................................................46
V. Accessories
24 Hr / 7 Day Time Clock Option ..................................................................................47
Connecting a Radio Receiver ........................................................................................48
VI. Troubleshooting and Maintenance
Troubleshooting.....................................................................................................49 - 50
Maintenance ...........................................................................................................51 - 53
VII. DC Operators
DC Systems (HRG 220 DC & HRG 222 DC)
Important Notes about DC Powered Gates .................................................................54
Wiring & Control............................................................................................................55
Battery Connection Diagrams...............................................................................56 - 57
VIII. Appendix
Wiring Size Schedules ...........................................................................................58 - 59
Parts Breakout Diagrams ......................................................................................60 - 64
Limited Warranty...........................................................................................................65

Installation and Maintenance Manual
Hy-Security Hydraulic Swing Gate Operator
v
Introduction
Welcome – We would like to take this opportunity to thank you for this
purchase. Hy-Security has manufactured the finest hydraulic gate
operators available since the 1970s. Our commitment to quality and
innovation will become evident as you become familiar with the features
and performance of this expertly engineered machine. All Hy-Security
operators are equipped with the Smart Touch Controller, a digital
electronic brain that offers unparalleled features.
Please take a few minutes to study the contents of this instruction manual.
The benefits of taking a little extra time to align the gate operator properly
and to verify a fully functional installation will ensure customer satisfaction
and a longer life with minimal maintenance costs.
Installers and owners must be certain to thoroughly review and
understand the Important Information regarding pedestrian
entrapment protection contained within this manual. There are
hazards associated with automatic gates that can be greatly reduced
with proper design, installation use. When an automatic gate is first
made functional, the installer must teach the owners and users how
to operate this system correctly. When the installation is complete,
leave this manual for the owner’s use and reference.
Please do not hesitate to give your Hy-Security distributor a call if you
experience any difficulties during the installation. They are experienced
and trained to assist in resolving any problems.

Installation and Maintenance Manual
Hy-Security Hydraulic Swing Gate Operator
vi
For warranty registration, please fill in this information, fax or mail a
copy to Hy-Security, then give this manual to the owner of the gate.
Owner Name: _______________________________
Telephone number: __________________________
Hy-Security Distributor: ________________________
Telephone number: __________________________
Installer name: ______________________________
Telephone number: __________________________
Serial number of operator: _____________________
Date installed: _______________________________
Model of Operator ____________________________
Warranty Registration
Hy-Security Address: FAX:
1200 W Nickerson [phone]
Seattle, WA 98119 Date: ________

Installation and Maintenance Manual
1
Available Models and Features
Hy-Security manufacturers twelve different models of hydraulic swing gate operators to suit the
size, weight and desired speed of the gate panel. All of the operator models are derived from the
standard HRG 220, upon which this manual is designed. Take a moment to identify the operator
model you have and note there are some changes in the instructions, especially in regards to final
adjustments of double swing gates. The following chart shows the differences at a glance:
Single Panel HRG 220A ST HRG 220B ST HRG 220C ST
Double Panel HRG 222A ST HRG 222B ST HRG 222C ST
24V UPS Models
Single Panel HRG 220A DC ST HRG 220B DC ST HRG 220C DC ST
Double Panel HRG 222A DC ST HRG 222B DC ST HRG 222C DC ST
Features:
Horsepower (all HRG 220 models are 1 HP, all HRG 222 models are 2 HP)
Time To Open/Close 14 sec 19 sec 30 sec
UL Usage Class 1 – 4 1 – 4 1 – 4
Warranty 5 years 5 years 5 years
SoftStop yes yes yes
SoftStart yes yes yes
Gate Panel Ratings
Weight Capacity 1000 lbs 1600 lbs 3000 lbs
Size Capacity 13 ft. wide 16 ft. wide 16 ft. wide
The HRG 220 series operator is the only truly industrial grade swing gate
operator on the market today. This tough operator is ideally suited to
dependable operation of massive iron or steel gates. Its 3000-lb capacity
provides plenty of power, and the Lift and Swing feature eliminates normal
obstacles such as heavy snowfall and inclined or irregular roadways. The
operator’s mechanism is wholly enclosed inside the post and uses no other
devices to push or pull on the gate panel. It’s unique closing action self
actuates a locking pin at the end of the gate for unparalleled security.
•Quarter turn rotating arc of 90 °or 100 °. No
actuating arms or back space required.
•Low profile power pack and electric panel are
designed to be remotely located. This allows for a
clean presentation at the side of the drive.
•Twelve-inch rise in the opening cycle allows the
swing gate to operate easily on slopes or rise over
curbs.
•Closing action drops locking pin at end of gate into
socket in driveway, allowing far better security.
•Operator post is treated with an industrial
galvanized flame spray finish to provide excellent
corrosion resistance.
•Heavy duty components handle gates to 16 feet
wide and up to 3000 lbs of any construction.
•Rated for continuous duty, up to 200,000
cycles with no maintenance.
•All components are designed for easy
removal during service.
•The hydraulic system features the latest
technology, modular manifolds and
individually replaceable cartridge valves.
•Fully compatible with all standard access
control equipment.
•Accessories include heaters, vehicle
detectors, photo eyes, gate edges
•Hand pump manual operation is standard
equipment.

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2
Available Models and Features
The Smart Touch Controller (Standard)
This is the brain of the all Hy-Security’s automatic operators. Truly high technology, but is also very
rugged to reliably serve in the harsh environments that exist in the real world. The Smart Touch Controller
is also very smart and can quickly be configured by an installer or user to adapt to about any functional
requirement of a specific site. All system settings are performed with the use of just four programming
buttons and an LCD display. The Smart Touch Controller has no switches of any type to set. An RS232
port is for external communication is standard. The system also has a real time clock and an EEPROM to
record system events. The log of events can be downloaded from the RS232 port with a PC computer or a
PDA with the Palm OS. Our optional vehicle detector modules set a new industry standard by
communicating a host of valuable performance data to the microprocessor in the Smart Touch Controller
via a serial data stream, allowing user-friendly diagnostics.
DC 24-Volt UPS Operators (Optional Version)
These gate operators function from 24 Volts DC all of the time to achieve a true UPS system. Our
Uninterruptible Power Supply is the most certain way to know that your gate will work when the AC
power fails. This system features fully sealed maintenance free batteries in a separate insulated and
ventilated enclosure.
Pedestrian Entrapment Protection
Read and understand all the Important Information, the Entrapment Protection Schematic and the UL
requirements on page 34 before beginning the installation. Be absolutely certain that the required type
and quantity of Entrapment Protection devices have been supplied and that you understand how to
install them correctly. Contact a distributor or the factory if there are any questions about Entrapment
Protection.
Basic Access Control
Radio Transmitter
Long Distance Control
Pushbutton Control Station
Programmable Time Clock
Card Reader
A
dvanced Access Control
Access Control Interface
Card Reader
Keypad
Telephone Entry
Input/Output
Computer Interface
RS232/485
Information
Signs
Labels
Warnings
Security
Key Locks
Closed Circuit
Television
Gate Position Indicator
Interlock/Sally Port
Gate Status Indicator
Obstruction Sensing Devices
Inherent Sensing Device
Gate Edges
Photo Eyes
Vehicle Detectors

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3
READ THIS FIRST!
Important Information – Review Before Installation
Automatic gate operators provide convenience and security to users. However, because these
machines can produce high levels of force it is important that all gate operator system designers,
installers and end users be aware of the potential hazards associated with improperly designed, installed
or maintained systems. Keep in mind that the gate operator is only one component of the total gate
operating system. It is the joint responsibility of the specifier, designer, purchaser, installer and end user
to verify that the total system is appropriately configured for its intended use. All parties should be
informed that entrapment in a moving gate could cause serious injury or death.
Common
Industry
Symbols
Important Instructions for Gate System Designers & Installers:
WARNING: To reduce the risk of serious injury or death, read and follow all instructions in the
gate operator handbook and on the warning labels.
Install an Automatic Gate Operator only When:
YThe entry is configured for vehicular use only. Pedestrians must be directed to a
separate walk-through entrance.
YThe Warning signs that have been supplied with this operator must be installed,
in manner clearly visible, in the area of both sides of the gate.
YAll exposed pinch points, are guarded. To reduce the risk of entrapment, the
gate must also be installed so that enough clearance is provided between the
gate and adjacent structures both when opening and closing.
YThe controls that operate the gate have been mounted far enough away from the moving gate such
that users cannot touch the gate while operating the controls. All easily accessible controls must
have a security feature to prevent unauthorized use.
-Dange
r
-
Keep Away
Attention
-Take Note-
Entrapment
Zone
Possible
Pinch Point

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Install An Automatic Swing Gate Operator Only When:
YThe gate moves freely in both directions. Never over-tighten a clutch or pressure relief
valve to compensate for a stiff moving gate.
YThe operator will not swing the gate into a public access area.
YThe operator will be properly electrically grounded and the intended supply voltage matches
the voltage label on the operator.
YThe operator controls will be located in a clear line-of-sight to the gate. Radio controls and
other remote access controls must be connected only to the Remote Open input.
YThe required external entrapment sensors will be installed. Be certain to carefully review
the instructions for placement, installation and adjustment of these external entrapment
sensors. External entrapment sensors must function to reverse the movement of the gate
in both the opening and closing directions. If edge (contact) sensors are used, they are
to be located on the inside and outside leading edge of the swing gate and along the bottom
edge of a swing gate that is greater than 6” above the ground. If photo eyes or other non-
contact sensors are used, they are to be mounted in locations most likely to guard against
entrapment. A combination of contact and non-contact sensors may be used, but all must
be recognized components under the UL 325 standard. See pages 32 and 33 for details on
the requirements.
YIf the Entrapment protection is provided by a continuous pressure actuation control, a
placard must be installed next to the control station stating “WARNING” – “Moving Gate has
the Potential of Inflicting Injury or Death - Do Not Start Gate Unless Path is Clear.”
Additionally, no other activation device shall be connected and an automatic closing device
of any kind shall not be used.
YThe automatic operator is labeled as appropriate for both the type and UL usage class of
the gate.
Class I: Intended to serve single to four family residential uses
Class II: Multi-family use, or any application intended to serve the general public
Class III: Commercial applications not intended to serve the general public
Class IV: Highest security. Security personnel prevent unauthorized access

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Important Information For Gate System Owners & Users
WARNING: To reduce the risk of serious injury or death, read and follow all instructions in the
gate operator handbook and on the warning labels.
Save These Important Owner and User Instructions:
(Installers – be certain to instruct the owners and users about the following items)
YAutomatic gates are for vehicular use only! Provide walkways and signs to direct
pedestrians to a separate walk-through entrance. Because an automatic gate can start at
any time without warning, always keep people away from the area of the gate.
YThe Warning signs that have been supplied with this operator must remain installed, in a
manner clearly visible, in the area of both sides of the gate.
YNever allow children to use or play with controls that operate the gate. Keep all remote
controls, especially radio transmitters, away from children.
YTeach all users how to turn off the electric power and how to release and move the gate
manually. Use the manual release only when the gate is not moving.
YTest the function of the gate operator monthly. The gate MUST reverse its direction of
travel upon contact with a rigid object, and/or stop upon a sensing a 2nd sequential
activation prior to reaching a full travel limit. Also test for the normal function of any non-
contact sensors. If the gate system employs the use of a transmitting edge sensor, be
especially certain to test and replace its battery on a routine basis.
YKEEP AUTOMATIC GATES PROPERLY MAINTAINED. Have a professional gate
installer perform routine tests of the entrapment protection sensors, such as photo eyes
and gate edges. Also, make all necessary repairs to the gate hardware to keep the gate
running smoothly. Failure to adjust and test a gate operator properly can increase the risk
of injury or death.
YIn addition to appropriately placed external entrapment sensors, ask your installer to
reduce the setting of the pressure relief valve to the lowest setting allowable that reliably
operates the gate. This valve controls the force of the operator, and the sensitivity of the
inherent reversing sensor.
YDo not attempt to disable the Warn Before Operate buzzer, except in Class IV
restricted access locations. This buzzer provides an alert that the gate is about to
move.

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Scope and Planning of Swing Gate Installations
Putting it all together: sample plans
The type and location of sensors needed for proper swing gate operation depends primarily on whether
the gate opens perpendicular to a wall (Fig. C) or opens to an open space (Fig. D)
Fig. C A swing gate that opens parallel to a wall or building.
This figure illustrates a sample plan for a gate, incorporating the elements described below.
1. The swing gate operator automates the gate. May be ordered for left hand or right hand as shown.
2. The weather resistant NEMA 3R controller box houses the Smart Touch control and hydraulic pump.
3. An entrance control opens the gate for entry.
4. Shadow loop prevents the gate from closing on a car. This loop is active only when the gate is open.
5. Obstruction loops (Located inside and outside the swing arc of the gate)
6. Optional free exit loop
7. Photo eyes stop the gate to help prevent vehicular or personal entrapment.
8. Safety mesh on the gate panel prevents reaching through the gate panel.
9. Warning signs alert users to the danger of entrapment when using automatic gate operators.
10. Sensing edges on the bottom of the gate and inside and the outside leading edge of the gate panel
send a signal to operator to stop and reverse when an obstruction is encountered.
11. The physical clearances must be configured to stop the gate panel 16 inches away from the wall to
protect someone from being crushed.
12. A warning buzzer sounds an alert when an obstruction is sensed and can warn before gate motion.

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Scope and Planning of Swing Gate Installations
Putting it all together: sample plans
Fig. D A swing gate that opens to empty space
This figure illustrates a sample plan for a gate, incorporating the elements described below.
1. The swing gate operator automates the gate. May be ordered for left hand or right hand as shown.
2. The weather resistant NEMA 3R controller box houses the Smart Touch control and hydraulic pump.
3. An entrance control opens the gate for entry.
4. Shadow loop prevents the gate from closing on a car. This loop is active only when the gate is open.
5. Obstruction loops (Located inside and outside the swing arc of the gate)
6. Optional free exit loop
7. Photo eyes stop the gate to help prevent vehicular or personal entrapment.
8. Safety mesh on the gate panel prevents reaching through the gate panel.
9. Warning signs alert users to the danger of entrapment when using automatic gate operators.
10. Sensing edges on the bottom of the gate and inside and the outside leading edge of the gate panel
send a signal to operator to stop and reverse when an obstruction is encountered.
11. A warning buzzer sounds an alert when an obstruction is sensed and can warn before gate motion.

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Tools Required for an Efficient Installation
5. Hammer
6. Screwdriver sets,
Straight and Phillips
7. Wrench set, open end,
1/4" through 1"
8. Electric drill and bits,
1/8" through 3/8"
9. Roto-hammer and bits to
accommodate anchor bolts
10. Level—it doesn’t need to look
like this one, but the installation
needs to be level!
11. Two pair wide jaw vice
grip pliers, or two C clamps,
4" capacity
4. Allen wrench set3. Concrete anchor
bolts, four 5/8” – ¾”
2. Carpenters
pencil or crayon
1. Chalkline or other
builders string

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Swing Gate Post Details

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HRG 220 - Pump Pack

Installation and Maintenance Manual
11
HRG 222 Pump Pack

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How Our Hydraulic Swing Gates Work

Installation and Maintenance Manual
13
Installation Preparation Checklist
1. Read all of the instructions, especially the
Important Information at the beginning of this
manual, before you attempt installation. This
section is focused upon mechanical installation.
For electrical setup, skip to the section on
system configuration and use of the Smart
Touch Controller.
2. Check to see that the mounting slab is
the right size and ready to have an
operator attached. Also check that
electrical conduits are correctly located
to enter the operator base. Hy-Security
recommends the slab reaches below the
local frost line and is poured together
with supporting post or pilaster.
NOTE: The backing post/column, (provided by
others) must accommodate all of the "tip
over" loads imposed by the gate panel.
Installation Process Overview
•Mount the control box and connect all
conduit fittings.
•Mount the operator post.
•Install all accessories such as: vehicle
sensing loops, access control devices,
gate edge sensors or photo eyes.
•Pull all wires and hoses into conduits.
Note: HRG 220 comes with up to 40’ of
hose for the HRG 222 with up to 100’ of
hose, however, you must advise the
factory on the accurate amount of hose
desired or it will not be shipped with the
operator.
•Test the basic operator functions.
•Mount the gate panel and make fine
adjustments.

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Field Hose Measurements for HRG Operators
Note: HRG operators are usually shipped without the hoses needed to complete the system.
Hy-Security will make these hoses in custom lengths as required, attach the quick disconnect fittings and
pre-charge the hoses with hydraulic fluid. The use of pre-charged hoses is important to avoid the
introduction of air into the system.
When field measuring for the necessary hose length to order, the following may be helpful:
1. There is little room in the base of the HRG operator post and limited room in the control/power panel,
therefore, your field measurements must be very accurate when calculating the length of the
necessary hydraulic hoses. If your dimensions are too little, you will not reach the connections, if
your measurements are too long, you will have trouble finding space for the excess hose.
2. Remember that two hoses are needed for each cylinder. This means that you need four hoses when
you are installing a HRG 222 (pair) operator.
1) Be sure to measure accurately the following distances: (the best way is to pull a cord through the
conduit, mark it, and then measure it.)
a) The bottom of the pump/control panel to the bottom of the trench, plus 24”
b) The total distance across the trench.
c) The distance back up to the bottom of the operator, plus 6”
1) The part number for the hoses is:
1/4" hose for HRG: HSFHO 004 SW
The HRG 220 includes up to 40’ total length for the two hoses required.
The HRG 222 includes up to 100’ total length for the four hoses required.
For assistance call your distributor.