Total Door Automation ZK1800 User manual

Swing Gate Operator
User’s Manual
Model: ZK1800
WARNING!
ONLY QUALIFIED AND EXPERIENCED TECHNICIANS
SHOULD ATTEMPT INSTALLATION OR SERVICE TO THIS
UNIT, OTHERWISE, SERIOUS PERSONAL INJURY,
DEATH, OR PROPERTY DAMAGE MAY OCCUR.
PLEASE KEEP THESE INSTRUCTIONS FOR FURTHER
REFERENCE.
Total Door Automation (Australia) Pty Ltd
www.totaldoorautomation.com.au
[email protected]m.au

ZK1800 SWING GATE OPERATOR USER’S MANUAL
2
CONTENT
1. Important Safety Information ……………………3
2. Additional Features………………………………3
3. Specifications ……………………………………4
4. Necessary Tools……………………………………4
5. Site Preparation ……………………………………4
6. Packing List…………………………………………5
7. Mechanical / Installation …………………………6
8. Mechanical / Adjustment…………………………14
9. Electrical / Control Box Mounting ……………15
10. Electrical / Main Terminal Wiring ……………16
11. Electrical / Setting ………………………………22
12. Maintenance ………………………………………23
13. Troubleshooting …………………………………24

ZK1800 SWING GATE OPERATOR USER’S MANUAL
3
1. Important Safety Information
Read the entire user’s manual before beginning installation, and carefully obey the
following instructions:
The gate operator should be installed by a qualified technician. DO NOT in any way modify
the components of the gate operator, otherwise, serious personal injury or property damage
may occur.
To prevent the risk of electrocution, be sure to turn off all power to the ZK1800 until
installation is complete.
The operator should be switched off before repairing it or opening its cover.
When opening or closing the gate, do not attempt to walk or drive through the gate. Do not
touch the gate while in operation.
The auto-stop function must be checked during installation to ensure that the gate can
auto-stop in the event of obstruction.
This auto-stop function should be regularly inspected and adjusted, if necessary.
Children should not be allowed to play near or operate automatic gates.
Keep the remote control away from children.
The automatic gate operator must be grounded.
Be careful when in close proximity to moving parts where hands or fingers could be pinched.
Do not allow control devices to be placed so that a person can access them by reaching
through the gate.
Never active your gate operator until you ensure that the area is clear of people, pets or other
obstructions.
The entrance is for vehicles only. Pedestrians must use a separate entrance.
Our company reserves the right to change the design and specification without prior
notification.
Failure to comply with the instructions above may result in personal injury or property damage. Our
company does not accept responsibility for damage or injury resulting from installing this operator.
2. Additional Features
Use this operator with single or double swing gates.
Supports gate leafs up to 300kg and 3m.
Supports up to 25 RF remotes, 2 included.
User programmable and user erasable remote codes.
RF hopping code technology prevents your remote code being accessible to others.
For your safety, the ZK1800 will stop if it encounters an obstruction during closing or opening.
Manual key release design for emergency purposes.

ZK1800 SWING GATE OPERATOR USER’S MANUAL
4
3. Specifications
Table 1 Technical data
4. Necessary Tools
The following tools may be necessary to install the operator. You will need an electric drill, hacksaw,
screwdrivers, tape measure, level, wire cutters and wire stripper, a socket set, and possibly access
to a welder if your installation cannot use the supplied brackets. If the brackets shipped do not fit
your gate because of the dimensions of your gate, you may have to fabricate brackets for your
application or notch a column in order to obtain the necessary set back.
5. Site Preparation
Before you begin the operator installation, make sure the following conditions are observed:
The gate and post must be suitable for being automated.
Check that the structure is sufficiently strong and rigid, the operator must operate on a
reinforced point on the gate and that its dimensions and weights conform to those listed in the
specifications of this document.
The gate should be mounted to the fence post and swinging freely, there should be little
resistance in the swing of the gate.
Make sure that the gate is plumb and level.
The fence posts must be mounted in concrete.
If you want to use electric lock, make sure the bottom of the gate is 45-50mm from the
ground. If the electric lock is not required, make sure the distance from the bottom of the gate
to the ground more than 20mm.
Model
ZK1800
Power supply
AC240V, 50Hz
Motor power
220W
Rated force
3500N
Working angle of gate
90or 105
90opening or closing time
(one gate leaf)
22 seconds
105opening or closing time
(one gate leaf)
27 seconds
Max. gate section weight
400 kg
Max. gate section width
3 meters
Max. travel distance (Fig.4)
265 mm（90）, 330mm(105)
Cycles per hour (20ºC)
≤15
Motor thermal protection
120ºC
Ambient temperature
-20ºC~+45ºC

ZK1800 SWING GATE OPERATOR USER’S MANUAL
5
6. Packing List
After receiving the product, you should make an unpack-inspection, in which you should check
whether the product was damaged. If you have any problem please contact dealer.
Table 2 Packing List of ZK1800 Swing Gate Operator
Item
Diagram
Quantity
Remark
For one
gate leaf
For two
gate leafs
Operator
1
2
Post bracket
1
2
Gate bracket
1
2
Control box
+2 remotes
1
1
Stop block
1
2
Optional
Electric Lock
1
1
Optional
Base plate
1
1
Optional
Accessories
Pin
For mounting
post bracket
1
2
In the
same
plastic
bag.
Circlip Ø12
1
2
Lock nut (M12)
For mounting
gate bracket
1
2
Spring washer Ø12
1
2
Plain washer Ø12
1
2
bubble level
1
2
Release key
1
2
User’s manual
1
2

ZK1800 SWING GATE OPERATOR USER’S MANUAL
6
α
Post bracket
A
B
Hinge
Post
DCE
Enlarge
FR
S
Gate bracket Base plate
(close position)
>0
Gate
Stop block
(open position)
5-10mm
α
90°
105°
A B
135
160 130
130
D(min)
90
90
E
85
85
F(min)
R
65
S
635
635
7. Mechanical / Installation
Begin with both operators unlocked. Next identify if this will be a “push to open” or a “pull to open”
installation. In either configuration, the gate is mounted on one face of the mounting post, and the
operator is mounted on the face 90 degrees from it. Below are schematics of both “push to open”
and “pull to open” configurations.
As shown in the diagram below, correctly mounting geometry assures that the desired degrees of
swing are achieved, that the gate speed is correct, and that the operator and gate will operate
properly and have a long life.
Fig.1 Pull to open mounting geometry

ZK1800 SWING GATE OPERATOR USER’S MANUAL
7
A
B
Hinge
Post
D
C
Enlarge
F
R
Gate
α
90°
105°
AB
135
160 130
130
D(min)
90
90
E
85
85
F(min)
R
65
S
635
635
α
Post bracket
S
Gate bracket Base plate
(close position)
Stop block
(open position) 5-10mm
>0
E
Fig.2 Push to open mounting geometry
Main structure and dimension (see Fig.3 and Fig.4)
Operator Limit switch cover
6
Limit switch
5
Release here
4
Wiring terminal block
3
2
1
5
3
1Front cover
2
4
6
4
7
7Lead screw socket
Fig.3

ZK1800 SWING GATE OPERATOR USER’S MANUAL
8
115
265mm / 330mm
153
890
32
(Max. travel distance)
Fig.4
Installed automatic gate operator (see Fig.5)
Locate the gate operator between the two hinges, the installation height range is 300 –800mm. this
will prevent the gate from twisting and flexing. Add a cross bar on the gate if necessary.
Note: If the operator is mounted at a height above the specified range, and the gate is not sturdy
enough, then it may result in bending or damage to the gate and gate operator.
2Gate
1
4
3
4
1
2
AC220V
7
5
5
6
Use cable through the concrete pad
3
300-800mm
8
Photocell (Not included)
7
Stop block (optional)
3
6
6
9
Gate operator
Electric & base plate(optional) Control box
External button switch(not included)
8
9Flashing light(not included)
Fig.5

ZK1800 SWING GATE OPERATOR USER’S MANUAL
9
1
3
4
1
2
3
Post bracket
M8 screw and plain washer
Bubble level
2
Straight plate
4
Rear parts of gate operator
Weld the straight plate to post bracket, cut plate if necessary in order to obtain the correct
mounting geometry.
Fix the post bracket on the cement pillar with screws and spacers (or welding for metal pillar).
Make sure that the bracket is plumb and lever. See Fig.6
The bracket installation should meet the specifications as shown in figure 7.
Fig.6
Fig.7
α（Angle）
A
B
D(min.)
E（Fig.8）
F(min.)
S(Fig.9)
90°
135
130
90
85
R
635
105°
160
130
90
85
65
635
A
B
Hinge
Post
DC
FGate
A
D
B
R

ZK1800 SWING GATE OPERATOR USER’S MANUAL
10
If it is not possible to maintain the quotas indicated in the table see Fig.7, different measurements
should be calculated with reference to the following items:
For α=90°, F≥R
For α=105°, F≥65mm
The difference between A and B must not exceed 30mm.
It is important to maintain the quota D, otherwise the gate will bump the post.
The thickness of gate (i.e. diameter of hinge) should be between 40mm and 70mm.
Front part of gate operator
Weld the straight plate to the gate bracket, make sure E=85mm.
Mark a vertical line around 635mm from the center of hinge. Fig.9
If the gate brackets shipped do not fit your gate because of the dimensions of your gate, you
may have to fabricate brackets for your application or notch a column in order to obtain the
necessary set back.
Fig.8
Fig.9
Mount the rear part of the gate operator on the post bracket using the pin supplied, secure
the pin using the circlip. Fig.10
Install the gate bracket on to the front part of gate operator using the lock nut. See Fig.11
S
S=635mm
Top view
Center of hinge Gate Pad（not supply）
S=635mm
2R E
S
Top view
Center of hinge Gate
E
Gate bracket
E
Weld the straight
plate to the bracket. E=85mm

ZK1800 SWING GATE OPERATOR USER’S MANUAL
11
Fig.10 Fig.11
Move the front part of gate operator up and down slowly, check the installation height of the
gate bracket, fit the gate bracket to the gate, and the centerline of the gate bracket should
align with the vertical line, and use a level to check the flatness of the operator (See Fig.12).
Tack weld the gate bracket on the gate, the bracket installation should meet the specifications
as shown in Fig.1 and Fig.2.
Release the gate operator, open and close the gate manually, performing complete opening
and closing travel. Movement must be smooth and the lead screw socket, should not reach
the mechanical stop.
If this is not the case, review bracket positioning and that its dimensions conform to those
listed in the specifications of this document.
After you have identified the desired position of the bracket, remove the gate operator and
permanently weld the gate bracket top, bottom and sides. See Fig.13.
Install the gate operator as shown in Fig.14.
Caution: welding with operator in place may damage the operator.
Fig.12 Fig.13
Circlip
4
2
1
3
Rear part of gate operator
Pin
Post bracket
1
2
3
4
3
2
11
2
3Front part of gate
operator
Gate bracket
Lock nut M12
Move the front part of gate operator up and down
and check the position of gate bracket with a
level, make sure that the gate operator is level.
Remove the gate operator, weld
the gate bracket on the gate.

ZK1800 SWING GATE OPERATOR USER’S MANUAL
12
Fig.14
Stop block –open position
After the gate reaches the desired angle (90°or 105°), ensure 5-10mm space exists
between the gate and stop block See Fig.1 or Fig.2. This margin is required to prevent the
gate from bumping on the stop block.
Fix the stop block to the ground with expansion bolts, add pad if necessary.
After mounting the operator, with the key unlocked, move the gate, verify that it stops at the
proper position.
Electric lock
An electric lock is provided for installation for gate lengths greater than 1.5 meters.
To install the base plate of the lock, place the base plate between the two gates, determine
the location, mark and drill the holes.
Fix the base plate to the ground with 3 screws, make sure the gate is higher than base plate
and that the lock pin can fit tightly in the hole in the plate.
Weld the steel plate of the lock to the primary gate, and then fix the lock to the steel plate.
See Fig.15 to determine the height of the electric lock.
3
4
1Pin
2Circlip
3Gate operator
4Sping washer ,plane washer
and lock nut M12
Fix the gate operator on the brackets, make sure
that the operator is level.
1
2

ZK1800 SWING GATE OPERATOR USER’S MANUAL
13
Plate or tab (see Fig.15)
The pair of gate sections will not start simultaneously. The gate section with the lock will start
to open earlier than the other gate section, so that both sections can be locked properly.
A plate or tab can be welded on the gate section with the lock so that when it closes, it will
trap the gate section without the lock between itself and the base plate, thus locking both
gate sections.
Top plate
With the gate in the desired closed position.
Weld a stop plate on the gate section without the lock.
Fig.15
Stop plate
A
B
Secondary gate
Primary gate
Plate or tab
Electric lock
Lock pin
Secondary
Primary
Steel plate
Gate
15
8-10
3-6
45-50
A- Top view
Release here
Electric lock
Base plate
B- Side view

ZK1800 SWING GATE OPERATOR USER’S MANUAL
14
8. Mechanical / Adjustment
Manual operation (see Fig.16)
If a power failure or a malfunction occurs the gate can be operated manually by releasing the
operator to manual operation.
Move the protection tab, insert the key supplied into the lock.
Rotate the key clockwise by 180ºto release the operator, open and close the gate manually.
Reverse these steps when engage the operator.
Fig.16
Limit switch
Limit switches are needed to stop the gate at the correct open and closed positions.
Isolate the power supply to the system.
Back off the screw retaining the front cover, remove the front cover. Slide out the aluminium
limit switch cover. (See Fig.17)
Release the operator, manually close the gate to fully closed position.
Slacken and then press down the screw locking the close limit switch by a screwdriver.
Move the close limit switch into the required position and tighten the limit switch lock
screw.(see Fig.18)
Manually open the gate to fully open position.
Slacken and then press down the screw locking the open limit switch by a screwdriver.
Move the open limit switch into the required position and tighten the limit switch lock screw.
NOTE:
Move the open limit switch to right to open more, move the open limit switch to left to open less.
Move the close limit switch to right to close less, move the close limit switch to left to close more.
After limit switch adjustment, with power on, you can open the gate then close the gate and observe
whether the gate has successfully reached the open and closed positions. If the gate does not reach
the desired position, readjust the limit switch to suit the desired distance, the process is the same as
the adjusting as above.
Rotate the key clockwise to release the operator.
Rotate the key anticlockwise to engage the operator.

ZK1800 SWING GATE OPERATOR USER’S MANUAL
15
Fig.17
Fig.18
Mechanical stop
Move the gate to fully open and closed position, slacken the screws on the mechanical stop, move
the mechanical stop to proper position until the stop is 10-20mm from the lead screw socket, tighten
the screws. See Fig.19
10-20mm 10-20mm
Mechanical Stop Lead screw socket
Fig.19
9. Electrical / Control Box Mounting
Install the cable
In order to protect the wires, between the gate operator and the control box, armored cable,
galvanized cable or PVC conduit must be set into the concrete when it is poured. To prevent
rainwater from entering into the cable, arrange the cable as shown in Fig.20-A.
Wires within the cable shall be located or protected so that no damage can result from
contact with any rough or sharp part.
The diameter of the cable must be more than 20mm, motor wire should be 0.75mm2, the
earth wire should be 1mm2, and limit switch wire should be 0.5 mm2.
Use another cable for safety devices (such as electric lock, infrared photocell, flashing light,
external button switch etc.), the wire size should be more than 0.5 mm2.
1
2
3
123
Limit switch cover
Front cover
Screw and cap
Limit switchScrew Move the limit switch
Close limit switch Open limit switch

ZK1800 SWING GATE OPERATOR USER’S MANUAL
16
Fig.20
Install the control box
The control box circuit should be equipped with breaker (10A).
Make sure that power is OFF before making any electrical connections.
Place the control box in the desired mounting position, open the cover of the control box,
remove the control board, mark the mounting holes, and install the control box, fix the control
board back to the box. See Fig.21
Perform the wiring.
Note: we regard the gate with the electrical lock as the primary gate, the other gate as the
secondary gate.
223
138
Fig.21 Control box mounting size
10. Electrical / Main Terminal Wiring
Note: following is wiring of ‘pull to open’ configurations. For ‘push to open’, please exchange
the motor wires ‘V1’ and ‘W1’, ‘V2’ and ‘W2’, exchange the limit switch wries ‘OP1’and ‘CL1’,
‘OP2’and ‘CL2’.
Connecting
Open the wiring terminal block cover, connect the gate operator to the control box as shown in table
3 and Fig.22, ensue that the wires and terminals match colors.
In order to prevent rainwater from entering main unit, remember to bend the cables downwards as
shown in Fig.23.

ZK1800 SWING GATE OPERATOR USER’S MANUAL
17
Table 3
Primary operator
E
U
V
W
CL
COM
OP
Colour
Yellow & Green
Blue
(white)
Brown
(red)
Black
Red
White
Green
Control board
E
U1
V1
W1
CL1
COM
OP1
Secondary operator
E
U
V
W
CL
COM
OP
Colour
Yellow & Green
Blue
(white)
Brown
(red)
Black
Red
White
Green
Control board
E
U2
V2
W2
CL2
COM
OP2
1
2
3
2
3
Main unit
Wiring terminal block
Cover
1
E
U
V
W
CL
OP
COM Green
White
Black
Red
Brown
Blue
Connect to control board
Blue
Blue
Blue
220V
Fig.22
Fig.23

ZK1800 SWING GATE OPERATOR USER’S MANUAL
18
Fig.24 Control board diagram
Ground E N L U1 V1W1U2 V2W2 LAMP LOCKOP1 Com CL1OP2 Com CL2 Com IR 12V O/S/C Com K T G
1 2 3 4
5
6
7
8
9
1011121314151718 1619

ZK1800 SWING GATE OPERATOR USER’S MANUAL
19
Table 4 Wiring notes of control board
Position
Function
Remark
1
Force adjustor (for secondary gate-leaf)
The resistance may be increased or
decreased by rotating clockwise or
anticlockwise.
2
Force adjustor (for primary gate-leaf
with electrical lock)
The resistance may be increased or
decreased by rotating clockwise or
anticlockwise.
3
Antenna
4
Receiver panel
5
Power indicator light (LED1)
1206 red
6
Learn indicated light (LED2)
1206 green
7
Learn button
6 mm x 6 mm
8
Beeper
DC12V
9
Set auto close function (SW)
10
External button switch/keypad interface
Connect external button switch/keypad
11
Infrared photocell
Normally open (12V)
12
Limit switch
Normally open
13
Electric lock
DC12V
14
Flashing light
AC240V
15
Fuse
AC250V: 5x20 10A
16
Secondary motor (for secondary
gate-leaf)
17
Primary motor (for primary gate-leaf
with electrical lock)
18
Power supply
AC240V
19
Ground
Power (see Fig.25)
Wire a standard grounded plug to your control board using standard electricians wiring practices.
Wire the opposite end of this cable to the ‘ ’, ‘N’, ‘L’ contacts of the control board. Connect L to the
power line, N to the neutral line, and ‘’ to the earth line.
Motor (see Fig.25)
Connect primary motor that on the primary gate (with electric lock) to ‘U1’, ‘V1’, ‘W1’. Connect
secondary motor to ‘U2’, ‘V2’ and ‘W2’.

ZK1800 SWING GATE OPERATOR USER’S MANUAL
20
Flashing light (See Fig.25)
Attach two wires of flashing light to port ‘LAMP’.
Fig.25
Electric lock DC12V (see Fig.26)
Connect two wires of electric lock to port ‘LOCK’. Wire size should be more than 1 mm2.
Limit switch (see Fig.26)
Connect primary limit switch that on primary gate operator (installed on primary gate with electric
lock) to port ‘OP1’, ‘COM’, ‘CL1’.
Connect secondary limit switch to port ‘OP2’, ‘COM’, ‘CL2’.
Fig.26
Note: Use operator with single gate, connect motor to ‘U1’, ‘V1’, ‘W1’, connect limit switch to
‘OP1’, ‘COM’, ‘CL1’, it is important to short the ‘OP2’ and ‘COM’, ‘CL2’ and ‘COM’ terminal
with the jumper wires. See Fig.27.
Fig.27
COMOP1LOCK
X5
CL1 OP2 COM CL2
Electric
lock open com close closecomopen
Connection of electric lock & limit switch
Primary limit switch Secondary limit switch
Power supply
Connection of motor & flashing light
X1
E N L
Earth Neutral Power
X2
U1 V1 W1
U V W WVU
W2
V2
U2
X3
Primary Motor Secondary Motor
LAMP
X4
Flashing light
Ground
Terminal 'E' on primary
gate operator see Fig.16
Terminal 'E' on secondary
gate operator see Fig.16
COMOP1LOCK
X5
CL1 OP2 COM CL2
Limit switch
open com close
X2
U1 V1 W1
U V W
Motor
For single gate
Short circuit