Self Repair. Installation Manual. [Revision: August 14, 2008, SR150000, Rytec Corporation 2007]

Transcription

1 Turbo-Seal Self Repair Installation Manual [Revision: August 14, 2008, SR150000, Rytec Corporation 2007]

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3 TABLE OF CONTENTS PAGE INTRODUCTION DOOR SERIAL NUMBER(S) HOW TO USE MANUAL INSTALLATION MATERIAL, TOOLS, AND EQUIPMENT ADDITIONAL REQUIREMENTS Labor and Site Requirements Forklift Requirements Electrician s Responsibilities Floor-Loop Activator Requirements Fill-In Material Requirements GENERAL ARRANGEMENT OF DOOR COMPONENTS ANCHORING METHODS Concrete, Block, or Brick Walls Wood, Block, Brick, or Insulated Walls Insulated Wall UNCRATING LOCATING CENTERLINE OF DOOR OPENING LOCATING SIDE COLUMNS SIDE COLUMNS HEAD ASSEMBLY COUNTERWEIGHTS DOOR SEALING CONTROL PANEL AND ELECTRICAL CONNECTIONS OPEN AND CLOSE LIMIT DOOR POSITIONS Close Limit Position Open Limit Position REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT Reversing Edge Switch Air Bleed Check Reversing Edge Switch Sensitivity Adjustment

4 KILL SWITCH CHECK AND ADJUSTMENT Kill Switch Check Kill Switch Air Bleed Adjustment Kill Switch Sensitivity Adjustment RESETTING BOTTOM BAR PHOTO EYES LIGHT CURTAIN (OPTIONAL) FREEZER DOOR DEFROST SYSTEM Heat Tape Circuit Heat Lamps SIDE SUPPORTS HEAT LAMP ASSEMBLY LAMP BULB AND RED SLEEVE INSTALLATION Heat Lamps with Unheated Blower SIDE SUPPORTS BLOWER HEAT LAMPS Heated Blower SIDE SUPPORTS BLOWER Heat Lamp Controls Blower Controls BLOWER SPEED BLOWER HEATER Blower Fin Adjustment FINAL CHECKS

5 INTRODUCTION INTRODUCTION The information contained in this manual will allow you to install your Rytec Turbo-Seal Self Repair Door in a manner that will ensure maximum life and trouble-free operation. Any unauthorized changes in procedure, or failure to follow 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 Customer Support Department at Always refer to the serial number of the door when calling the representative or Customer Support. 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. DOOR SERIAL NUMBER(S) To obtain your DOOR SERIAL NUMBER, there are three universal locations where this information can be found. These are at the inside of either side column (approximately eye level), on the drive motor, and on the inside door of the System 3 control panel. (See Figure 1.) IMPORTANT: When installing multiple doors of the same model but in different sizes, verify the serial number in the control panel with the one in the side column. Drive Motor Gearbox Assembly System 3 Control Panel A HOW TO USE MANUAL Left Side Column Figure 1 Right Side Column Throughout this manual, the following key words are used to alert the reader to potentially hazardous situations, or situations where additional information to successfully perform the procedure is presented: 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 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: 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. 1

6 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 below). 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 % 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: 2,000-pound lift capacity. minimum height ability door height, plus 12 in. side-shift capability (desired). Electrician s Responsibilities For complete details on the responsibilities of the electrician, refer to the Rytec System 3 Drive & Control Installation & Owner s Manual. Floor-Loop Activator Requirements If a floor-loop activator was ordered and shipped with your Rytec Door, the following additional items will be required to install the activator. NOTE: For complete floor-loop installation instructions, refer to the manual that was shipped with the activator. 1. Concrete saw (with water-cooling attachment). 2. Water supply and garden hose. 3. Wet/dry shop vacuum feet of 16-gauge, 19-strand, type XLPE, copper, crosslink polyethylene jacket wire (or equivalent). The size of the floor loop will determine the length of wire required. 5. Bondo P606 Flexible Embedding Sealer (or equivalent) required to fill saw cuts in floor after the activator is installed. For cold temperature applications, Bondo P610 Speed Set must be added to the P606 to ensure the sealer cures properly. 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 gauge hot-rolled sheet steel in. x 2-in. x ³ ₁₆-in. angle iron. 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 purposes only. It should not be relied upon solely during the installation of your door and its sub-assemblies. 2

7 INSTALLATION ANCHORING METHODS Fused Disconnect Head Assembly (Includes Drive Motor Gearbox Assembly, Fabric Roll, and Optional Hood) Concrete, Block, or Brick Walls Concrete Wall Side Column Expansion Anchor System 3 Control Panel Left Side Column (Includes Serial Number Plate, Counterweight and Light Curtain) A Figure 2 NOTE: The above illustration shows the front side of the door. Left and right are determined when viewing the front side of the door. ANCHORING METHODS Bottom Bar Assembly Right Side Column (Includes Counterweight and Light Curtain) 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 3 through Figure 6 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 Customer Support Department at 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 the door to a concrete floor. If expansion anchors are used, a quarterly inspection should be implemented for safe and secure door operation. A Figure 3 Wood, Block, Brick, or Insulated Walls A Wood Wall Crush Plate (¹ ₂-in. Thick, 6-in. x 8-in. Steel) Insulated Wall Through Bolt or Threaded Rod A Continued on next page. Figure 4 Insulated Wall Figure 5 Side Column Through Bolt or Threaded Rod Side Column Aluminum-Clad Lumber (Front and Back Side Full Length) 3

8 INSTALLATION UNCRATING Through Bolt or Threaded Rod Insulated Wall Side Column Centerline of Opening A UNCRATING Aluminum-Clad Lumber (Back Side Full Length) Figure 6 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. 1. Remove the top of the crate. (See Figure 7.) 2. Remove the front of the crate. Head Assembly (Located in Rear of Crate) Overall Width of Door Opening A Half Width of Door Opening 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.) Open Crate by First Removing Top, Then Removing Front A Figure 7 LOCATING CENTERLINE OF DOOR OPENING NOTE: Accurate measurements are critical for the proper installation and operation of your Rytec door. Verify all measurements. 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 Rytec Customer Support Department at 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.) 4

9 INSTALLATION SIDE COLUMNS Half of Door Production Width Centerline of Opening This Dimension Must Be Equal on Both Sides of Door Opening Extend and Mark Edges of Door Along Floor A Figure 9 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. The floor must be level within 0.12 in. from side-toside. 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 Customer Support Department if the floor is more than 1 in. out of level. Line Level Water Level A SIDE COLUMNS Figure 11 Shim Plate (If Required) 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. A This Dimension Must Be Equal on Both Sides of Door Opening Figure 10 Shim Plate (If Required) 1. Remove the right side column from the shipping crate. 2. Remove the cover from the side column by removing the screws that hold the cover 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. (See Figure 12.) 5

10 INSTALLATION HEAD ASSEMBLY 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. Anchor Holes Carpenter s Level Right Side Column 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. A Production Width Line 4. Once the side column is set plumb and square, anchor it to the wall and floor. (See Figure 12.) Predrilled anchor holes have been provided in the side column. DO NOT securely tighten the anchors at this time they will be tightened later on, after the head assembly is installed. 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. Figure Mount the left side column to the wall and floor following the above procedure 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. 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. HEAD ASSEMBLY 1. Remove the head assembly from the crate. NOTE: If the head assembly contains a hood, remove the side cover from both ends of the head. Save all hardware for later use. 6

11 INSTALLATION COUNTERWEIGHTS Anchor Hole 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. Secure the head assembly to the forklift before lifting it into position. NOTE: Personal injury or equipment damage may result from items not being secured. 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 13.) Head Assembly Alignment Pin Inserted in the Alignment Hole A Head Assembly Hardware Figure 14 Anchor Side Column 5. Once the head assembly is set plumb and square, anchor it to the wall. NOTE: Mounting holes in the head assembly are predrilled from the factory for the load bearing cross-sectional area. Do not add additional holes for mounting. Please consult your Rytec representative or call the Rytec Customer Support Department at 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 A Figure Attach each side column to the head assembly with hardware provided in the small parts carton. (See Figure 14.) 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, 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 15.) 7

12 INSTALLATION COUNTERWEIGHTS 4. Swing guide plate up for installation. (See Figure 17.) At this point the counterweight is free standing. Secure counterweight from falling over while installing the guide plate assembly. Personal injury can result. Guide Plate NOTE: For photo purpose, the guide plate is shown and should NOT be installed at this time. Swing Up A Figure Set mounting plate on top of the guide plate. 6 to 8 in. 6. Secure mounting plate and 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. (See Figure 18.) A Mounting Plate Guide Plate Hex Head Cap Screws with Split Lock Washers Figure Install counterweight guide plate toward the rear of the column. (See Figure 16.) Counterweight Guide Plate A Figure 18 A Figure Remove the shipping tape from around each counterweight strap. NOTE: Door must be in the fully open position. 8

13 INSTALLATION COUNTERWEIGHTS 8. Route each strap over its associated idler pulley as shown in Figure 19. Counterweight Strap Spool Idler Pulley To check the position of each counterweight, first release the motor brake by pulling on the brake release cable. Then manually move the door to its fullyclosed position. The clearance between the top of each counterweight and the top of its associated side column, must be at least 2 in. Counterweight Strap Counterweight 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. Hex Head Cap Screws Counterweight Strap Split Lock Washer Clamp Bars A NOTE: Right Column Profile Shown Figure 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 20. IMPORTANT: The 6 to 8 in. mounting height for each counterweight, as indicated in Figure 15, is adequate for most Turbo-Seal Self Repair doors. However, for extra-wide or -short doors, the counterweights may have to be adjusted closer to the bottom of the side column. A Figure 20 Counterweight 11. Tighten the clamp bars to secure each strap. Then carefully remove the support block out from under each counterweight to allow the weights to hang free. If necessary, readjust the straps. 9

14 INSTALLATION DOOR SEALING 12. 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. 13. 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. 14. Attach the side column covers using the saved hardware. DOOR SEALING Caulk the side columns and head assembly where they meet the wall. IMPORTANT: Use caulk as directed on instructions. Improper wall preparation may result in poor adhesion. CONTROL PANEL AND ELECTRICAL CONNECTIONS Once the door has been assembled, see the Rytec System 3 Drive & Control Installation & Owner s Manual for information on control panel installation, electrical connections, door limit settings, and initial door start-up procedure. 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 electrician. All wiring and conduit must meet all local and state codes. Wires provided with the door are labeled with terminal or contact numbers. OPEN AND CLOSE LIMIT DOOR POSITIONS See the Rytec System 3 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 yellow vinyl loop on the bottom bar to gently seal against the floor. (See Figure 21.) DO NOT allow the rubber reversing edge, enclosed in the yellow 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. Fabric Panel A Rubber Reversing Edge Yellow Vinyl Loop Figure 21 ¹ ₂ to 1 in. Open Limit Position When the door is knocked out of position, the System 3 Drive and 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 plastic breakaway tab into the yellow channel guides of each side column. (See Figure 22.) Plastic Breakaway Tab Yellow Channel Guide A Figure 22 10

15 INSTALLATION REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT Reversing Edge Switch (On Side Opposite Door Motor) Air Bleed Adjustment Screw 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. If the switch is working properly, the door will immediately reverse direction and run to the open position. Push the control panel pushbutton to close the door after the check is completed. If the door does not reverse direction, check the air bleed and sensitivity of the reversing edge switch. Reversing Edge Switch Air Bleed Check PVC Hose Must Be Tight on Lower Input Hose A Figure 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 located inside the bottom 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 23.) 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 contact. The PVC hose is on the lower air input post. To adjust the switch, first remove the wires and resistor from the contact terminals and attach an ohmmeter across the two terminals. (See Figure 25.) Access Cover Reversing Edge Switch Resistor A Bottom Bar Assembly Figure 23 Sensitivity Adjustment Screw A Remove Wires and Resistor to Test and Adjust Switch 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 24.) Figure 25 11

16 INSTALLATION KILL SWITCH CHECK AND ADJUSTMENT 2. Turn the sensitivity adjustment screw, located on the face of the switch, clockwise or counterclockwise until continuity is achieved. Then adjust the screw a three-quarter turn counterclockwise. Adjusting the screw counterclockwise decreases sensitivity, clockwise increases sensitivity. (See Figure 25.) 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 CHECK AND ADJUSTMENT A kill switch has been mounted in the bottom bar assembly. The purpose of this switch is to prevent the door from being operated if the breakaway bottom bar becomes separated from either side column. Kill Switch Check A Plastic Tabs Out of Side Column Figure 26 Air Switch Bladder Bottom Bar Assembly Bottom Bar Assembly Take precautions to prevent the door from being operated when performing the following procedure. 1. Move the door to approximately head or chest height and then stop the door. NOTE: When a kill switch is activated, it should not be possible to restart the door until the door is reassembled and the control panel is reset. Breakaway Tabs 2. Push the breakaway bottom bar out of the side column. Door should not operate until door panel is reset. (See Figure 26 and Figure 27.) If the kill switch did not operate properly: Adjust the kill switch and then recheck it. (See "Kill Switch Air Bleed Adjustment" on this page.) If the kill switch operated properly: Reinstall the bottom bar into the side column. (See RESET- TING BOTTOM BAR on page 13.) A Figure 27 Kill Switch Air Bleed Adjustment 1. The kill switch is mounted in the bottom bar assembly, on the end below the door motor. To access the switch, first remove the access cover. (See Figure 28.) 12

17 INSTALLATION RESETTING BOTTOM BAR Sensitivity Adjustment Screw Upper Air Input Post A Figure Make sure the clear PVC hose is tight on the air input post so that air leakage cannot occur and vibration will not cause the hose to fall off. Also make sure the hose is not kinked. (See Figure 29.) Air Bleed Adjustment Screw (One on Each Side of Switch) A Bottom Bar Assembly Figure 29 Access Cover Kill Switch PVC Hose Must Be Tight on Air Input Post 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. (See Figure 29.) Kill Switch Sensitivity Adjustment The kill switch assembly is a normally closed contact. The PVC hose is on the upper air input post. 1. Remove the wires from the contact terminals and attach an ohmmeter across the two terminals. (See Figure 30.) A Figure To adjust the switch, turn the small adjusting screw located on the face of the switch clockwise or counterclockwise until continuity is achieved. Then turn the screw two turns clockwise for final adjustment. Adjusting the screw clockwise decreases sensitivity, counterclockwise increases sensitivity. (See Figure 30.) 3. Reconnect the wires onto the switch. Replace the access cover on bottom bar. NOTE: If the kill switch is set too sensitive, it may cause the door to stop during the opening or closing cycles. If this occurs, readjust the kill switch sensitivity setting. RESETTING BOTTOM BAR Remove Wires to Test and Adjust Switch The Turbo-Seal Self Repair 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 following: 1. The breakaway tabs have popped out of the side column s channel due to impact. (See Figure 31.) 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 Customer Support Department at

18 INSTALLATION PHOTO EYES Breakaway Tabs Door Panel Has Been Reset and Is Shown in Normal Operating Position Side Column Channel A Figure The door panel will momentarily pause and then execute the reset procedure. 3. The door panel s breakaway tabs will roll upward above the side columns channel. (See Figure 32.) A Breakaway Tabs Side Column Channel Figure The photo eye senses if the path is clear from any obstructions. 5. Then the door panel will guide itself into the channel and resume its normal operation. (See Figure 33.) A Figure 33 NOTE: There is no warning like a light or horn should the door panel not reset itself due to an obstruction beyond the photo eye parameter. Should that option be required, these items can be added to the system. The door function is fully automatic, it will reset, rise to the open position, and reinsert the bottom bar according to factory installed parameters. Cycling the door and checking for proper door operation is not required unless prescribed, but an occasional test of the self repair system would ensure its proper operation. Should slight adjustments of the door be needed, please contact your Rytec Customer Support at PHOTO EYES There are two sets of photo eyes in the side columns. One in front of the brush seal and one behind. Each set contains an emitter and receiver module. The mounting brackets and conduit for photo eyes are built into the side columns and head assembly. 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. NOTE: The cables and photo eyes are preinstalled in the side columns at the factory. The receiver module can be identified by the two small lights, one yellow and one green. The emitter module has only a green light. The yellow alignment light will be lit when the photo eyes are aligned. (See Figure 34.) When installing and routing the cables, allow plenty of slack in the lines so they hang loose without strain. 14

19 INSTALLATION PHOTO EYES NOTE: Photo eyes are joined for photo purposes. Receiver Module Power Light (Green) Right Side Column Front of Head Assembly Alignment Light (Yellow) A Figure 34 Emitter Module 1. Locate cables in the right side column. One end of the cable should be routed through the conduit and connected to the photo eye. The opposite end should be routed to the junction box. 2. Route front cable through top of side column and into head assembly. (See Figure 35.) NOTE: Left side column shown. A Front Cable and Conduit Figure Route rear cable through top of side column and into head assembly. 5. Route cable through the rear conduit of the head assembly. (See Figure 37.) Right Side Column Rear Cable and Conduit Front of Head Assembly A Front Cable Side Column Figure Route left cables through top of column and into head assembly. (See Figure 38.) Conduit A Figure Route cable through the front conduit of the head assembly. (See Figure 36.) 15

20 INSTALLATION LIGHT CURTAIN (OPTIONAL) Cable Routing Left Side Column A Figure Route all four cables to junction box. (See Figure 39.) NOTE: Be sure to route cables away from all moving parts. Use cable ties as required. Junction Box Conduit with Cables from Right Column NOTE: The light curtains and cables are already pre-installed in the side columns at the factory. Routing of cables for the light curtains should follow the same procedure as for the photo eyes. (See PHOTO EYES on page 14.) FREEZER DOOR DEFROST SYSTEM A Turbo-Seal Self Repair door configured for freezer use utilizes an optional defrost system to help prevent frost build-up on the warm side of the door panel. A freezer door can be equipped with one of three defrost systems. The defrost system for your particular door was determined at the time the door was ordered. The three available defrost systems are: heat lamps, heat lamps with unheated blower, and heated blower. In addition, all doors configured for freezer use are fitted with an electrical heat tape circuit. This heating element helps prevent frost build-up in the side columns and across the head assembly. The following procedure pertains to the installation of the heat tape circuit. (The procedure for installing the defrost system begins on page 17.) Heat Tape Circuit A length of electrical heat tape was factory installed in each side column. You will need to complete their installation across the head assembly. For shipping, the free end of each length of heat tape was coiled and tied near the top of the side column. Cables A Figure Connect cables to junction box. Use schematics in back of manual. LIGHT CURTAIN (OPTIONAL) There are two sets of light curtains in the side columns. One in front of the brush seal and one behind. Each set contains an emitter and receiver module. The mounting brackets and conduit for light curtains are built into the side columns and head assembly. The light curtains are provided as a safety feature. If the light curtains 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. Avoid routing the heat tape near any moving parts. Also, make sure the heat tapes are not kinked or twisted and that all slack is pulled from both lengths of tape. 1. Locate, untie, and unroll each length of heat tape while taking care to avoid damage. 2. Route the free end of each tape up and through the hole located in the back corner of the head assembly. (See Figure 40.) 16

21 INSTALLATION FREEZER DOOR DEFROST SYSTEM NOTE: The figure below is just a generalization and does not depict your specific door. Route Heat Tape Up and Through Hole in Corner of Head Assembly A Figure 40 Heat Tape 3. Route the heat tape from the left side column, along the end of the head assembly, and over to the junction box while making sure all slack is pulled from the tape. The junction box is centered in the front of the head assembly. (See Figure 41.) Secure the length of the heat tape to the head assembly using all retainers and hangers mounted along the end and the front of the head assembly. NOTE: The figure below is just a generalization and does not depict your specific door. Wire both lengths of heat tape according to the schematic that was shipped with the door make sure they are properly grounded as detailed in the schematic. 7. Wire both lengths of heat tape according to the schematic that was shipped with the door make sure they are both properly grounded as outlined in the schematic. Heat Lamps A freezer door can be equipped with heat lamps to help prevent frost build-up on the warm side of the door panel. SIDE SUPPORTS A door configured with heat lamps utilizes an oversized U-shaped hanger assembly to support the lamps over the door panel. This wall-mounted bracket consists of two side support brackets with a center support bracket in between. NOTE: The left and right side supports are assembled as mirror images of each other. However, the parts used for each side are identical. 1. Locate two vertical supports, two side support brackets and one center support bracket. Assemble the left and right side supports as shown. (See Figure 42.) Junction Box Left Side Support Hex Nut and Washer Side Support Bracket (Part of Left Side Support) Heat Tape Retainer Hex Screw Center Support Bracket A Heat Tape from Left Side Column Figure Install the other length of heat tape in the right side column in a similar manner as used to install the first length of heat tape. 5. Pass both heat tapes through the same connector on the side of the junction box. 6. Secure the connector to lock the heat tapes in place. Do not overtighten the connector. A Hex Screw Vertical Support (Part of Left Side Support) Appropriate Wall Mounting Hardware Figure 42 Hex Nut 17

22 INSTALLATION FREEZER DOOR DEFROST SYSTEM IMPORTANT: Position each side support with the bottom edge of its side support bracket 4¹ ₂ in. below the head assembly. Face the open side of each side support away from the head assembly with the distance between the side supports equal to the length of the center support bracket. Also, position the side supports so the center support bracket will be centered across the width of the head assembly. (See Figure 43.) Lock Washer Heat Lamp Mounting Bracket Heat Lamp Fixture Bracket (One on Each End of Lamp Fixture) Hex Nut Serrated Nut Hex Screw 2. Attach the side supports to the wall using the appropriate anchoring method for your particular wall. (See ANCHORING METHODS on page 3.) Also, position each bracket so that it is centered across the width of the head assembly. (See Figure 43.) A Center Support Bracket 4¹ ₂ in. Bottom Edge of Side Support Mount Side Support with Bottom Edge 4¹ ₂ in. Below Head Assembly Front View of Head Assembly Figure 43 Heat Lamp Fixture Bottom Edge of Head Assembly 3. Attach the center support bracket to the ends of the left and right support brackets. Each end of the center support bracket is held in place by a pair of ³ ₈-16 x 1¹ ₄-in. hex screws and nuts that are located in the small parts carton. (See Figure 42.) HEAT LAMP ASSEMBLY 1. Attach a heat lamp fixture bracket to the ends of each lamp fixture. Each bracket is held in place by a pair of x ³ ₄-in. Phillips head screws, lock washers, and hex nuts located in the small parts carton. (See Figure 44.) A Phillips Head Screw Heat Lamp Fixture Figure Mount the heat lamp fixtures to the mounting brackets along the bottom edge of the hanger assembly. The lamps are held in place by ³ ₈-16 x 1-in. hex screws and nuts located in the small parts carton. (See Figure 44.) LAMP BULB AND RED SLEEVE INSTALLATION Never touch the glass surface of the lamp bulb or the red sleeve with your fingers, and never handle them with a dirty or oily rag. Any debris or oil on the surface of the lamp will lead to a hot spot which will reduce the life of the lamp and even result in immediate failure. With the lamp fixtures mounted, a lamp bulb and red sleeve can now be installed in each fixture. 1. Remove the end cover plates from the lamp fixture. (See Figure 45.) 18

23 INSTALLATION FREEZER DOOR DEFROST SYSTEM Lamp Fixture 5. After the lamp bulb is wired in place, cut off the excess wire leading away from each screw terminal. Lamp Bulb The disconnect must be in the OFF position and properly locked and tagged before performing the following procedure. 6. Wire each lamp fixture according to the schematic that was shipped with the door. Screw A End Cover Plate Red Sleeve 7. Reattach all end cover plates. 8. Direct the lamp fixtures to aim at the area of the floor where the bottom bar meets the floor. Figure 47 shows the correct angle to aim a fixture. Figure 48 shows two angles NOT to use. Figure Locate the lamp bulb and the red sleeve. 3. Slide the sleeve over the lamp. Then install the lamp in the fixture. (The sleeve blocks most of the radiant light from the lamp, but it does not affect the radiant heat output.) 4. Connect the wire on the ends of the lamp to the screw terminal located at each end of the fixture. (See Figure 46.) Leave a ¹ ₄-in. loop on the end of the wire as shown in Figure 46. If the loops are not included, the bulb can become damaged when the fixture expands as a result of the heat output from the lamp. Lamp Fixture Aim Fixture Toward Area of Floor Where Bottom Bar Meets Floor (Allows Radiant Heat to Rise Across Entire Face of Door Panel) Lamp Fixture (Cover Removed) Wire on End of Lamp A Correct Angle to Aim Fixture ¼-in. Loop Figure 47 Screw Terminal A Lamp Bulb with Red Sleeve Figure 46 19

24 INSTALLATION FREEZER DOOR DEFROST SYSTEM Damage to Panel Can Result if Lamp Fixture Is Aimed Directly at Panel Vertical Support Side Support Bracket Blower Support Panel Center Support Bracket Aiming Lamp Fixture Straight Down Will Have No Effect on Defrosting the Door Panel A Blower and Heat Lamp Support Figure Assemble each side support, using two hex screws, washers, and hex nuts. (See Figure 50.) Hex Nut A Incorrect Angles to Aim Fixture Vertical Support Washer Figure Tighten the hex nut on each end of the lamp fixtures to lock the lamps at the adjusted angle. Heat Lamps with Unheated Blower If your door is equipped with heat lamps and an unheated blower, the blower and lamp(s) will be installed on a pair of wall-mounted brackets. Therefore, the wall must be capable of supporting up to 400 pounds it is important to use mounting hardware appropriate for your particular wall application. (See ANCHORING METHODS on page 3.) SIDE SUPPORTS NOTE: The left and right side supports are assembled as mirror images of each other. However, the parts used for each side are identical. 1. Locate two vertical supports, two side support brackets, one blower support panel, and one center support bracket. (See Figure 49.) A Hex Screw Figure 50 Side Support Bracket Side Supports Blower and Heat Lamp IMPORTANT: Position each side support with the bottom edge of its side support bracket 4¹ ₂ in. below the head assembly. Face the open side of each side support away from the head assembly with the distance between the side supports equal to the length of the center support bracket. Also, position the side supports so the center support bracket will be centered across the width of the head assembly. (See Figure 51.) 3. Attach the side supports to the wall using the appropriate anchoring method for your particular wall. (See ANCHORING METHODS on page 3.) Also, position each bracket so that it is centered across the width of the head assembly. (See Figure 51.) 20

25 INSTALLATION FREEZER DOOR DEFROST SYSTEM A ¹ ₂ in. Mount Side Support with Bottom Edge 4¹ ₂ in. Below Head Assembly Head Assembly (Shown with Slanted Hood) Support Bracket Front View of Head Assembly 3. Wire the blower according to the schematic that was shipped with the door. HEAT LAMPS 1. Locate the center support bracket and attach it to the side supports. Use four ³ ₈-16 x 1¹ ₄-in. screws and ³ ₈-16 nuts provided. (See Figure 54.) Figure 51 BLOWER 1. Bolt the blower support panel to the blower unit. The bottom edge of the blower fits in a channel along the bottom edge of the panel. Use five ⁵ ₁₆-18 x ³ ₄-in. screws provided. (See Figure 52.) Screw Nut Center Support Bracket Blower Support Panel A Figure 54 Support Panel A Blower Figure 52 Blower Unit 2. Attach the blower support panel (with blower) to the side supports. Use four ⁷ ₁₆-14 x 1¹ ₄-in. screws provided in the small parts carton. (See Figure 53.) Attach Blower Support Panel to Brackets 2. To install the heat lamp(s) on the center support bracket, follow the procedure outlined in HEAT LAMP ASSEMBLY on page 18. Heated Blower If your door is equipped with a heated blower, the blower will be installed on a pair of wall-mounted brackets. Therefore, the wall must be capable of supporting up to 400 pounds it is important to use mounting hardware appropriate for your particular wall application. (See ANCHORING METHODS on page 3.) SIDE SUPPORTS NOTE: The left and right side supports are assembled as mirror images of each other. However, the parts used for each side are identical. 1. Locate two vertical supports, two side support brackets, one blower support panel, and one center support bracket. (See Figure 55.) A Screw Figure 53 21

26 INSTALLATION FREEZER DOOR DEFROST SYSTEM Vertical Support Side Support Bracket Also, position each bracket so that it is centered across the width of the head assembly. (See Figure 57.) Blower Support Panel A ¹ ₂ in. Mount Side Support with Bottom Edge 4¹ ₂ in. Below Head Assembly Head Assembly (Shown with Slanted Hood) Support Bracket Front View of Head Assembly A Blower Support Heated Blower Figure Assemble each side support, using two hex screws, washers, and hex nuts. (See Figure 56.) Vertical Support Hex Nut Washer Figure 57 BLOWER 1. Bolt the blower support panel to the blower unit. A lip along the bottom edge of the blower fits down in a channel along the bottom edge of the panel. Use five ⁵ ₁₆-18 x ³ ₄-in. screws provided in the small parts carton. (See Figure 58.) Support Panel Blower Support Panel Hex Screw Side Support Bracket A Side Supports Heated Blower Figure 56 IMPORTANT: Position each side support with the bottom edge of its side support bracket 4¹ ₂ in. below the head assembly. Face the open side of each side support away from the head assembly with the distance between the side supports equal to the length of the center support bracket. Also, position the side supports so the center support bracket will be centered across the width of the head assembly. (See Figure 57.) A Blower Figure 58 Blower Unit 2. Attach the blower support panel (with blower) to the side supports. Use four ⁷ ₁₆-14 x 1¹ ₄-in. screws provided in the small parts carton. (See Figure 59.) 3. Attach the side supports to the wall using the appropriate anchoring method for your particular wall. (See ANCHORING METHODS on page 3.) 22

27 INSTALLATION FREEZER DOOR DEFROST SYSTEM A Attach Support Panel to Brackets Screw Figure Wire the blower according to the schematic that was shipped with the door. Heat Lamp Controls If your door is equipped with heat lamps, they are controlled by the control panel. Refer to the Rytec System 3 Drive & Control Installation & Owner s Manual. With the defrost system in the MANUAL mode, the heat lamps will immediately power up. When in the AUTO mode, the heat lamps are operated automatically by the control system. An automatic timer function can be set to periodically cycle the lamps on and off. Placing the defrost system in the OFF mode turns off the lamps and disables the automatic timer function. Blower Controls BLOWER SPEED If your door is equipped with a blower (unheated or heated), the blower fan speed has four modes of operation (OFF, LOW, HIGH, and AUTOMATIC). Refer to the Rytec System 3 Drive & Control Installation & Owner s Manual. With the blower switch in the AUTOMATIC position and the door closed, the blower will run at low speed. When the door is open, the blower will operate at high speed. With the blower switch in the HIGH or LOW position, the blower will run at high or low speed regardless of the position of the door. The blower speed you select (LOW, HIGH, or AUTO- MATIC) will depend on the environmental conditions (temperature, humidity, etc.) of the installation site. Placing the switch in the OFF position will override the control system and prevent the blower from turning on. BLOWER HEATER If the blower is equipped with an internal heater (heated blower), the heat level is controlled by the control panel. Refer to the Rytec System 3 Drive & Control Installation & Owner s Manual. The standard heated blower has two heating levels. An optional heated blower is available with three heating levels. The required heating level is set according to the environmental conditions of the installation site. Blower Fin Adjustment All blowers (unheated and heated) are equipped with air deflection fins located along the bottom of the blower unit. To redirect the airflow, loosen the nuts that lock the fins in place and reposition the fins. Tighten the nuts to lock in the adjustment. (See Figure 60.) Blower Unit Adjustment Locking Nut A Figure 60 Air Deflection Fins 23

28 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 OPEN AND CLOSE LIMIT DOOR POSITIONS on page 10. 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 11. 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 19. Ensure that the straps are in full contact with all rollers. Counterweights: Counterweights should be adjusted as shown in Figure 15. Adjust if necessary. Kill Switch: When the bottom bar assembly is separated from either end bracket, the kill switch must operate as described in KILL SWITCH CHECK AND ADJUSTMENT on page 12. Photo Eyes: Make sure the photo eyes are working as described in DAILY INSPECTION on page 6 in the Turbo-Seal Self Repair Owner s manual. Defrost System (Freezer Door Only): Heat tape, heat lamps, and blower are adjusted and operating properly as indicated in FREEZER DOOR DEFROST SYSTEM on page