Maximum Controls MAX MEGATRON 2500 Installation instructions

MAX megatron 2500
Installation and Owners Manual
www.max.us.com
4009963
High Traffic Commercial
Brushless DC High Profile
Swing Gate Operator
Made in USA
CONFORMS TO UL STD 325
UL CLASS - I, II, III, IV
CERTIFIED TO CAN/CSA STD
C22.2 NO. 247

1
© 2014 Maximum Controls LLC.
All rights reserved. No part of this
manual may be reproduced in any
means: graphics, electronics or
mechanical, including photocopying
without the expressed written
permission of the publisher. Materials
components and specifications are
subject to change without notice.
Magatron 2500 Specifications
Important Safety Information
UL 325 Model Classifications
UL 325 Required Entrapment Protection
UL 325 Compliant Installation Requirements
Intended Use of Swing Gate Operator
Installation
Gate Operator Position
Single Gate Operator
Dual Gate Operators
Arm Position Options
Arm Connection to Gate
Optional Remote Power Supply Kit - MAX Magic Box
Solar
Install Warning Signs
Entrapment Protection
In-Ground Loops
Wiring operator
Gate Operator System Overview
Input AC Power
Optional Remote Power Supply Kit - MAX Magic Box
Solar Power
Secondary Operator to Matrix 1
Turn ON / OFF Operator Power
matrix 1
Matrix 1 Overview
Wiring Overview
Primary Gate -Open Left / Open Right
Close Timer
Selectable Gate Speed Control
Battery Back-Up Mode
Anti-Tailgate
Single Pass Anti-Tailgate
Radio Receiver
Radio Safety Pause
Gate in Motion Alarms
OBD Port Black Box
Maglock
Plug-In Loop Detectors
In-Ground Loop Connection
ID Plug
Gate Tamper
UL Entrapment LEDs
Emergency Vehicle / Max Open Inputs
Gate Disable
Partial Open
UL Alarm / Alarm Reset Button
Gate Status Monitoring
OPEN / STOP / CLOSE Connection
CLOSING Photocell Connection
Gate Operators Communication LEDs
24V Power for Matrix 1
Battery in Use LED
Motor Motion LEDs
Optional External Open/Close Key Switch
Adjustments
Open and Close Limits
Release Handle Clamp
Reverse Sensor (ERD)
Maintenance
Qualified gate operator technician
End user/Home owner
Megatron 2500 Wiring Schematics
Manual Release
Audible Alarm
Replacement Parts List
Warranty
Table of contents
2
2
3
3
4
5
6
7
8
9
10
10
11
12
13
14
15-16
17
18
19
20
21
36
36
37
38
39
40
41
33
34
35
22
23
24
24
24
24
25
25
26
26
26
26
27
27
27
28
28
28
28
29
29
30
30
30
30
31
31
31
31
32

2
WARNING – To reduce the risk of injury or death:
1. READ AND FOLLOW ALL INSTRUCTIONS.
2. Never let children operate or play with gate controls. Keep the remote control away from children.
3. Always keep people and objects away from the gate. NO ONE SHOULD CROSS THE PATH OF THE MOVING GATE.
4. Test the gate operator monthly. The gate MUST reverse on contact with a rigid object or stop when an object activates the
non-contact sensors. After adjusting the force or the limit of travel, retest the gate operator. Failure to adjust and retest the
gate operator properly can increase the risk of injury or death.
5. Use the emergency release only when the gate is not moving.
6. KEEP GATES PROPERLY MAINTAINED. Read the owner’s manual. Have a qualified service person make repairs to gate
hardware.
7. The entrance is for vehicles only. Pedestrians must use separate entrance.
8. SAVE THESE INSTRUCTIONS
UL 325 Class of Operation - Class I, II, II, IV
Gate Type - Vehicular Swing Gate
Max Gate Weight / Length - 2500lbs/15 ft or 2000 lbs/20 ft
90° Opening Time - 16 selectable speeds from approximately 11.5 sec to 20 sec depending on the weight and length of gate.
Cycles per Hour AC Input Power - Continuous
Battery Back-Up Cycles - 400 continuous cycles for a 2500 lbs gate
Input AC Power - Switchable: 115VAC or 230VAC single phase
Motor - 24VDC Brushless (equivalent to 1 HP AC motor)
Operating Temperature - -4°F to 158°F (-20°C to 70°C)
Entrapment Protection:
- UL 325 Type A Inherent (ERD sensor)
- Input for UL 325 Type B1 (photocell) and B2 (reverse edge)
megatron 2500 specifications
important safety information

3
CLASS I
Residential Vehicular Gate Operator - A vehicular gate operator
(opener or system) intended for use in a home of one to four
single family dwellings, or a garage or parking area associated
therewith.
CLASS II
Commercial/General Access Vehicular Gate Operator - A
vehicular gate operator (opener 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.
CLASS III
Industrial/Limited Access Vehicular Gate Operator - A
vehicular gate operator (opener or system) intended for uses
in an industrial location, loading dock area or other location
not intended to service the general public.
CLASS IV
Restricted Access Vehicular Gate Operator - A vehicular gate
operator (opener or system) intended for use in a guarded
industrial location or buildings such as airport security area or
other restricted access locations not servicing the general
public, in which unauthorized access is prevented via
supervision by security personnel.
The same type of device shall not be utilized for both the primary and the secondary entrapment protection means. Use of a single device to
cover both the opening and closing directions is in accordance with the requirement; however, a single device is not required to cover both
directions. A combination of one Type B1 for one direction and one Type B2 for the other direction is the equivalent of one device for the
purpose of complying with the requirements of either the primary or secondary entrapment protection areas.
A- Inherent entrapment protection system.
B1 - Provision for connection of a non-contact sensor
(photoelectric sensor or the equivalent).
B2 - Provision for connection of a contact sensor
(edge device or the equivalent).
C- Inherent adjustable clutch or pressure relief device.
D- Provision for connection of an actuating device
requiring continuous pressure to maintain opening
or closing motion of the gate.
E- An audio alarm.
Gate Type Protection Type Class I & II Class III Class IV
Swing Gate
A, B1, B2, C, D
A, C A, B1, B2, C
A, B1, B2, C, D, E A, B1, B2, C, D, E
A, B1, B2, C, D
Secondary
Primary
SECURITY
AUTHORIZED
PERSONNEL
ONLY
ul 325 model classifications
ul 325 required entrapment protection

4
AInstall the gate operator only when:
1The operator is appropriate for the construction of the gate and the usage Class of the gate,
2All exposed pinch points are eliminated or guarded.
BThe operator is intended for installation only on gates used for vehicles. Pedestrians must be supplied with a separate access
opening. The pedestrian access opening shall be designed to promote pedestrian usage. Locate the gate such that persons
will not come in contact with the vehicular gate during the entire path of travel of the vehicular gate.
CThe gate must be installed in a location so that enough clearance is supplied between the gate and adjacent structures when
opening and closing to reduce the risk of entrapment. Swinging gates shall not open into public access areas.
DThe gate must be properly installed and work freely in both directions prior to the installation of the gate operator.
Do not over-tighten the operator clutch or pressure relief valve to compensate for a damaged gate.
EFor gate operators utilizing Type D protection:
1The gate operator controls must be placed so that the user has full view of the gate area when the gate is moving,
2 A gate operator shall additionally be provided with a placard that is marked in letters at least 1/4-in (6.4-mm) high with
the word “WARNING” and the following statement or the equivalent: “Moving Gate Has Potential of Inflicting Injury or
Death - Do Not Start Gate Unless Path is Clear”.
3An automatic closing device (such as a timer, loop sensor, or similar device) shall not be employed, and
4No other activation device shall be connected.
FControls intended for user activation must be located at least ten feet (10’) away from any moving part of the gate and where
the user is prevented from reaching over, under, around or through the gate to operate the controls. Outdoor or easily
accessible controls shall have a security feature to prevent unauthorized use.
GThe Stop and/or Reset button must be located in the line-of-sight of the gate. Activation of the reset control shall not cause
the operator to start.
HA minimum of two (2) WARNING SIGNS shall be installed, one on each side of the gate where easily visible.
IFor gate operators utilizing a non-contact sensor:
1See instructions on the placement of non-contact sensors for each Type of application,
2Care shall be exercised to reduce the risk of nuisance tripping, such as when a vehicle, trips the sensor while the gate is
still moving, and
3One or more non-contact sensors shall be located where the risk of entrapment or obstruction exists, such as the
perimeter reachable by a moving gate or barrier.
JFor a gate operator utilizing a contact sensor:
1One or more contact sensors shall be located where the risk of entrapment or obstruction exists, such as at the leading
edge, trailing edge, and post mounted both inside and outside of a vehicular horizontal slide gate.
2One or more contact sensors shall be located at the bottom edge of a vehicular vertical lift gate.
3One or more contact sensors shall be located at the pinch point of a vehicular vertical pivot gate.
4A hardwired contact sensor shall be located and its wiring arranged so that the communication between the sensor and
the gate operator is not subjected to mechanical damage.
5A wireless device such as one that transmits radio frequency (RF) signals to the gate operator for entrapment protection
functions shall be located where the transmission of the signals are not obstructed or impeded by building structures
natural landscaping or similar obstruction. A wireless device shall function under the intended end-use conditions.
6One or more contact sensors shall be located on the inside and outside leading edge of a swing gate. Additionally, if the
bottom edge of a swing gate is greater than 6 inches (152 mm) above the ground at any point in its arc of travel, one or
more contact sensors shall be located on the bottom edge.
7One or more contact sensors shall be located at the bottom edge of a vertical barrier (arm).
ul 325 compliant
installation requirements

5
The operator is intended for use on a VEHICULAR swing gate ONLY. It is intended to be used WITH appropriate entrapment
protection safety devices and in-ground vehicle loop detection system.
Pedestrians MUST use a separate entrance.
The gate operator IS NOT intended to be
used on a PEDESTRIAN gate.
Entrapment Area
In-Ground Loops:
Help protect the gate
operator from accidentally
opening and/or closing on
vehicles in the gate’s path.
Sensing Edge: Helps
protect the gate operator
from accidentally opening
and/or closing on vehicles
in the gate’s path.
Entrapment Protection Photocell:
Helps guard against the opening
gate from entrapment.
Closing Gate Protection Photocell: Helps protect the gate operator
from accidentally closing on vehicles in the gate’s closing path.
Moving Gate Can Cause
Serious Injury or Death
KEEP CLEAR! Gate maymove at any time
without prior warning.
Do not let children operate the gate or play
in the gate area.
Thisentrance is for vehiclesonly.
Pedestrians must useseparate entrance.
Warning Signs: Should be installed
on both sides of gate area and
easily visible.
intended use of
swing gate operator

6
Read and understand this entire manual before installation. Check with the local building department prior to installing this gate
operator to comply with local building code requirements. The gate must be installed in a location so that enough clearance is
supplied between the gate and adjacent structures when opening and closing to reduce the risk of entrapment. Swinging gates
should not open into public access areas.
The gate must be properly installed and work freely in both directions prior to installation of the gate operator.
Hinge Pivot Point
Illustrations not to scale
Gate Bracket Pivot Point
Arm
Pivot
Point
Longer
than “E”
Locked Position
Long Arm Short Arm
Shorter
than “D”
15” Min
Operator
Pivot
Point
Concrete Pad
24” x 24”
DO NOT allow arm to touch
hood in gate’s OPEN position.
TOO MUCH STRESS is put on
the arm in this position during
gate operation.
Open Position
Closed Position
Outside Property
Inside Property
2” Min
2” Gate Frame
installation
Gate Operator position
AShould be at least 1/4 the gate length.
B15” minimum for open gate clearance (2” thick gate).
CDistance “A” minus 8 inches (A - 8 = C).
D&EArm should be 90° from gate when OPEN
and in the straight “locked” position when CLOSED.
Measurement Guidelines
A
B
C
E
D
Hood
Preferred arm position is 90°
from open gate. See page 10
for arm position options and
connection to gate.

7
Concrete Pad Input Power
Conduit
Check local building
codes in your area for
depth of concrete
before installation.
6” Above Ground
Ground Level
Secure gate operator to concrete
pad with four (4) 1/2” x 3” (min)
sleeve anchors.
Arm MUST be installed level.
Concrete Depth Note: The heavier the gate, the deeper the concrete
pad should be. At least two feet recommended for heavier gate.
installation
single Gate Operator
•REQUIRED - AC input power wire to the GATE OPERATOR.
•OPENING cycle protection device wires (photocells) to the GATE OPERATOR. See page 13.
•CLOSING cycle protection device wires (photocells) to the GATE OPERATOR. See page 13.
•In-ground loop wires to the GATE OPERATOR. See page 14.
Conduit Guidelines and Suggestions
1/2
“Optional” Input Power Note:
24VDC low voltage power wires can be run
from a remote power supply (MAX Magic
Box) to power the gate operator if desired.
See page 10 for more information.
Support Bar: See below
Illustration not to scale
The gate must be properly installed and work freely in both directions prior to the installation of the gate operator.
See “Gate Operator Position” on page 6 for operator position.
Support Bar
A support bar should be installed at the gate bracket height across the ENTIRE gate to keep the gate pickets from bending.
YES
YES
NO
NO
Gate Bracket
Support Bar Too High & Not Long Enough
Support Bar

8
The gates must be properly installed and work freely in both directions prior to the installation of the dual gate operators.
See “Gate Operator Position” on page 6 for operator positions.
Each entrapment protection device MUST be connected to corresponding gate operator.
Outside Property
Inside Property
to Secondary Operator
to Secondary Operator
to Primary Operator
to Primary Operator
Illustrations not to scale
installation
Photocell
(OPENING Cycle
ONLY)
Photocell
(OPENING Cycle
ONLY)
Sensing Edges
Entrapment Area
Entrapment Area
RS-485
Input
Power
Input
Power
•REQUIRED - Run AC input power wire to EACH gate operator.
•REQUIRED - Run RS-485 wires from SECONDARY operator to the PRIMARY OPERATOR.
•Run UL 325 entrapment protection device conduits to EACH Corresponding GATE OPERATOR. (see below & page 13)
•Run the CLOSING cycle protection device conduit (photocells) to the PRIMARY OPERATOR. (page 13)
•Run in-ground loop wires to the PRIMARY OPERATOR. (page 14)
dual Gate Operators
Primary
Primary
Secondary
Secondary
“Optional” Input Power Note:
24VDC low voltage power wires can be run from a remote
power supply (MAX Magic Boxes) to power the gate
operators if desired. See page 10 for more information.
Support Bars: See bottom of page 8.
Arms MUST be installed level.
Conduit Guidelines and Suggestions
Illustration not to scale
Check local building codes in your area for
depth of concrete before installation.
Secure EACH gate
operator to concrete
pad with four (4)
1/2” x 3” (min)
sleeve anchors.
Concrete Depth Note: The heavier the gates, the deeper the concrete
pads should be. At least two feet recommended for heavier gates.
1/2
6” Above
Ground

9
installation
arm position options
Gates in Closed Position
Gate in Opened Position
Arms are NOT installed in LOCKED position.
High Traffic Arm Option
Retro-Fit Arm Option
If a vehicle tries to push gates
open, arms will give when NOT
in the locked position and allow
gates to move without damaging
the gate operators.
The tamper relay will be
activated for a few seconds
which will trigger a camera or
alarm system if desired.
When replacing an existing gate operator, the arm may not be able
to conform to the preferred arm position (90° from gate in open
position). The positions illustrated below can be acceptable as long
as the gate operator cycles smoothly and there is NO gate hesitation
when gate starts cycling in either direction.
After you’re satisfied testing the arm in the FULL OPEN and FULL CLOSED positions, weld gate bracket and arm.
Full Open
Full Closed
Illustrations not to scale
Arm MUST be installed level.
Preferred arm position
is 90° from open gate.
weld completely around arm tubing and gate bracket.
Locked Position
Gate Bracket
Assembly Arm Elbow
Assembly
arm connection to gate
Arm
Re-Attach Arm to Operator:
Limit Pin
Limit Tabs
Slot
Release Handle Clamp
Limit pin MUST fit into slot in
bottom of release handle clamp
directly under the arm when
re-attaching arm to operator.
90°
Gate in Opened Position
90°

10
A remote power supply is for installations where it is too costly or difficult to trench a 115/230 VAC power line to the operator
but instead run a low voltage power line to the operator. A MAX Magic Box Kit (sold separately) is required to remotely install
the MAX PS-24 power supply.
Install the MAX Magic Box near the 115 VAC or 230 VAC input AC power source, up to 500 ft away from gate operator.
Remove MAX PS-24 power supply from gate operator and place in MAX Magic Box. See page 18 for MAX Magic Box wiring
instructions.
NOTE: A MAX Magic Box kit is required for EACH gate operator when using dual gate operators.
At MAX Magic Box
Concrete Pad
24VDC Low Voltage Power
2-Wires - 10 AWG Min.
24VDC Low Voltage Power
Conduit
Ground Level
MAX PS-24
Power Supply
Removed from
Operator
500 ft MAX
500 ft MAX
At Gate Operator
optional remote power supply kit - max magic box
installation
Input Power
To Operator
24 VDC
230V
AC ON
POWER
OFF
MAX PS-24
POWER SUPPLY
FUSE
7 AMP
IN
Madein USA
Select Input Voltage:
115VAC or230VAC
disconnect
power before
servicing unit
WARNING
WARNING
HIGH
HIGH
VOLTAGE
VOLTAGE
!
warranty
VOIDED
if label is
REMOVED
Power/Solar In
Connector
Wire
Nuts
MAX
Magic
Box Kit
Operator
MAX Magic Box
Near Power Source
115/230 VAC Power Source
Input AC Power
Conduit not supplied
24VDC Low
Voltage
Power

11
MAX Solar
Panel
Approx. 45°
solar
installation
Refer to Solar application guide.

12
installation
A minimum of two (2) WARNING SIGNS shall be installed,
one on each side of the gate where easily visible.
Moving Gate Can Cause
Serious Injury or Death
KEEP CLEAR! Gate may move at any time
without prior warning.
Do not let children operate the gate or play
in the gate area.
This entrance is for vehicles only.
Pedestrians must use separate entrance.
Moving Gate Can Cause
Serious Injury or Death
KEEP CLEAR! Gate may move at any time
without prior warning.
Do not let children operate the gate or play
in the gate area.
This entrance is for vehicles only.
Pedestrians must use separate entrance.
Moving Gate Can Cause
SeriousInjury or Death
KEEPCLEAR!Gatemaymoveatanytime
without priorwarning.
Donotletchildrenoperatethegateorplay
in the gatearea.
This entranceis forvehiclesonly.
Pedestriansmustuseseparate entrance.
install warning signs

13
Install photocells to help protect against entrapment during the OPENING cycle of the gate (secondary entrapment protection).
Install photocells to help protect vehicles during the CLOSING cycle of the gate.
Install sensing edge to help protect vehicles from a moving gate. See pages 16 & 23 for wiring instructions.
Beam Height:
21” Normal
27.5” Max.
Beam: 5” or LESS from CLOSED gate.
Photocell
(OPENING Cycle)
Photocell (CLOSING Cycle)
Photocell (CLOSING Cycle)
Photocell (OPENING Cycle)
Install just above gate operator.
Entrapment
Area
Gate OpenGate Open
Gate Closed
Top View
Side View
If this dimension is less
than 16”, then secondary
entrapment protection is
REQUIRED in this area.
CLOSING Cycle NOTE: Additional CLOSING Cycle Photocells
can be installed anywhere needed. Run all additional CLOSING
Cycle photocell’s conduit to the GATE OPERATOR.
OPENING Cycle NOTE: Additional OPENING Cycle Photocells
can be installed anywhere needed. Run all additional
OPENING Cycle photocell’s conduit to the GATE OPERATOR.
Dual Gate Operators NOTE: Run
EACH OPENING Cycle Photocells
conduit to each corresponding
GATE OPERATOR. See page 8.
Run OPENING Cycle
photocell conduit to
GATE OPERATOR.
Illustrations not to scale
installation
entrapment protection
Outside Property
Inside Property
Control Box
Control Box
Run CLOSING Cycle conduit to GATE OPERATOR.
SENSING EDGE
Run wire to
GATE OPERATOR.
SENSING EDGE
Mount on end of gate.
Conduit

14
Run
in-ground
loops conduit
to GATE
OPERATOR.
Install in-ground loops to help protect vehicles from a moving gate. See pages 23 & 27 for wiring instructions.
Refer to loop maunufacturer’s
instructions to determine
specific loop dimensions.
It is recommended that a
licenced installer perform
this work.
Center
Loop
Safety
Loop
Safety
Loop
Exit
Loop
4 ft
4 ft min.
4 ft
4 ft
4 ft
4 ft
4 ft 4 ft
1 1/2”
Typical
1/4” Saw Cut
Saw Cut
Backer Rod
Loop Wire
Pavement
Sealant
Illustration not to scale
Side View of
Saw Cut
Loop lead wires are
twisted 6 twists per
foot minimum inside
conduit.
Safety Loops
Are placed on each side of the gate to
prevent the gate from closing on a
vehicle in it’s path. They will stop or
reverse the cycling of the gate while a
vehicle is in or near the gate’s pathway.
Center Loop
Will ONLY HOLD the gate in the Full
Open Position when a vehicle is on the
center loop. However, it WILL NOT stop
or reverse the gate once it starts to
close.
Exit Loop
Automatically opens the gate for exiting
vehicles without having to use a radio
transmitter (remote control). The exit
loop can be placed a minimum of 4 feet
away from the safety loop or far enough
away from the gate so it has opened by
the time the vehicle approaches it.
installation
in-ground loops
Outside Property
Inside Property

15
Check with local building department prior to installing any permanent wiring on this gate operator. Make sure all wiring
complies with local code requirements.
MAX PS-24 Power Supply: AC power management for the
AC input power to the gate operator. See pages 17, 18 & 21.
Release Handle Clamp: Manually move the gate when
handle is raised. See page 34 & 38.
Audible Alarm: Sounds when there is a problem with cycling
the gate. Push the alarm reset button on the control box to
shut off alarm (see below). Alarm can sound every time
operator is cycled using ONLY battery back-up power when
turned ON, See page 39.
24VDC Motor
MAX MC-100 Motor Controller: Manages UL entrapment
protection devices and operator motor reversing ERD
sensitivity adjustment. See pages 16, 20, 21 & 32.
MAX BC-7 Battery Module: Battery Back-Up and DC power
management for the gate operator. See page 16.
Limit Tabs: Adjusts the OPEN and CLOSE gate positions.
See page 33.
Limit Switch Box: Contains the limit switches. Gate operator
will NOT function when limit switch box is not connected.
See page 33.
Matrix 1: Manages control panel operations. Manages
inputs/outputs, loops and reports problems with gate
operator. See Matrix 1 Section starting on page 22.
Alarm Reset Button:
Push to shut off alarm
and/or reset Matrix 1.
See pages 30, 35 & 39.
Wiring operator
Gate Operator System Overview
1
1
2
3
4
5
6
7
8
9
9
A
2
3
4
5
6
A
7
8
Gate Operator
Alarm Reset Button

16
ALARM
PWR 24V -
GND -
RS-485 (-) -
RS-485 (+) -
LIMIT
SWITCH
BATTERY
PACK
MOTOR
INPUTS POWER IN MOTOR
www.max.us.com
Power
INPUTS
MC-100
JOG
RIGHT
JOG
LEFT
UL
Entrap
Matrix
On Line
ERD
Sensitivity
Photo
Cell
Limit SW
On Line Edge 2
Edge 1
Edge 1 Edge 2
Photo Cell
GND
Jog RT
Jog LT
MOTOR OVERLOAD
Motor Controller
ERD
Min
Max
Sensitivity
Wiring operator
1
2
3
4
5
6
7
A
B
C
D
E
F
G
H
I
J
K
L
M
A
BC
D
E
F
G I K
H J L
M
BATTERY Plug: MUST be plugged into BATTERY IN port Before use.
POWER/SOLAR IN Port: MAX PS-24 Power Supply connection.
Battery Voltage LEDs: Show amount of battery power available.
LEDs are always ON when using AC power. Test battery button must be
pressed to show battery power when using battery power ONLY.
ON/OFF Battery Button:
IMPORTANT: Battery power automatically turns ON when MAX PS-24 Power
Supply AC POWER Switch is turned ON.
To turn OFF ALL POWER to operator:
1. Turn OFF AC POWER Switch on MAX PS-24 Power Supply.
Battery power remains ON.
2. WAIT for 15 seconds.
3. Press and HOLD (approx. 5 seconds) the YELLOW ON/OFF BATTERY
button until MAX BC-7 LEDs turn ON, then release button.
LEDs will turn OFF.
Replace Battery LED: Replace battery when lit.
TEST Battery Button: Press to show amount of battery power available when
using battery power ONLY (Battery voltage LEDs will light respectively).
Battery IN Error LED: Lights when there is a battery connection problem.
Make sure battery plugs are correctly installed and there is no damaged or
loose wires.
MOTOR OVERLOAD LED: Excessive current being drawn by motor when lit.
ERD LED: ERD sensor has been activated when lit.
ERD Sensitivity Knob: Changes sensitivity of ERD sensor.
ERD Sensitivity LED: MAX sensitivity reached when lit.
Jog LEFT/RIGHT Buttons:
Push and HOLD buttons accordingly to move the gate (release the button to
stop gate). WARNING: Avoid moving arm while using Jog buttons.
INPUTS:
Jog LT/RT: Connects to External Open/Close Key Switch. Connect a
single key switch to control dual gate operators, See page 32.
GND: Low Voltage Common connection.
Edge 1: Connects to a Sensing Edge. Multiple sensing edges can be
connected.
Edge 2: Connects to a second Sensing Edge. Multiple sensing edges can
be connected.
PHOTOCELL: Connects to a UL 325 Standard OPENING Cycle photocell
ONLY. Multiple OPENING Cycle photocells can be connected.
Matrix On Line LED: Gate operator is successfully communicating with
Matrix 1 when lit.
Limit SW On Line LED: Limit Switch Box is successfully communicating
with MC-100 Motor Controller when lit.
Edge 1 LED: Reversing Edge 1 input has been activated when lit.
Edge 2 LED: Reversing Edge 2 input has been activated when lit.
UL Entrap LED: Edge1/Edge2/Photocell input has been activated when lit.
Photocell LED: Photocell input has been activated when lit.
Power LED: Low voltage power is connected when lit.
OPENING Cycle
Photocells
ONLY.
24V ONLY
Photocell
Power.
Photocell (N.O.)
Edge 1
(N.O.)
Edge 2
(N.O.)
GND
GND
GND
24V
24V
RS-485
GND
Sensing Edges
To Matrix 1
Gate Operator System Overview continued
MAX MC-100 Motor Controller
DUAL GATE OPERATORS NOTE: Connect EACH photocell/reverse
edge to the corresponding gate operator. See page 8.
POWER
IN
POWER/SOLAR
IN
BATTERY
IN
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Made in USA
BATTERY
PACK
TO MOTOR
CONTROLLER
E1/2
Battery Voltage
Replace
Battery
ON/OFF
Battery
TEST
Battery
Battery IN
Error
F
MAX BC-7
Battery Module
IMPORTANT
connect to
“BATTERY IN”
before use
E1
/2
Battery Voltage
Replace
Battery
ON/OFF
Battery
TEST
Battery
Battery IN
Error
F
MAX BC-7
Battery Module
Made in USA
3
4
5
6
7
1
2
MAX BC-7 Battery Module
External Open/Close
Key Switch,
Dual Gate Operators
See page 32.

17
warranty
VOIDED
if label is
REMOVED
disconnect
power before
servicing unit
WARNING
WARNING
HIGH
HIGH
VOLTAGE
VOLTAGE
!
230V
AC ON
POWER
OFF
MAX PS-24
POWER SUPPLY
FUSE
7 AMP
IN
Made in USA
Select Input Voltage:
115VAC or 230VAC
AC ON
POWER
OFF
MAX PS-24
Power Supply
MAX PS-24
POWER SUPPLY
FUSE
7 AMP
IN
Made inUSA
Remove and wire input AC power wire to the MAX PS-24 power supply as shown.
Choose either 115V or 230V setting on input AC power selector switch.
NOTE: AC power wire is required for EACH gate operator
when using dual gate operators.
Chassis (Green)
Neutral (White)
Line (Black)
Chassis (Green)
Neutral (White)
Line (Black)
Single Phase 115VAC Only
115VAC
Single Phase 230VAC Only
230VAC
Input AC Power Options
Operator MUST be Properly GROUNDED
Input AC Power
Selector Switch
7 Amp
Fuse
Set to 115V
115V
230V
Set to 230V
input ac power
Wiring operator
CAUTION: If power selector
switch is set for 115V but
input power is actually 230 V,
7 Amp Fuse will blow.
Power Terminal
Proper grounding of this
gate operator is a
requirement for
LIGHTNING PROTECTION
in lightning prone areas.
To be effective, ground connections should be made
with a minimum 12 AWG, 600 volt insulated wire to
a ground point within 10 feet of the gate operator.
The ground point must be at an electrical panel, a
metallic cold water pipe that runs in the earth, or a
grounding rod.
Ground
within 10 ft
of operator.
WARNING
WARNING
connect chassis
to ground rod for
lightning protection
DO NOT remove any existing green ground wires.
IMPORTANT NOTE: Make sure there are NO exposed
bare wires at the power terminal connection.
NOTE: Consult city codes for AC line wiring.
Beware of existing underground services.
115 OR 230VAC
Power Wire
CAUTION: MAKE SURE CIRCUIT
BREAKER IS OFF BEFORE WIRING
DANGER
HIGH VOLTAGE!
DO NOT
TURN POWER
ON AT THIS
TIME.

18
POWER
IN
POWER/SOLAR
IN
BATTERY
IN
www.max.us.com
Made in USA
BATTERY
PACK
TO MOTOR
CONTROLLER
E1/2
Battery Voltage
Replace
Battery
ON/OFF
Battery
TEST
Battery
BatteryIN
Error
F
MAXBC-7
BatteryModule
IMPORTANT
connect to
“BATTERY IN”
beforeuse
E1
/2
Battery Voltage
Replace
Battery
ON/OFF
Battery
TEST
Battery
Battery IN
Error
F
MAX BC-7
Battery Module
Made in USA
A MAX Magic Box Kit (sold separately) is required to remotely install the MAX PS-24 Power Supply.
Remove MAX PS-24 power supply from gate operator and install in MAX Magic Box, plug in power supply to PS-24 connector.
Wire input AC power to the MAX PS-24 Power Supply.
Choose either 115V or 230V setting on input AC power selector switch. Run 24V low voltage wires (10 AWG min, not included)
from the MAX Magic Box connection and wire to POWER/SOLAR IN connector (Polarity Matters!). Plug connector into
POWER/SOLAR IN port on the gate operator’s MAX BC-7 battery module.
NOTE: A MAX Magic Box kit is required for EACH gate operator
when using dual gate operators.
IMPORTANT NOTE: Maximum Control’s
remote power supply technology does NOT
utilize the battery power from the MAX BC-7 Battery
Module during NORMAL gate operation. Battery power is
reserved for back-up power ONLY when an AC power failure
occurs. As a result, battery life is NOT shortened.
This low voltage system can CONTINUOUSLY cycle the gate during
NORMAL gate operation, perfect for high traffic gate applications.
POWER/SOLAR IN
Port
POWER/SOLAR IN
Connector
(Included in kit).
Connect Input
AC Power wire
(See page 17 for
wiring)
At Gate Operator
Wiring operator
IMPORTANT: MAX Magic Box and Gate
Operator MUST EACH be Properly GROUNDED.
Proper grounding is a requirement for
LIGHTNING PROTECTION in lightning prone
areas. To be effective, ground connections
should be made with a minimum 12 AWG, 600
volt insulated wire to a ground point within 10
feet of the MAX Magic Box and gate operator.
The ground point must be at an electrical panel,
a metallic cold water pipe that runs in the earth,
or a grounding rod.
NOTE: Beware of existing underground
services.
optional remote power supply kit - max magic box
MAX Magic Box MUST
be Properly GROUNDED
Pos +
GND
Polarity Matters!
Ground Rod
within 10 ft
of Box
NOTE: Consult city codes
for AC line wiring.
Input Power
To Operator
24 VDC
At MAX Magic Box
230V
AC ON
POWER
OFF
MAX PS-24
POWER SUPPLY
FUSE
7AMP
IN
Made in USA
Select Input Voltage:
115VAC or 230VAC
disconnect
power before
servicingunit
WARNING
WARNING
HIGH
HIGH
VOLTAGE
VOLTAGE
!
warranty
VOIDED
if label is
REMOVED
Input AC Power
Power In
From
PS-24
Pos +
GND
24V Wire in Conduit
10 AWG Minimum
115 VAC or
230 VAC
Input AC Power
MAX PS-24 Power Supply
removed from operator
24V
Wires
10 AWG
Minimum
MAX BC-7
Battery Module
Ground
Input AC Power Selector Switch
CAUTION: If power selector switch is
set for 115V but input power is actually
230 V, 7 Amp Fuse will blow.
CAUTION: MAKE SURE CIRCUIT
BREAKER IS OFF BEFORE WIRING
DANGER
HIGH VOLTAGE!
DO NOT TURN POWER
ON AT THIS TIME.