turbo-seal insulated install. run power lines from disconnect to control panel. 5. run power lines...

R Y T E C

P.O. Box 403, One Cedar Parkway, Jackson, WI 53037 Phone: 262-677-9046 Fax: 262-677-2058

Rytec Website: www.rytecdoors.com, Rytec On-line store: www.rytecparts.com Rytec E mail: [email protected], Parts E mail: [email protected]

[Revision: December 2nd, 2014, R11701100, ©Rytec Corporation 2010]

Turbo-Seal Insulated

Installation Manual

http://www.rytecdoors.com/

http://www.rytecparts.com/

mailto:[email protected]

mailto:[email protected]

TABLE OF CONTENTS

PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MATERIAL, TOOLS, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fill-In Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL ARRANGEMENT OF DOOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

COUNTERWEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DOOR SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 13

DOOR OPEN- AND CLOSE-LIMIT POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT . . . . . . . . . . . . 14

Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 15

KILL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RESETTING BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PATHWATCH LED™ WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Testing Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AIR CURTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SIDE COLUMN HEATED BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Insulated Panel Travel - Shimming Panel……………………...……………………21

1

INTRODUCTION INTRODUCTION The information contained in this manual will allow you to install your Rytec Turbo-Seal Insulated® Door in a manner that will ensure maximum life and trouble-free operation.

Any unauthorized changes in procedure, or failure to fol- low the steps as outlined in this manual, will automatically void the warranty. Any changes in the working parts, assemblies, or specifications as written that are not authorized by Rytec Corporation, will also cancel the warranty. The responsibility for the successful operation and performance of this door lies with the owner of the door.

DO NOT OPERATE OR PERFORM MAINTENANCE ON THIS DOOR UNTIL YOU READ AND UNDER- STAND THE INSTRUCTIONS CONTAINED IN THIS MANUAL.

If you have any questions, contact your Rytec representative or call the Rytec Technical Support Department at

NOTE: NOTE is used to provide additional information to aid in the performance of the procedure or operation of the door, but not necessarily safety related.

DOOR SERIAL NUMBER(S)

To obtain your DOOR SERIAL NUMBER, there are three universal locations where this information can be found. These are on the door of the System 4 control panel, the left side column (remove lower side column cover) at approximately eye level and the drive motor. (See Figure 1.) IMPORTANT: When installing multiple doors

of the same model but in differ- ent sizes, verify the serial number in the control panel with the one in the side column.

Drive Motor

800-628-1909. Always refer to the serial number of the door when calling the representative or Technical Sup- port. The serial number plate is located inside one of the side columns.

A wiring schematic is provided with each individual door, specifically covering the control and electrical components of that door.

HOW TO USE MANUAL

Throughout this manual, the following key words are used to alert the reader to potentially hazardous situations, or situations where additional information to suc- cessfully perform the procedure is presented:

System 4 Control Panel

Gearbox Assembly

Lifting Pockets

Air Curtains

WARNING is used to indicate the potential for personal injury, if the procedure is not performed as described.

CAUTION is used to indicate the potential

A8700065

Left Side Column With Heated Blower

Right Side Column With Heated Blower

Figure 1

for damage to the product or property damage, if the procedure is not followed as described.

IMPORTANT: IMPORTANT is used to relay

information CRITICAL to the successful completion of the procedure.

NOTE: The lifting pockets mounted to the top of the head assembly are there for forklift operation only. It’s not necessary to remove the lifting pockets after installation.

2

INSTALLATION—MATERIAL, TOOLS, AND EQUIPMENT INSTALLATION

MATERIAL, TOOLS, AND EQUIPMENT 1. Threaded rod (¹/₂-in. diameter) and other various

wall anchor hardware and material. Concrete anchor bolts (¹/₂-in. diameter). (See “ANCHORING METHODS” on page 3.)

2. Assorted shim stock.

3. Double-sided tape (to temporarily hold shims).

4. Carpenter’s or spirit level (4-ft. minimum length).

5. Carpenter’s square.

6. Fish tape.

7. Hammer drill. 8. Masonry drill bit (for ¹/₂-in. diameter anchors).

9. Three or four bar clamps (48-in. long).

10. Hammer or mallet, and block of wood.

11. Crowbar or pry bar.

12. Assorted hand tools (pliers, tape measure, etc.).

13. Socket and wrench sets.

14. Water level, line level, or transit.

15. Two ladders (taller than height of door opening).

16. Forklift (see “Forklift Requirements”).

ADDITIONAL REQUIREMENTS Labor and Site Requirements

1. Two installers.

2. An electrician is required for making all electrical connections. (See “Electrician’s Responsibilities”.)

NOTE: All electrical work must be performed in accordance with local and state building codes.

3. 100% accessibility to the door opening during the

entire installation process. No traffic should be allowed to pass through the opening while the door is being installed.

Forklift Requirements

A forklift supplied by the customer, dealer, or installer is mandatory for the safe and proper installation of this door. The forklift should have:

• 4,000-pound lift capacity.

• minimum height ability — door height plus 42 in.; 39 in. if lifting pockets are removed.

• side-shift capability (desired).

Electrician’s Responsibilities

For complete details on the responsibilities of the electrician, refer to the Rytec System 4 Drive & Control Installation & Owner’s Manual.

1. Install fused disconnect and Rytec control panel. (See Figure 2 for typical installation.)

2. Install all necessary conduit tubing.

NOTE: Separate high and low voltage conduit. 3. Run electrical power lines to disconnect.

4. Run power lines from disconnect to control panel.

5. Run power lines from control panel to upper junction box.

6. Run power lines from control panel to door motor.

7. Run low-voltage cables from door to control panel.

8. Mount rear photo eyes.

9. Wire low-voltage safety devices and activators (if used).

High and low voltage wires/cables in separate metal conduit run to the bottom of the System 4 control panel. All wires/cables cut to length DO NOT leave excess wire/cable loops on the door or in the control panel. Fill-In Material Requirements

Some applications may require the use of a door pullout (extension) to gain clearance of an existing obstruction between the door and the door opening. The following materials can be used to fill the space or gap between the door and the door opening.

1. 16-gauge hot-rolled sheet steel. 2. 2-in. x 2-in. x ³/₁₆-in. angle iron.

3. Insulated panels.

NOTE: If any pullout or buildout is used in the installation it must be insulated to prevent frost and ice buildup on or in the door. Fail- ure to properly insulate the pullout can affect the operation of the Turbo-Seal Insulated door. It is very important to seal and caulk around the pullouts to prevent frost and ice buildup.

3

INSTALLATION—GENERAL ARRANGEMENT OF DOOR COMPONENTS GENERAL ARRANGEMENT OF DOOR COMPONENTS

Figure 2 shows the location of the major components of the door and the general placement of the associated sub-assemblies for a typical installation.

This illustration is provided to you for informational pur- poses only. It should not be relied upon solely during the installation of your door and its sub-assemblies.

Fused Disconnect

Head Assembly (Includes Drive Motor Gearbox Assembly, Fabric Roll)

Lifting Pockets

A8700042

Figure 3

System 4 Control Panel

Left Side Column with

Air curtains

Bottom Bar Assembly

ANCHORING METHODS

Correct anchoring of the side columns to the wall and the floor is important for the smooth and safe operation of the door. The wall material should be strong enough to support the weight of the door and all wall anchors.

Figure 4 through Figure 7 show anchoring methods for various types of walls. Use the method that is best suited for your particular installation site.

All necessary anchoring hardware and material required for the installation of this door are the responsibility of the door owner. If you have any questions, call your Rytec representative or the Rytec Technical Support

Heated Blower (Includes Serial Number Plate, Counterweight, and Patchwatch LED)

Right Side Column with Heated Blower (Includes

Department at 800-628-1909. NOTE: Use ¹/₂-in. diameter threaded through bolts

or ¹/₂-in. diameter threaded rods to anchor the door to all wall applications. Use ¹/₂-in. diameter concrete anchor bolts to anchor

Counterweight and Patchwatch LED)

Figure 2

the door to a concrete floor. If expansion anchors are used, a quarterly inspection should be implemented for safe

NOTE: Figure 2 shows the front side of the door. Left and right are determined when view- ing the front side of the door.

UNCRATING

Your Rytec door has been crated to allow for minimal handling of assemblies during the installation process.

NOTE: Remove parts and sub-assemblies from the shipping crate in the order directed throughout this manual.

and secure door operation. Concrete, Block, or Brick Walls

Concrete Wall

Expansion Anchor

Side Column

1. Remove the top of the crate.

2. Remove the front of the crate. (See Figure 3.)

A0500005

Figure 4

Patchwatch LED™ is owned by Rytec High Performance Doors.

4

INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING Wood, Block, Brick, or Insulated Walls

Wood

LOCATING CENTERLINE OF DOOR OPENING

NOTE: Accurate measurements are critical for the proper installation and operation of your

Wall

Crush Plate (¹/₂-in. Thick, 6-in. x 8-in. Steel)

Side Column

Rytec door. Verify all measurements. 1. Measure the width of the door opening.

2. Divide the measurement in half to locate the centerline. Then mark the centerline along the floor. (See Figure 8.)

A0500037

Insulated Wall

Figure 5

Through Bolt or Threaded Rod

Centerline of Opening

Insulated Wall


Side Column

Overall Width of Door Opening

A0500001

Half Width of Door Opening

A0500039

Aluminum-Clad Lumber (Front and Back Sides — Full Length)

Figure 6

Insulated Wall

Figure 8

LOCATING SIDE COLUMNS

1. Locate the layout drawing of the door. It should be attached to the small parts carton packed inside the shipping crate. This drawing identifies the production width of your door. Verify the dimension provided by measuring the width (length) of the head assembly.

2. Using the centerline as a reference point, lay out and mark half of the door’s production width along the floor. (See Figure 9.)


Side Column

A0500038

Aluminum-Clad Lumber (Back Side — Full Length)

Figure 7

This door is equipped with a breakaway bottom bar assembly. To ensure that it works properly, the width of the door opening must not be smaller (narrower) than the production width of the door. If the width of the opening is narrower than the width of the door, do not proceed with the installation. Contact your Rytec representative or the Rytec Technical Support Department at 800-628-1909.

5

INSTALLATION—SIDE COLUMNS

Half of Door Production Width

Centerline of Opening

This Dimension Must Be Equal on Both Sides of Door Opening

A0500002

Extend and Mark Edges of Door Along Floor

Figure 9

Water Level

Shim Plate (If Required)

3. With a carpenter’s square placed against the wall, mark both sides of the door along the floor. Extend the line along each edge.

4. Check the floor for level across the door opening.

A0500004 SIDE COLUMNS

Figure 11

The floor must be level within 0.12 in. from side-to- side. If one side of the opening is higher than the other, a shim under the side column will be required.

Figure 10 and Figure 11 show two methods that can be used to ensure level side columns.

NOTE: Contact the Rytec Technical Department if the floor is more than 1 in. out of level.

Line Level

The following procedure details the installation of the side columns in standard and freezer door applications. They are virtually the same except that the freezer door will come with insulated channels.

Side columns are extremely heavy; use proper lifting and support equipment when removing from crate. Personal injury may result from using improper handling procedures.

This Dimension Must Be Equal on Both Sides of Door Opening

A0500003

Shim Plate (If Required)

1. Remove the right side column from the shipping crate.

2. Remove the covers from the side column by removing the screws that hold the covers in place. Save all hardware for later use.

3. Stand the right side column on the floor. Place it against the wall, just outside the line indicating the production width of the door. Use bar clamps as needed. (See Figure 12.)

Figure 10

6

INSTALLATION—SIDE COLUMNS

IMPORTANT: It is critical that the side columns are mounted square and plumb with the wall, and level across the door opening. Using a 4-foot level and carpenter’s square will help ensure the columns are correctly set. Place shims where necessary.

In addition, the use of bar clamps will allow you to temporarily secure the columns to the wall, while allowing you to make slight adjustments during the installation process.

Before drilling any holes, ensure there are no electrical wires, water pipes, or gas lines, etc., buried in the floor or hidden in the wall.

4. Once the side column is set plumb and square,

anchor it to the wall and floor. Predrilled anchor points have been provided in the side column. DO NOT securely tighten the anchors at this time —

Anchor Point A8700004

Carpenter’s Level

Right Side Column

Production Width Line

Figure 12

they will be tightened later on after the head assembly is installed. (See Figure 12 and Figure 13.)

NOTE: Use ¹/₂-in. expansion shell or stud-type anchors for concrete walls. Use through bolts or threaded rods for brick walls and other applications where expansion anchors are not appropriate.

If a stud-type anchor is used for the bottom anchor, the anchor must not extend more that 1¹/₂ in. above the base plate of the side column.

5. Mount the left side column to the wall and floor in the same manner that was used for installing the right side column.

6. With both columns set and snugly bolted in place, check the overall squareness of each column. (See Figure 13.)

Compare the diagonal measurements and the upper and lower horizontal measurements across the columns. The columns are square and parallel when the diagonal measurements are equal and the horizontal measurements are equal.

If either column requires a slight repositioning (when the difference of either comparison is greater than ¹/₄ in.), use a block of wood and a mallet to nudge the column into position.

7

INSTALLATION—HEAD ASSEMBLY

Horizontal Measurements Must Be Equidistant.

Diagonal Measurements Must Be Equidistant

The head assembly is extremely heavy; use proper lifting and support equipment when removing from crate. Personal injury may result from using improper handling procedures.

Secure the head assembly to the forklift prior to lifting it to the top of the side columns.

2. Lift head assembly into position by using one of two

methods:

a. Use the fork pockets on top of the head assembly. The lifting pockets are provided to prevent damage to the foam panel. (See Figure 15.)

NOTE: Personal injury or equipment damage may result from the head assembly not being secured.

A8700037

HEAD ASSEMBLY

Figure 13

1. Remove head assembly from crate. (See Figure 14.)

Head Assembly

Fork Pockets

A8700044 Figure 15

A8700043

Figure 14

b. For overhead clearance problems, secure head

assembly with C-clamps and a strap from the rear spreader to the forks of the forklift or mechanical lift before lifting it into position. (See Figure 16 and Figure 17.)

NOTE: Personal injury or equipment damage may result from the head assembly not being secured.

To prevent damage to door components, use cloth or packing material between the forks and the head assembly. Pay close attention to the foam door panel.

8

INSTALLATION—HEAD ASSEMBLY

Forks Strap

4. Attach head assembly to each side column. Hard- ware is located in the small parts carton. a. Install two ³/₈-16 x 1¹/₄-in. hex flange machine

screws and ³/₈-16 serrated flange hex lock nuts. Install machine screws from the bottom of the side column. (See Figure 19.)

NOTE: Items have been removed for clarity.

A8700045 Figure 16

Forks

C-Clamps Hex Flange Machine Screws and Serrated Flange Lock Nuts

A8700051 Figure 19

A8700046 Figure 17

b. Install five ³/₈-16 x 1¹/₄-in. hex flange machine screws. (See Figure 20.)

3. With the head assembly safely secured to the forklift, place it on top of the side columns. Line up the alignment pin on the head assembly with the alignment hole in the side column. (See Figure 18.)


Hex Flange Machine Screws

Alignment Pin Inserted in Alignment Hole

Head Assembly

A8700051

Hex Flange Machine Screws (Two Installed from Bottom)

Figure 20

A8700015

Figure 18

5. Once the head assembly is set plumb and square,

anchor it to the wall.

9

INSTALLATION—COUNTERWEIGHTS

NOTE: Anchor points in the head assembly are predrilled at the factory for the load bear- ing cross-sectional area. Do not add additional points for mounting. Please consult your Rytec representative or call the Rytec Technical Support Department at 800-628-1909 with questions.

6. After the head assembly is secured to both side columns, securely tighten all floor and wall anchors.

7. Unclamp the head assembly from the forklift and then remove the forklift.

8. Remove the bar clamps that were used to secure the side columns to the wall.

COUNTERWEIGHTS

6 to 8 in.

A counterweight can weigh in excess of 100 pounds. Make sure that safe handling procedures are followed and that each counterweight is securely supported during its installation. If not handled properly,

A8700012

Figure 21

a counterweight can damage door components and cause serious personal injury.

1. Place a counterweight in the bottom of each side

column.

2. Securely block each counterweight 6 to 8 in. above the bottom of the side column. (See Figure 21.)

At this point the counterweight is free standing. Secure counterweight from fall- ing over while installing the guide plate assembly. Personal injury can result.

NOTE: For photo purpose, the guide plate is shown

and should NOT be installed at this time.

3. Install counterweight guide plate toward the rear of the column. (See Figure 22.)

Guide Plate

A8700007

Figure 22

4. Swing guide plate up for installation. (See Figure 23.)

10

INSTALLATION—COUNTERWEIGHTS

Guide Plate

Counterweight Strap

Plastic Tie

Swing Up

A8700008 Figure 23

A8700047 Figure 25

5. Set mounting plate on top of the guide plate. 6. Secure mounting plate and guide plate to the coun-

terweight with two ³/₈-16 UNC x 1³/₄ hex head cap screws and ³/₈ in. split lock washers. (See Figure 24.)

Mounting Plate

8. Route counterweight strap over idler pulley and

feed through access hole in the head assembly. (See Figure 26.)

NOTE: The counterweight strap is installed at the factory. The factory standard is three pre- wraps around the counterweight spool.

Hex Head Cap Screws with Split Lock Washers

Guide Plate


Counterweight

Counterweight Strap Spool

Idler Pulley

Counterweight Strap

A8700006

A8700055

Figure 26

Guide Roller

Figure 24

7. Remove the plastic tie from each counterweight

strap. (See Figure 25.)

NOTE: Door must be in the fully open position.

9. With the straps hanging straight, attach them to the

counterweights using two ³/₈-16 UNC x 1³/₄ hex head cap screws, ³/₈ in. split lock washers, and clamp bars provided in the small parts carton. Route the straps through the clamp bars as shown in Figure 27.

11

INSTALLATION—ANTENNA

IMPORTANT: The 6 to 8 in. mounting height for

each counterweight, as indicated in Figure 21, is adequate for most Turbo-Seal Insulated Doors. However, for extra-wide or -short doors, the counterweights may have to be adjusted closer to the bottom of the side column.

To check the position of each counterweight, first release the motor brake by pulling on the brake release cable. Then manu- ally move the door to its fully closed position. The clearance between the top of each counterweight and the top of its associated side column must be at least 2 in.

If an adjustment is necessary, move the door to the fully open position. After placing a support block under the counterweight, readjust the strap, as required, until the 2-in. clearance is achieved.

10. Tighten the clamp bars to secure each strap. Then carefully remove the support block from under each counterweight to allow the weights to hang free. If necessary, readjust the straps.

11. After all adjustments are complete, cut off any excess strap to within 6 in. of the upper clamp bar. Use tape or a tie strap to attach the loose end of each strap to the main length of strap.

12. Secure bottom guide plate to the counterweight

with two ³/₈-16 UNC x 1³/₄ hex head cap screws and ³/₈ in. split lock washers.

13. Attach the side column covers using the saved hardware.

ANTENNA IMPORTANT: The antenna is a fragile and highly

sensitive instrument. Extreme care should be used in handling this piece of equipment.

1. Remove antenna from small parts carton.

2. Carefully remove packing material from antenna. Inspect for damage.

NOTE: Do not install antenna if it is found to be damaged. Call your local Rytec representative or the Technical Support Department at 800-628-1909 for a replacement.

Hex Head Cap Screws

Counterweight Strap

3. Remove machine screw from the bottom of the side column. (See Figure 28.)

Split Lock Washer

Clamp Bars

Counterweight Machine Screw

A8700009

Figure 27

A8700052 Figure 28

12

INSTALLATION—ENCODER 4. Install antenna mounting bracket to side column

along with machine screw previously removed.

5. Install antenna onto mounting angle and secure with two M4 x 12 mm Phillips flathead machine screws, M4 flat washers, and M4 hex head nuts. Hardware is located in the small parts carton.

6. Route antenna cable over side column to the encoder. (See Figure 29.)

NOTE: To secure antenna cable, use plastic ties as required.

Mounting Bracket

Socket Head Cap Screw Encoder

Feig Encoder

Hub Shaft

Encoder Mounting

Plate Encoder Coupling

Shaft

Split Lock Washer

Eurodrive Washer

To Wireless Antenna

Machine Screw

Antenna A9800016

DOOR SEALING

Figure 30

A8700020

ENCODER

Nut, Washer, and Machine Screw

Figure 29

Foam insulation is built into the side column. The insulation is a technical and important item in the proper operation of the Turbo-Seal Insulated Door. From the moment the door is uncrated until the door is installed, strict care should be taken not to damage the insulation on the back side of the side column. (See Figure 31.)

1. Install the Feig encoder hub shaft end to the end of the encoder coupling shaft and tighten set screw. The Feig encoder hub can be found in the small parts carton.

NOTE: The Eurodrive washer, split lock washer, and encoder coupling shaft are factory installed on the gearbox. Use a mild thread locker on set screw.

2. Install encoder mounting plate with encoder using

four M8 x 1.25 x 18 mm socket head cap screws.

3. Connect encoder cable to encoder.

4. Install plastic zip tie into socket head screw and secure the encoder cable. (See Figure 30.)

NOTE: The zip tie that is used to secure the encoder cable is of special design. The ribbed end inserts into the valley of the socket head cap screw.

All hardware is located in the small parts carton.

In addition to the insulation, a thermal break foam core is constructed into the components of the door assembly. This gives the door an extra barrier to combat against temperature differential. (See Figure 32.)

For a tight and air-proof seal, a bead of caulk should be applied at the inside perimeter of the door assembly. Use a construction grade of caulk to seal the door. IMPORTANT: Use caulk as directed per manu-

facturer’s instructions. Improper wall preparation may result in poor adhesion. The door may not be altered in any form to apply caulk.

13

INSTALLATION—CONTROL PANEL AND ELECTRICAL CONNECTIONS

NOTE: Foam insulation is shaded in gray.

Wall

NOTE: If a floor loop is used, all wiring from the fused disconnect to the control box and from the control box to the motor mount side column, as well as conduit running from the control box to the floor, is provided by the door owner/installer or the

A8700032

Foam Insulation

Figure 31

Foam Core

Foam Insulation

Foam Insulation

electrician. All wiring and conduit must meet all local and state codes. Wires provided with the door are labeled with termi- nal or contact numbers.

DOOR OPEN- AND CLOSE-LIMIT POSITIONS

See the Rytec System 4 Drive & Control Installation & Owner’s Manual for the proper procedure for setting the open and close door limits. The close- and open-limit door positions are detailed below.

Close-Limit Position

The close-limit position should be adjusted so that the door travel allows the black vinyl loop on the bottom bar to gently seal against the floor. (See Figure 33.)

DO NOT allow the rubber reversing edge, enclosed in the black vinyl loop, to come in contact with the floor.

Damage to the rubber reversing edge or other bottom bar parts can occur if the door seal is allowed to seal too tightly against the floor.

Foam Panel

A8700038

Figure 32

CONTROL PANEL AND ELECTRICAL CONNECTIONS

Once the door has been assembled, see the Rytec Sys- tem 4 Drive & Control Installation & Owner’s Manual for information on control panel installation, electrical connections, door limit settings, and initial door start-up procedure.

Foam End Tab

Black Vinyl Loop

A8700079

Figure 33

14

INSTALLATION—REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT

Open-Limit Position

When the door is knocked out of position, the System 4 Drive & Control takes over and will raise the tabs high enough to be reinserted into the side columns. The open-limit switch should be adjusted so that the door travel allows a minimum of half the foam breakaway tab into the yellow channel guides of each side column. (See Figure 34.)

Reversing Edge Switch Air Bleed Check

The disconnect must be in the OFF position and properly locked and tagged before performing the following procedure.

1. The reversing edge switch is located inside the bot-

tom bar assembly, on the end opposite the drive motor. To inspect and adjust the switch, remove the access cover from the face of the bottom bar assembly. (See Figure 35.)

Foam End Tab

Access Cover

Yellow Channel Guide

A8700080 Figure 34

Bottom Bar Assembly

REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT

Do not stand under the door panel when testing the reversing edge. If the reversing edge switch is not working properly, the panel could strike personnel and cause injury.

To check the reversing edge switch, run the door through the down cycle. As the door is lowered, tap the bottom of the reversing edge. The door is set up from the factory for 3 impacts of the reversing edge before remaining open. If the reversing edge is tripped 3 times consecutively the door will remain open and code F:361 will appear on the display. Push and hold the STOP/ RESET button 3 to 5 seconds and the control will reset. Push the down arrow to close the door.

If the door does not reverse direction, check the air bleed and sensitivity of the reversing edge switch.

A8700080

Figure 35 2. Make sure the clear PVC hose is in tight contact

with the air input post so that air leakage cannot occur and that vibration will not cause the hose to fall off. Also make sure the hose is not kinked. (See Figure 36.)

15

INSTALLATION—KILL SWITCH INSPECTION

Reversing Edge Switch (On Side Opposite Door Motor)

Air Bleed Adjustment Screw

2. Turn the sensitivity adjustment screw clockwise until continuity is achieved. Then turn the sensitivity screw 2 full turns counterclockwise for a standard setting. Some doors may require a further adjustment counterclockwise. (See Figure 37.)

NOTE: Testing the reversing edge is the best way to determine sensitivity.

PVC Hose — Must Be Tight on Lower Input Hose

A7500227

Figure 36

3. The air bleed has been set at the factory and should

not require adjustment. If adjustment is necessary, turn the air bleed adjustment screws located on the front and back of the switch fully clockwise — but do not overtighten. Then turn each screw back (counterclockwise) one full turn.

Reversing Edge Switch Sensitivity Adjustment

The disconnect must be in the OFF position and properly locked and tagged before performing the following procedure.

1. The reversing edge switch is a normally open con-

tact. The PVC hose is on the lower air input post. To adjust the switch, first remove the resistor from the contact terminals and attach an ohmmeter across the two terminals. (See Figure 37.)

Reversing Edge Switch

Resistor

3. Reattach the wires and resistor; then replace the access cover.

NOTE: If the reversing edge is too sensitive, the door may reverse direction during the closing cycle without coming in contact with an object. If this occurs, readjust the reversing edge switch.

KILL SWITCH INSPECTION

Kill switches have been mounted at each end of the bottom bar assembly. The purpose of these switches is to prevent the door from being operated if the breakaway bottom bar becomes separated from one or both of the side columns.

Take precautions to prevent the door from being opened or closed while performing the following procedure.

1. Move the door so that the bottom bar assembly is

approximately head or chest height.

2. Push the breakaway bottom bar out of the side column. It should not be possible to restart the door.

If the kill switch operated properly: Reinstall the bottom bar into the side column. (See “RESET- TING BOTTOM BAR” on page 16)

If the kill switch did not operate properly: Check wiring. If wiring is OK, repair or replace the switch.

Sensitivity Adjustment Screw

Remove Resistor to Test and Adjust Switch

Performing this adjustment without the door in the JOG MODE may cause personal injury or death.

A7500227

Figure 37

16

INSTALLATION—RESETTING BOTTOM BAR

Whisker Switch

NOTE: Should the door panel have been damaged during the impact, remove the door from service and repair. If you have any questions, contact your Rytec representative or call the Rytec Technical Support Department at 800-628-1909.

Bottom Bar Assembly

Foam Breakaway Tab

Foam Tabs Out of Side Column

A8700003 Figure 38

Side Column Channel

Foam Breakaway Tab A8700081

Figure 40

2. The door panel will momentarily pause and then

execute the reset procedure.

3. The door panel’s foam breakaway tabs will roll upward above the side column’s channel. (See Figure 41.)

Bottom Bar Assembly

Foam Breakaway Tab

A8700081 Figure 39

RESETTING BOTTOM BAR

The Turbo-Seal Insulated Door is a fully automated self- resetting door. After a strike and a clear sensor path, the door will automatically reset the bottom bar. The process goes as follows:

1. The foam breakaway tabs have popped out of the side column’s channel due to impact. (See Figure 40.)

A8700071

Side Column Channel

Figure 41

17

INSTALLATION—PATHWATCH LED™ WARNING LIGHTS 4. The photo eye senses if the path is clear of any

obstructions.

5. Then the door panel will guide itself into the channel and resume its normal operation. (See Figure 42.)

NOTE: The Pathwatch LED’s are already pre- installed in the side columns at the factory. Be sure to route cables away from all mov- ing parts. Use cable ties as required.

Door Panel Has Been Reset and Is Shown in Normal Operating Position

Amber and Red Pathwatch LED Warning Lights

RY-WI Cover

A8700080

A8700017

Front

Figure 43

Figure 42

NOTE: The door function is fully automatic; it will

reset, rise to the open position, and rein- sert the bottom bar according to factory- installed parameters. Cycling the door and checking for proper door operation is not required unless prescribed, but an occa- sional test of the self-repair system would ensure its proper operation. Should slight adjustments of the door be needed, please contact your Rytec Technical Sup- port at 800-628-1909.

PATHWATCH LED™ WARNING LIGHTS

The standard setting for the warning lights is: 3 seconds prior to the door closing, the lights will flash yellow and then change to a steady red while closing. Adjustments to the closing time can be made through the System 4 Control Panel. Please contact your Rytec Technical Support department at 800-628-1909 for assistance. (See Figure 43.)

IMPORTANT: Photo eyes are used as a safety

feature and not as a door opener. Never try to interrupt either set of photo eyes as the door is closing. Wait for the door to perform its normal cycle before entering or exiting doorway.

1. Connect cable to front warning light.

2. Route front cable:

a. Down the side column.

b. Through the angle iron bracket at the bottom of the side column.

c. Up the rear of the side column through the back angle corner pieces.

d. Through the top access hole in the head assembly and to the rear junction box.

NOTE: Use the conduit mounted on the rear panel of the head assembly to route the cable across to the junction box.

3. Secure cable with plastic ties to the rear angle corner pieces.

4. Connect cable to junction box per schematic.

Rear

1. Connect cable to rear warning light.

2. Route rear cable:

a. Up the rear of the side column through the back angle corner pieces.

b. Through the top access hole in the head assembly and to the rear junction box.

Patchwatch LED™ is owned by Rytec High Performance Doors.

18

INSTALLATION—PHOTO EYES

NOTE: Use the conduit mounted on the rear panel of the head assembly to route the cable to the junction box.



PHOTO EYES

The photo eyes are provided as a safety feature. If the photo eyes are correctly installed, interrupting either set of eyes as the door is closing will reverse the direction of the door and hold it in the fully open position until the interruption is removed.

Your Turbo-Seal Insulated Door is equipped with two sets of photo eyes. The front set of eyes monitors the front side of the door — they are mounted in holes 18 inches from the bottom. The rear set of eyes monitors the back side of the door — they are mounted in holes 28 inches from the bottom.

The transmitter and receiver can be identified in two

Receiver Module Designation

A2500259

Front

Figure 45

Alignment Light (Yellow)

ways. The transmitter is designated SMT 3000 on the white label or by a single green light that comes on at the clear end of the transmitter. (See Figure 44.) The receiver is designated SMR 3215 on the white label or by a yellow light that illuminates only when it is in proper alignment with the transmitter. (See Figure 45.)

NOTE: When the cable is connected to the photo

eye, there is only a ¹/₄-inch window to see the green or yellow LED light.

Transmitter Module Designation

Power Light (Green)

A2500258

Figure 44

1. Connect cable to front photo eye.

2. Route front cable:

a. Down the side column.

b. Through the angle iron bracket at the bottom of the side column.

c. Up the rear of the side column through the back angle corner pieces.

d. Through the top access hole in the head assembly and to the rear junction box.

NOTE: Use the conduit mounted on the rear panel of the head assembly to route the cable across to the junction box.



Rear

1. Connect cable to rear photo eye.

2. Route rear cable:

a. Up the rear of the side column through the back angle corner pieces.

b. Through the top access hole in the head assembly and to the rear junction box.

NOTE: Use the conduit mounted on the rear panel of the head assembly to route the cable to the junction box.

3. Secure cable with plastic ties to the rear angle cor-

ner pieces.


19

INSTALLATION—AIR CURTAIN Testing Photo Eyes

With the power on, the green light on the transmitter indicates the photo eye module is powered up. When the yellow light on the receiver module is also lit, the transmitter and receiver modules are properly aligned.

Placing your hand in front of the receiver breaks the light path and causes the yellow light to go out. Removing your hand causes the yellow light to go back on.

3. Install right side of air curtain to mounting bracket using two 10-24 x ³/₄-in. cap screws and ¹/₄-in. lock- washers. (See Figure 48.)

Hardware Air Curtain

NOTE: Hardware is located in the small parts carton. 1. Install left air curtain mounting bracket using two

¹/₄-20 x ³/₄-in. hex flange serrated machine screws and ¹/₄-in. hex serrated flange lock nuts. (See Figure 46.)

Right Air Curtain Mounting Bracket

A8700076

Figure 48

Air Curtain

Hardware

4. Repeat procedure for left side of air curtain.

(See Figure 49.)

Left Air Curtain Mounting Bracket

Hardware

Hardware Left Air Curtain Mounting Bracket

A8700074

Figure 46

Air Curtain

2. Repeat procedure for right mounting bracket.

(See Figure 47.)

Hardware A8700077

Figure 49

Hardware

5. Repeat procedure for opposite air curtain assembly.

6. Route electrical wiring to the junction box through the angle brackets located behind the front panel of the head assembly.

A8700075

Figure 47

Right Air Curtain Mounting Bracket

20

INSTALLATION—SIDE COLUMN HEATED BLOWER Side Column Heated Blower

There are two holes are in the bottom of the side column. These holes expose the interior of the yellow fiberglass triangular extrusions. Warm air blows into these holes up the triangular extrusions and exit two holes at the top of the side column. (See Figure 50 and Figure 51.)

NOTE: Heated blowers are shipped loose and holes are pre-cut in side columns.

NOTE: Use the wire chase in the side column to route the cable to the power source. The cable can be routed through a hole in the head assembly. Leave excess cable in the bottom of the side column to allow for removal of bottom cover in the future.

3. Be sure that the cable doesn't interfere with the

travel of the counterweight.

4. Using the supplied Tek® screws, mount the heated blower to the side column cover pre-drilled holes.

5. Plug supplied cord into end of heated blower.

6. Turn the thermostat control fully clockwise to set blower heat to high.

Warm Air Top Exit Holes

Thermostat Control

A8700086

Figure 50 A8700088

Figure 52

Warm Air Bottom Supply Holes

7. Install side column covers and turn on the electrical

supply.

NOTE: The fan for the side column heaters must be rotating for the defrost system to work properly. During shipment the fan may bind against the casing. If the fan is not turning, rotate the fan on the shaft and the fan should begin to turn. If not, check for proper voltage to the fan and contact Rytec Technical Support for assistance at 1-800-628-1909.

A8700087

Figure 51

After 30 minutes the surface of the heater housing should be warm to the touch and frost should begin to dissipate. Please contact Rytec Technical Support at 1-800- 628-1909 with any questions.

1. Remove side column covers.

2. Starting from the bottom, route the supplied cord up the side column through the head assembly and to the junction box.

21

FINAL CHECKS FINAL CHECKS

NOTE: Check all of the following door components and systems once the door panel has been cycled at least 20 times.

Side Columns: Check that side columns are plumb and square and that all anchor bolts are secure and tight.

Head Assembly: Check that all mounting hardware is in place and tight.

Bottom Bar: Smoothly travels up and down within the side columns.

Limit Positions: Adjusted properly. Up and down travel of the door should be as described in “DOOR OPEN- AND CLOSE-LIMIT POSITIONS” on page 13.

Motor: Check that the door travels in the proper direction when the button is pressed.

Reversing Edge: Works properly. As the door is closing, if the reversing edge makes contact with an object, the door should immediately return to the fully open position as described in “REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT” on page 14.

Timers: Automatic timers must be set to ensure that the door closes properly, as described in the Rytec System 3 Drive & Control Installation & Owner’s Manual.

Activators: Operate as specified by manufacturer.

Caulk: Ensure that the side columns and head assembly are caulked where they meet the wall of the building.

Counterweight Straps: Check the routing of all counterweight straps as indicated in Figure 26. Ensure that the straps are in full contact with all rollers.

Counterweights: Counterweights should be adjusted as shown in Figure 21. Adjust if necessary.

Kill Switch: When the bottom bar assembly is knocked out of the side column(s), the kill switch must operate as described in “KILL SWITCH INSPECTION” on page 15.

Photo Eyes: Make sure the photo eyes are working as described in “DAILY INSPECTION” on page 6 in the Turbo-Seal Insulated Owner’s Manual.

Defrost System: Make sure the blowers are adjusted and operating properly.

Insulated Panel Travel: The foam of the insulated panel of the door varies in thickness and compression. Therefore, the panel may require shimming. A 20”X20” section of Rilon™ material shipped with the door to use as shim material. This material can be cut to use as shim material. (See Figure 53)

Operate the door several times and watch the yellow plastic bottom bar travel as the door opens and closes. The yellow plastic bottom bar should remain centered in the opening throughout the travel of the door. You may notice the bottom bar shifting left and right but again it should remain in the center of the opening.

If the yellow bottom bar is traveling too far in one direction it will be necessary to shim the panel to correct the travel.

To shim the panel place a piece of the Rilon™ material between the panel and the drum; when the door is in the closed position.(See Figure 54)

Lock out and tag out the electrical supply before placing the shim material between the drum and insulated panel. DO NOT attempt to perform this procedure with the power on or serious injury could result.

When the shim has been installed repeat testing of the panel travel to ensure the shimming is correct.

It is possible that both sides may require shimming.

NOTE: Shim opposite the direction the bottom bar is traveling. For example, if the bottom bar is traveling to the right too far, shim on the left between the drum and panel. Service Bulletin #196 contains more detail. Can be found on Rytec Knowledge Center website.

Figure 53

Figure 54

22

NOTES

turbo-seal insulated install. run power lines from disconnect to control panel. 5. run power lines...

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