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Slide gate operator

FAAC 844 Slide Gate Operator Repair in Dallas–Fort Worth

Shield Gate Repair services the FAAC 844 slide operator on residential and commercial rack gates. The 844 is electromechanical with an oil-bath clutch — not hydraulic — and the calls we see are a gate that overruns its limit, a clutch slipping on a heavy gate, or an operator that quits on hot afternoons.

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Is this a FAAC 844?

The 844 is a compact gearmotor bolted to a foundation plate on a concrete pad beside the gate, with a plastic cover and a pinion driving a steel rack welded or screwed along the bottom of the gate. The 780D control board is built into the operator under its own cover, with its F, + and – programming keys on that cover, so there is usually no separate control box.

FAAC's manual covers the 844 ER Z16 CR, 844 R, 844 R CAT and 844 R RF, with CAT and RF versions set up for chain drive and idle transmissions. The Z16 or Z20 refers to the pinion, and it changes the gate's rating and speed.

The 844's closest look-alike is FAAC's 746, a lighter slide operator. FAAC's parts list shows the two sharing the upper housing, cover base, release lever unit and MLS limit switch, so the label, not the shape, is how to tell them apart.

  • A compact gearmotor with a plastic cover on a concrete pad beside the gate opening
  • A steel rack along the gate meshing with a pinion on the operator (or a chain on CAT/RF versions)
  • A keyed protection door with the release lever behind it
  • Two magnets on the side of the rack (magnetic limit) or two steel plates on top of it (inductive limit)
  • A plastic oil filler cap and a vent screw label on the housing

Also labelled: 844 ER, 844 ER Z16 CR, 844 R, 844 R CAT, 844 R RF, 844 ER CAT, 844 ER RF

844 at a glance

Drive
Electromechanical, non-reversing; rack or chain pinion
Versions (FAAC manual)
844 ER Z16 CR, 844 R, 844 R CAT, 844 R RF
Power supply
115 or 230 VAC (+6% −10%), 60 Hz
Absorbed power
650 W
Motor
1700 rpm · 7 A at 115 V, 3.5 A at 230 V · 70 µF (115 V) / 35 µF (230 V) starting capacitor
Reduction ratio
1:30
Pinion / rack
Z16 or Z20 · module 4 rack
Maximum thrust
250 lbf (Z16) · 180 lbf (Z20)
Maximum gate weight
3,950 lb (Z16) · 2,200 lb (Z20)
Gate speed
32 ft/min (Z16) · 40 ft/min (Z20)
Use frequency
70% at 75°F; FAAC notes direct sunlight can reduce it to 20%
Clutch
Twin-disk in oil bath
Oil
0.5 gal FAAC XD 220
Winding thermal protection
248°F
Operating temperature
−4°F to +131°F
Protection class / weight
IP44 · 32 lb
Control board
780D, built into the operator
Limit switch
Magnetic (MLS) or inductive

From FAAC’s published documentation. Your unit’s label and manual take precedence.

What your 844 is doing, and what usually causes it

  • The gate reaches the end but the motor keeps running, then everything stops

    Usually: Limit magnet or plate missed — knocked off, moved, or too far from the sensor — so the motor runs its 120-second limit and the 780D goes into alarm. A failed limit switch if the reference is correctly placed.

    What we do: We watch FC1 and FC2 as the gate travels, reset magnets to ¼–½ inch (or plates under 3/16 inch), and replace the switch only if the LED still does not change.

  • The motor runs but the gate barely moves or slips on heavy days

    Usually: Clutch set too light, the lighter standard clutch spring on a gate over 2,200 lb, board thrust set low, or wheels and track binding.

    What we do: We release the gate and push it along the track first. If it rolls freely, we set the clutch and board force; if it does not, the gate hardware is the repair.

  • It stops working on hot afternoons and comes back later

    Usually: FAAC's 70% use frequency is measured at 75°F and it warns direct sunlight can cut that to 20%; the winding cut-out is 248°F. Low oil reduces cooling in the oil bath.

    What we do: We check oil level against the copper winding, check cycle settings such as pause time, and look at the work the operator is being asked to do in full sun.

  • Grinding or clicking as the gate moves

    Usually: Rack sitting on the pinion instead of meshing, rack sections out of step at joints, worn pinion teeth, or a pad that has moved.

    What we do: We check the 1/16-inch clearance FAAC specifies, re-space rack joints and replace the pinion if teeth are worn.

  • The gate opens but will not close

    Usually: A closing photocell or edge device tripped, or a missing jumper between the FSW CL and –TX FSW terminals where none is fitted.

    What we do: We read the FSW CL and SAFE LEDs and bypass each device temporarily to find the one holding the gate.

  • An alarm is sounding and the gate will not respond

    Usually: The audio alarm output triggers after two sequential activations of an entrapment device and sounds until a STOP command.

    What we do: We clear the STOP input, find what triggered twice, and test the encoder or edge before returning to service.

  • I released it for a power cut and now it will not pick the gate back up

    Usually: Lever not fully closed, key not turned back counter-clockwise, or the gate not moved far enough for the release to engage.

    What we do: We follow FAAC's sequence — cut power, close the lever, turn the key back, move the gate until it engages — then check the release lever unit for wear.

844 down? Tell us what it is doing — we will tell you what it needs.

(214) 735-4314

How the 844 works — and what that means for repair

Electromechanical, with the gears and clutch running in oil

FAAC describes the 844 as an electro-mechanical operator that moves the gate through a rack or chain pinion. A 650 W motor drives a 1:30 reduction, and the twin-disk clutch runs in an oil bath filled with FAAC XD 220. The oil is lubrication and cooling, not a hydraulic circuit — there is no pump, no pressure setting and no seal-kit rebuild in the hydraulic sense.

The gearing is non-reversing, so FAAC says the gate is mechanically locked when the motor is off and needs no separate lock. A gate that can be pushed along its track with the operator engaged has a released lever, a slipping clutch or a stripped pinion.

Two layers of force limiting

The 844 limits force twice. The 780D board adjusts motor thrust over 50 levels and, where an encoder is fitted, uses it as anti-crushing: on an obstacle the gate reverses for 2 seconds, and a second hit during that reverse stops it. Behind that sits the mechanical clutch.

FAAC ships the clutch set to maximum, with a spring suited to gates up to 2,200 lb and an alternative spring supplied for heavier gates. To adjust it, power is cut, the motor shaft is held with a wrench and the adjustment screw turned — clockwise for more torque, counter-clockwise for less. An 844 on a heavy gate that still has the lighter spring fitted is a classic cause of slipping.

Limit sensing is the most common 844 fault

The 844 stops at each end when its limit sensor sees a reference on the rack: two magnets on the side of the rack for the MLS magnetic switch, or two steel plates on top of the rack for the inductive switch. FAAC gives the gap as ¼ to ½ inch for magnets and under 3/16 inch for plates.

On the 780D, the FC1 and FC2 LEDs are on when free and go off when a limit is engaged. If the switch never sees its reference, FAAC says the motor runs for 120 seconds and the board goes into alarm. Magnets knocked loose, a plate that has crept, or a gate that has dropped on its wheels all produce exactly that.

Rack and pinion setup

FAAC uses a module 4 rack and specifies that once the rack is fitted, the gearmotor is lowered by about 1/16 inch so the rack does not rest its weight on the pinion. It also says not to grease between rack and pinion, and not to weld rack sections to their spacers or to each other.

The pinion choice changes the numbers: FAAC rates the Z16 for gates to 3,950 lb at 32 ft per minute and the Z20 for gates to 2,200 lb at 40 ft per minute. A Z20 swapped onto a gate that was set up for a Z16 is a heavier load than the operator was specified for.

844 parts we repair, adjust or replace

A failed part is not a failed operator. These are the components that actually wear or fail on the 844, and what we do about each.

  • Twin-disk oil-bath clutch and adjustment spring

    Adjusted

    Mechanical overload protection behind the electronic force limit.

    Signs it has failed: Gate slips under load, or will not slip at all on an obstruction.

  • Gear oil (FAAC XD 220)

    Serviced

    Lubricates and cools the motor, clutch and gears; must cover the copper winding.

    Signs it has failed: Level below the winding, overheating in summer, oil at the housing joint.

  • Limit switch (MLS magnetic or inductive) and rack references

    Adjusted

    Stops the motor at each end of travel.

    Signs it has failed: Overrun and 120-second alarm, FC LED not changing, magnets missing.

  • 780D control board

    Part replaced

    Logic, thrust, decelerations, braking, encoder, safety inputs; built into the operator.

    Signs it has failed: Dark display, F1 (5 A / 10 A) or F2 (800 mA) fuse open, no response to keys.

  • Starting capacitor

    Part replaced

    Starts the single-phase motor — 70 µF on 115 V, 35 µF on 230 V.

    Signs it has failed: Motor hums without turning, or starts only in one direction.

  • Pinion (Z16/Z20) and rack

    Part replaced

    Transfers drive to the gate; the pinion size sets speed and weight rating.

    Signs it has failed: Worn or chipped teeth, rack bearing on the pinion, noise at joints.

  • Release lever unit, lock and key

    Repaired

    Disconnects the drive so the gate can be pushed by hand.

    Signs it has failed: Lever will not close, key seized, drive not re-engaging.

  • Encoder (where fitted)

    Part replaced

    Anti-crushing detection and precise decelerations and partial opening.

    Signs it has failed: ENC LED not flashing while the motor turns; nuisance reversals.

Repair or replace your 844? The honest answer

The 844 is a long-lived, heavily built slide operator and most faults are adjustments — limits, clutch, oil — or single parts such as the 780D, capacitor or pinion. Replacement makes sense when the gearbox or motor is worn out, or when the gate is heavier or busier than the 844 was set up for.

Repair it when

  • Overrunning or stopping short — reset magnets or plates and decelerations.
  • Slipping — clutch adjustment or the heavier-gate spring FAAC supplies.
  • Board, fuse or capacitor failure after a surge.
  • Noisy drive — rack mesh, joint spacing or a worn pinion.

Replace or upgrade when

  • Worn gears or a failed stator where parts cost approaches a new operator — we price both.
  • A Z20 pinion on a gate heavier than its 2,200 lb rating; the fix may be the Z16 pinion rather than a new operator.
  • Very high cycle counts in full sun, where FAAC’s own use-frequency curve says the operator is working beyond its range.
Call Now — (214) 735-4314Request a Free Estimate for FAAC 844 repair

Case studies

FAAC repairs we have documented

Other FAAC operators, written up in full — the same diagnose-first approach we take on a 844.

All case studies

Our FAAC work

Photographs from our own FAAC jobs — a mix of models, not all of them the 844. None of it is stock.

  • A FAAC sliding gate operator mounted at the base of a dark aluminium slide gate, with the drive rack visible along the gate frame
  • Close view of a FAAC operator housing opened for service, showing the hydraulic pump and control board inside
  • A FAAC swing gate operator arm connected to a metal driveway gate post
  • A dark metal estate driveway gate closed between stone pillars, fitted with a concealed gate operator

How we diagnose and repair a 844

  1. Read the 780D status LEDs

    OP-A, OP-B, FC1, FC2, FSW OP, FSW CL, STOP, SAFE and ENC tell us whether the fault is a limit, a safety device, a command input or the drive.

  2. Release and push the gate the full length

    Key clockwise and lever pulled, then the gate rolled end to end by hand to check wheels, track, top guide and stops before any electrical work.

  3. Check drive, oil and clutch

    Oil covering the copper winding, rack mesh and clearance, pinion wear, and clutch slip against the gate’s real weight.

  4. Set limits, force and decelerations

    Magnets or plates positioned so the gate stops ¾ to 2 inches short of its mechanical stop, then thrust, braking and encoder sensitivity set and a full cycle run.

  5. Quote, repair and test safeties

    Price agreed before parts are fitted; photocells, edges and encoder reversal tested at the end.

FAAC warranty on the 844

The FAAC International 844 manual (Rev. 01, December 2010) states a limited warranty of 24 months from the date of invoice. It extends only to wholesale customers buying through FAAC International's normal distribution channels; FAAC International does not warrant its products to end consumers, who must ask their selling dealer about that dealer's warranty.

  • Maintenance parts such as oil are not covered.
  • Damage from lightning, electrical power surge, hail, flood, vehicles and improper installation is excluded — impact from vehicles is a real risk for a pad-mounted slide operator.
  • Check the manual that came with your operator; later FAAC International terms may differ from the 2010 statement.

Our warranty on the repair

Every repair is backed by a clear written warranty. No hidden terms and no confusing fine print: what is covered is explained before we begin, and it is separate from whatever FAAC covers on the operator itself.

What our warranty covers

The 844 in Dallas–Fort Worth conditions

Direct sun cuts the 844’s duty cycle

FAAC's use-frequency curve for the 844 is measured at 75°F and it says plainly that exposure to direct sunlight can reduce use frequency to as low as 20%. A dark 844 on a south-facing pad at a busy HOA or commercial slide gate in a DFW July is a long way from 75°F. Heat-related stopping is a duty-cycle problem first, and we look at shading, pause time and cycle count before parts.

Oil level matters more in heat because the oil bath carries heat away from the motor and clutch. FAAC asks for a yearly check in medium use and every 6 months in heavy use.

Pads, flooding and clay

FAAC recommends the concrete pad sit at least 4 inches above grade to avoid flooding the operator, which is rated only IP44. On low driveways that collect storm runoff, a pad poured flush is a recurring cause of wet boards. Seasonal clay movement shifts the pad and the track independently, changing the pinion-to-rack clearance FAAC sets at about 1/16 inch.

Surges and hail

FAAC's 844 manual recommends grounding the operator with a ground rod if needed and adding a surge suppressor to protect against surges and lightning. The 780D lives inside the operator under a plastic cover, so a lightning strike nearby or a hail-cracked cover letting water in both end at the same board.

FAAC 844 repair across DFW & Surrounding Areas

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FAAC 844 repair questions

Is the FAAC 844 a hydraulic operator?

No. FAAC describes it as electro-mechanical. Its motor, clutch and gears run in FAAC XD 220 oil for lubrication and cooling, but there is no hydraulic pump or pressure circuit.

How do I release a FAAC 844 to move the gate by hand?

Per FAAC: open the protection door, insert the key, turn it clockwise and pull the release lever. To restore, cut power, close the lever, turn the key counter-clockwise, remove it and move the gate until the release engages.

How heavy a gate can an 844 move?

FAAC rates it for 3,950 lb with the Z16 pinion and 2,200 lb with the Z20. The standard clutch spring suits gates up to 2,200 lb; FAAC supplies an alternative spring for heavier gates.

Why does my 844 run on past the end of travel?

Usually the limit switch is not seeing its magnet or plate. FAAC notes that if the references are not detected, the motor runs for 120 seconds and the board goes into alarm.

What oil does an 844 use and how often should it be checked?

FAAC XD 220 only, about half a gallon. FAAC recommends checking once a year in low or medium use and every 6 months in heavy use; the level should cover the motor’s copper winding.

Do you carry 844 parts?

We carry common control boards. 844-specific parts such as a limit switch, pinion or release lever unit may need to be ordered, and we tell you before booking the repair.

Request a free estimate for your 844

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