technical m anualdoc-s0508-3r14-imei02 • technical manual • issue 5 | page chapter 2: technical...

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© Copyright 2014 RAYNOR Garage Doors, Inc. All rights reserved. No part of this work (including attachments and inclusions) may be reproduced or transmitted in any form or by any means, electronic or mechanical, or by any information storage or retrieval system without permission in writing from the publisher.

RC200 are registered trademarks of RAYNOR

RAYNOR Garage Doors 1101 E. River Rd. Dixon, Il 61021 USA RAYNOR on the World Wide Web: www.RAYNOR.com

Table of Contents

DOC-S0508-3R14-IMEI02 • Technical Manual •Issue i | P a g e

TableofContentsRapidCoil™ Series RC200............................................................................................................................ 1

Chapter 1: Before You Begin ........................................................................................................................ 1

1.1. Safety ............................................................................................................................................ 1

1.1.1. Hazard Standards ................................................................................................................. 1

1.1.2. Installation Precautions ......................................................................................................... 1

1.1.3. Operation Precautions .......................................................................................................... 1

1.1.4. Maintenance Precautions ...................................................................................................... 2

1.1.5. Electrical Precautions ............................................................................................................ 2

1.2. Installation Tools ........................................................................................................................... 3

Chapter 2:...................................................................................................................................................... 5

Technical Characteristics .............................................................................................................................. 5

2.1. Introduction .................................................................................................................................... 5

2.2. Specifications: ............................................................................................................................... 5

2.2.1. RC200 ................................................................................................................................... 5

2.2.2. Classification ......................................................................................................................... 5

2.2.3. Description of Criteria ............................................................................................................ 6

2.2.4. RC 100 EN Standards ........................................................................................................... 7

2.3. Space requirements ...................................................................................................................... 8

2.2.5. RC200 ................................................................................................................................... 8

2.2.6. Fore frame ............................................................................................................................. 8

2.2.7. Mounting details .................................................................................................................... 9

Chapter 3: Mechanical Installation .............................................................................................................. 11

3.1. Door Installation .......................................................................................................................... 11

3.1.1. Introduction .......................................................................................................................... 11

3.1.2. Assemble the Door .............................................................................................................. 11

3.1.3. Mounting the door ............................................................................................................... 15

3.3. Install Door Curtain ..................................................................................................................... 18

3.4. Control box, Photo Eyes and Anti-roll off switch ......................................................................... 20

3.1.4. Control Box mounting .......................................................................................................... 20

3.1.5. Photo eye ............................................................................................................................ 20

Figure 3-14: Photo Eyes and CBX .............................................................................................................. 21

3.1.6. Anti-roll off switch ................................................................................................................ 21

3.5. Install covers ............................................................................................................................... 22

3.7. Door Limit Position ...................................................................................................................... 23

3.8. Manual Operation ........................................................................................................................ 24

3.1.7. Optional manual operation .................................................................................................. 25

Chapter 4:.................................................................................................................................................... 27

Lubrication and Maintenance ...................................................................................................................... 27

Table of Contents

ii | P a g e DOC-S0508-3R14-IMEI02 • Technical Manual • Issue

4.1. Door lubrication ........................................................................................................................... 27

4.1.1. Lubrication of door new install ............................................................................................. 27

4.1.2. Re-lubrication of existing door ............................................................................................. 28

4.2. Inspection/Maintenance .............................................................................................................. 31

4.2.1. Philosophy ........................................................................................................................... 31

4.2.2. Inspection Summary ........................................................................................................... 31

DOC-S0508-3R14-IMEI02 • Technical Manual • Issue 1 | P a g e

Chapter 1: Before You Begin

1.1. Safety

1.1.1. Hazard Standards

Throughout this manual, there are labels that indicate situations during the installation process that pose risks to installers and/or equipment.

The mechanical and electrical components of the door may have posted warning and caution information as well. These typically include the following symbols indicating the type of risk and precaution to be taken.

The Warning sign indicates a danger to installation technicians who may be exposed to severe physical harm or death from electrical components. The symbol includes specific information regarding the risk such as “High Voltage” or “Keep Hands Clear.”

The Caution sign indicates installation technicians to observe safe operating procedures. Failure to comply with the procedure may result in injury or damaged equipment. The sign includes procedural text such as “Lockout for Safety” or “Lookout for Forklifts.”

Note indicates a related comment or instruction in the manual.

1.1.2. Installation Precautions

Only certified RAYNOR door installers may install RAYNOR doors. Always use proper tools, procedures and techniques when installing your RAYNOR door. Installation of the RAYNOR door requires the assistance of qualified electricians and forklift operators. Installation contractors should ensure that those participating in the installation process have received the appropriate training and certification required to complete the installation.

Installation performed by untrained technicians may result in injury and/or damage to equipment.

Installation technicians may be exposed to injury from electrical components.

Damage to equipment is possible.

Failure to follow the instructions found in this manual may result in an inoperable door and void its warranty. Installation by unauthorized persons may also void your warranty.

1.1.3. Operation Precautions

The following precautions should be taken when operating RAYNOR doors.

Read this manual prior to operating RAYNOR doors.

Keep the control box closed while operating the door.


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Keep all safety features, such as covers and safety warnings, visible and readable at all times. Observe all safety warnings and procedures.

Avoid contact with all chains, bearings and other moving parts during activation of the door.

1.1.4. Maintenance Precautions

The following precautions should be taken when performing maintenance on RAYNOR doors.

Only certified personnel should perform maintenance on RAYNOR doors. Maintenance performed by untrained technicians may result in injury and/or damage to equipment.

Service performed by unauthorized persons may void the RAYNOR door warranty.

Use only RAYNOR Factory Direct replacement parts. All door parts are engineered specifically for use within the door.

Return the door to the original factory condition when maintenance is complete. Take extra care to ensure that all safety features are restored to their original condition.

Observe all electrical precautions.

1.1.5. Electrical Precautions

Electrical shock can be deadly! Take extreme care when performing installation and maintenance tasks on the electrical components of the door.

Follow the precautions listed below:

All electrical parts used to install or repair RAYNOR doors must be UL approved.

Lockout and tag electrical components in accordance with OSHA regulations and approved electrical codes prior to performing maintenance. Lockout is required for service or maintenance on all mechanical and electrical components, including performance of the following tasks.

o Removal of covers, side guides, motor, limits and other protective devices

o Inspection of the door

o Inspection or maintenance of the Control Box

o Maintenance or repair of the opening commands

Disconnect the Uninterruptible Power Supply (UPS), if present, when performing maintenance. Refer to the UPS Manual for information on disconnecting the UPS.

Take special care when addressing frequency inverter failure modes. The frequency inverter stops the door when it senses voltage loss, phase differences and thermal overload. This stops the door from further operation, but does not disconnect the power. Observe the following precautions related to the frequency inverter.

Keep the frequency inverter cover closed at all times.

Disconnect the main power supply, wait 15 minutes and reconnect the power supply after resolving frequency inverter failure modes.

Disconnect the power and proceed with lockout procedures to perform service after the frequency inverter has stopped the door.


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1.2. Installation Tools

You need the following tools to complete the installation of your RAYNOR door successfully.

Water Level Threaded Rod

(2) Ladders Universal Pliers

Wire Stripper Allen Wrenches (Metric/US)

(3) Clamps Fork Lift

Screwdrivers Hammer

Grinder Metric Wrenches

Tape Measure

Utility Knife

Circuit Tester V.O.M.

Punch

Reciprocating Saw

Hammer Drill


Chapter 2: Technical Characteristics

2.1. Introduction

All RAYNOR RapidCoil™ doors have been engineered with a patented doors system, with a unique design, that leads the industry of High Performance doors. RAYNOR RapidCoil™ doors have the following characteristics instilled them:

Sealing

Safety

Self-Reintroducing

High Speed

Holding Power (wind load)

High Cycle

RAYNOR continuously develops its products to accurately meet the specific needs of every sector of the door industry.

In the context of this policy, of continuous development of its product, RAYNOR reserves the right to change the characteristics of its products or parts, without prior notice.

2.2. Specifications:

2.2.1. RC200

Application Type: Interior applications Maximum Dimensions: W 12’-0” x H 12’-0” Standard Opening Speed: Up to 48” per/sec Standard Closing speed: 24’ per/sec Operation: Gravity driven, with flexible weighted soft bottom edge Door post: 2 1/8” x 1 7/16” x 1/8” Galvanized steel or Stainless steel Inner Guide (Polyethylene): PE-UHMW/Specifically produced for RAYNOR Drums and shafts: Drive and Roll-up Drum Ø 102 mm, 14 gauge steel. Shaft Ø 25

mm solid steel with welded flanges. Door Curtain Material: 27oz/sq yd PVC vinyl, 9 standard colors Door Curtain temp range: 40°F - 104°F Reintroduction block: Fixed to side guide, ensures an automatic reinsertion upon

opening. Motor: 1-2 horsepower 230/400 50 Hz 3 phase motor, IP65/NEMA4 Reduction: 28:1 Worm gear reduction, Size 50 Control Box: NEMA 4X, Composite box (16” x 14” x 8”), UL labeled Safety Devices: Photo electric cell, WDD Bottom edge, Anti-roll off switch Supply Power: 208-240 single or three phase, 480 three phase and 575 three

phase. Single Phase 110vac (up to 130sqft)

2.2.2. Classification

In the United States there are no performance standards in place yet for High Performance Doors. In future, with the help of such organizations as DASMA and with collaboration from the



Industry, such standards will eventually be put in place. In Europe High Performance Doors must meet the EN 13241-1 classification. Chart 2-1 differentiates the different class criteria were applicable.

Classification Chart 2-1

Class 0 1 2 3 4 5

Water permeability NPD 30 Pa (.63psf) 50 Pa (1psf) >50 Pa /1psf

Wind load (static) NPD

300 Pa

(6.3psf)

450 Pa

(9.4psf)

700 Pa

(14.62psf)

1,000 Pa

(21psf)

>1,000 Pa

(21psf)

Wind permeability NPD

24 m³/h/m²

14.13 ft³/m/ft³

12 m³/h/m²

7.06 ft³/m/ft³

6 m³/h/m²

3.53 ft³/m/ft³

3 m³/h/m²

1.77 ft³/m/ft³

1.5 m³/h/m²

0.88 ft³/m/ft³

NPD: No performance determined

2.2.3. Description of Criteria

The follow section gives a brief overview on the individual criteria’s of the EN Standards and how to decipher the results.

Water permeability

o Test that determines the water permeability and determines at what wind pressure the door remains water tight

Example: Class 1 = Water tight up to 30 Pa (.63psf) of pressure. At higher pressure, water enters through the door. Refer to Chart 2-1 for the other Class pressure ratings.

Wind Load (resistance)

o Test that determines to what wind pressure, in Pascal, the door resists in the closed position.

Example: Class 1 = The door resists in the closed position 300 Pa (6.3psf) of pressure. Refer to Chart 2-1 for the other Class pressure ratings.

Wind permeability

o The quantity of air, in m³/h/m² (ft³/m/ft²), which passes through the door, measured pressure of 50 Pa (1psf). Example: Class 1 = a loss through the door of 24 m³ (14.13 ft³) of air per hour (min) and m² (ft²) of door. 144 m³/h (84.76ft³/m) of air will pass through a Class 1 door of 6 m² (64.5ft²) in size.

Safety during opening

o Test to check if the door creates no danger in terms of cuts, sliding, pressure, etc… during operation

Mechanical resistance

o Control of the mechanical aspect of the door.

Unintended movements

o Control of the forces needed to manually open the door.

Thermal resistance


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o Test that determines the quantity of energy loss through the door. The result is a U value in W/m²K

Performance

o Test number cycles during which the durability of the water and wind permeability and thermal resistance are tested.

2.2.4. RC 100 EN Standards

EN Standards Chart 2-2

Criteria Standard Test method Result

Water Permeability EN 12425 EN 12489 Class 2

Wind Load EN 12424 EN 12444 Class 2*

Wind Permeability EN 12426 EN 12427 Class 1

Safety during opening EN 12453 EN 12445 Pass

Mechanical Resistance EN 12604 EN 12605 Pass

Unintended Movements EN 12604 EN 12605 Pass

Thermal Resistance EN 12428 EN 12428 6.02 W/m²K

Performance (Cycles) EN 12604 EN 12605 1,000,000

* Indicated wind-load classification is for maximum dimension. For doors up to W 6’-6” x H 11’ 6” = Class 3

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Chapter 3: Mechanical Installation

3.1. Door Installation

3.1.1. Introduction

Complete any additional structure support for the door frame and/or removal of prior door that might have been in opening. Plan and prepare how the door will be attached to opening Refer to Chapter 2 of this manual. Verify opening dimensions and cross reference them to the ordered dimensions. The dimensions should match, if not take corrective measures, by assuring correct door dimension was ordered properly. The RAYNOR door should not be field modified without the explicit approval from RAYNOR Door.

All doors have a manufactures serial number located on each end of the shipping crate. This serial number can be found on all the door components packaged in the shipping crate. The locations are as follows:

Side guides Serial number on label above photo eye mounting position. Head unit Serial number stamped on non-motor side, and labeled on

horizontal sealing profile. Control box Serial number labeled on shipping box, also label on the front

and inside of control box panel. Accessory Kit On box of package accessory kit.

When multiple doors are ordered, always confirm that all serial numbers match with all door components. If shipping crates have multiple doors packed, or components are sent separate from the door shipping crate, it is crucial to match the serial numbers exactly.

3.1.2. Assemble the Door

Unpack door from shipping crate. While unpacking make sure items ordered with door are present in crate.

1. Carefully move head unit, side guide assemblies and junction brackets with hardware to unobstructed area by door opening. See Figure 3-2.

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Chapter 3: Mechanical installation

DOC-S0508-3R14-IMEI02 • Technical Manaul • Issue 15 | P a g e

Secure straps around drum (if necessary) and fork lift blades to prevent the head unit from rolling of the end of the fork lift blades.

Insure the load is balanced on fork blade before trying to lift all the way. Motor side is heavier than the belt side, so slightly favor that side.

Use an authorized operator for lifting device/equipment. Unauthorized personal should not attempt to use lifting device/equipment.

7. Lift the door with the forklift. The door will tilt to a vertical position as you lift the forks.

As the door moves upright the ends of the side guides will drag on the floor, make sure side guides do not get snagged by cracks or obstructions. Snagging of the guide will pull head unit off the fork blades and cause injury and/or damage.

3.1.3. Mounting the door

8. Place lifted door assembly against the door opening while keeping a watchful eye for possible obstructions.

9. Temporarily attach the door with clamps or some other secure method.

Do not permanently secure the door yet. You must first ensure the door is level, plum and square.

Keep fork lift under door header to hold the weight until the head unit is secure to the wall.

10. Using a level, check each side of the door for level and plum. See Figure 3-8.

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3.4. Control box, Photo Eyes and Anti-roll off switch

3.1.4. Control Box mounting

1. Mount the Control Box on the motor side of the door, approximately 5’ 3” to center from the floor level. See Figure 3-14.

If position of control box varies from above placement, additional cables will need to be purchased. Motor and encoder cable cannot be spliced. If cables are spliced door will be susceptible to intermittent or major failures.

2. Run cables in specific conduit/tray dictated per NEC or local code.

Typically, the motor cable will require ¾” conduit and you will need minimum of ½” conduit for low voltage cables. It is our recommendation to use ¾” conduit for the low voltage cables instead of ½” do to future add-ons or modifications.

Run conduit and/or cables into the bottom of the control box, ONLY! Do not drill into the side or top of the control box. Doing so will void warranty! (If you are running conduit, place the motor cable in its own conduit.)

3.1.5. Photo eye

1. Mount the photo eyes in the pre-drilled holes in the side guides (located approximately 6” from the floor). See Figure 3-14.

Ensure that the photo eyes are not sticking past the C Channel of the inner guide. Doing so, will risk the photo eye to impacts and damage.

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MEI02 • Technical Manual • Issue

Chapter 4: Lubrication and Maintenance


4.2. Inspection/Maintenance

4.2.1. Philosophy

RAYNOR doors are virtually maintenance free. The door design allows for accidental impacts to the door, combined with the full reinsertion feature of the door, it is nearly impossible to track how many times the door has been impacted or when. That is the sole reason inspection of the door parts is crucial and necessary.

Only trained and certified personnel should perform maintenance on the RAYNOR door. Maintenance and/or inspection by unqualified technicians may result in injury or damage to equipment.

Use all safe electrical and mechanical practices will doing routine inspections on the RAYNOR door, i.e. Lock Out Tag Out, when doing mechanical repairs.

4.2.2. Inspection Summary

Table 4-3 will have categories, components, inspection description and corrective measures to use as a guide line for inspecting the RAYNOR RapidCoil™ 200 door. Typically you should practice doing a bi-yearly inspection and lubrication on the door and/or every 50,000 cycles. If cycles are very low yearly, an annual inspection is all that is needed and it is under the discretion of the certified technician to control re-lubrication application.

Table 4-3 Inspection List

Category Component Inspection Description If No, Corrective Measures

Door Condition

All door and components

Is door in operation Is customer happy with door

and/or functionality Are activations suitable for traffic

Check with customer with issues on door operation.

Try to diagnose what the problem is.

Talk with customer about the issues of door, try to correct. Call RAYNOR for assistance in the matter

Take corrective matters by adjusting or upgrading activations

Safety controls

Photo eyes Are eyes clean and free of debris Door reverses when beam is

broken Adjusted, secured and aligned in

accordance to RAYNOR’s guide lines

Clean/wipe the photo eyes Replace or fix any damaged parts Adjust, secure or align to the

guide lines provide in this chapter and the RAYNOR Electrical Manual.



Bottom Edge

Door reverse when edge tripped

Try to re-sync transmitter to receiver

Damage or kinked edge replaces edge going across door.

Any repeater stations that can interrupt signal? –adjust frequency in repeater

Reset Receiver with purchased WDD tester. Try to sync door again.

With control box open does WDD work? – remote mount receiver closer to door

Door controls

Activations Test each activation for proper function and distance from the door (where applicable). The distance assures that there is enough time for the door to open.

Adjust position of activations, adjust timers, and upgrade activation.

Function buttons

Test each button on the CBX front panel for proper operation o Emergency stop o Front panel push button o Rotary disconnect(if

applicable)

Repair as needed

Timers Test each timer for adequate times to allow for proper door operation and traffic flow.

Adjust timers as needed, refer to RAYNOR Electrical Manual for assistance

Door Limits Test each limit for proper function and position

Refer to the limit Positions in this manual

Curtain Bead Inspect for cracks or excessive dryness.

Lubricate or repair

Curtain Inspect for punctures or other damage

Repair as needed

Windows Inspect for holes, cracking or hazing

Replace window as needed. For hazing use NOVUS 2 to clarify window.

Bottom Bag Holes, or other damage

Repair as needed

Side Guides

Side guide Ensure that covers are installed, securely fastened and not damaged.

Verify that inner side guide plastic track is not pinched in areas and is dirt free

Inspect for any damage on guide assemblies

Remove any excess old grease

Repair as needed



Head Unit Head Unit Inspect drums for damage Inspect reintroduction blocks for

damage. Remove old excess grease from

reintroduction block bearings if present.

Repair as needed

Motor Verify that the motor mounting bracket is tight against the head unit and are free of damage.

Make sure Motor Fan is present and working properly.

Verify there are no leaks present on reduction.

Verify keyway for manual operation is free from damage.

Repair as needed

Cables Verify cables are in good condition and not spliced.

Repair as needed

Anti-roll off switch

Inspect switch whisker for damage Assure proper operation of switch

by manually activating it and visual seeing that input 4 illuminates when switch whisker pressed in.

Repair as needed

For an example of an inspection check list please see the back of this manual along with the maintenance log.

Index


C

Cable ........................................................................ 20 Conduit .................................................................... 20 Control box .............................................................. 20

E

Electrical .................................................................... 2

F

Forklift ................................................................. 1, 15 Forklift operators ....................................................... 1 Frequency inverter .................................................... 2

H

Hazards ...................................................................... 1

I

Installation ................................................................. 1

M

Maintenance .............................................................. 2 Motor....................................................................... 20

O

Operation ................................................................... 1

P

Photo eye Mounting ............................................................. 20

S

Safety ......................................................................... 1

T

Tools .......................................................................... 3

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