Therm-L-Tec Building Systems LLC Therm-L-Tech Power Operated Retrofit Kit 230 VAC or 440/480 VAC 50/60 Hz Installation and Setup Manual Rev. A 01/2015
Index Index 1 Electrical Requirements for Therm-L-Tec Power Operated Doors 2 Mounting of Control Box and Motor 3 Further Requirements 4 Wiring the Motor 5 Wiring the Pull Cord Switches Wiring the Safety Reversing Edge 6 Installing the Photoeye s 7 Installing the Sensor Extension Cords 8 Installing and wiring the control cables 9 Installation of the Photoeye s: Open Position Sensor Installation of the Photoeye s: Close Position Sensor 11 Final Adjustment, fine tuning 12 M 1000 I/O Ports 13 Appendix A: Wiring Diagram 230 VAC 14 Wiring Diagram 440/480 VAC 15 Appendix B: Pull Cord Location Guide 16 Therm-L-Tec Building Systems, LLC. 15115 Chestnut Street Basehor, KS 66007 U.S.A. Tel: (913) 728 2662 Web Site: http://www.thermltec.com E-Mail: scole@themltec.com 2014 Therm-L-Tec Building Systems, LLC Page 1 of 16
Electrical Requirements for Therm-L-Tec Power Operated Doors 1) Power to the operator must be preceded by a fused disconnect! Failure to install a properly fused disconnect will void manufacturer s liability in the event of equipment failure. The operating voltage of this unit cannot be altered in the field. Fuse requirements Operating Voltage Phases Fuse Rating 208 VAC 3 Phase FRN 5 AMP 240 VAC 3 Phases FRN 4 AMP 480 VAC 3 Phases FRN 2 AMP The incoming 3 phases from the fused disconnect to the operator are terminated on the 3 Terminal Blocks Label: L1, L2, L3 and GND Page 2 of 16
2) Freezer doors are equipped with a self-regulating heat cable. Fuse protection is supplied in the junction box. The heat cable requires 110 VAC 7 Amps. Because of the nature of the self regulating heat cable, if the temperature is below freezing when power is applied, the fuse may blow. This can be remedied by bypassing the fuse for one minute, then re-applying power to the feed side of the fuse. The wiring diagram is located inside the cover of the supplied junction box. Mounting of Control Box and Motor: The Motor should always be mounted on the side of the header in which the door opens, i.e. Right Hand open should mount on the right hand side of the Header and vice versa for left hand open. The Control Box should be mounted as close as possible to the motor, keeping the cable between Motor and Enclosure as short as possible to reduce EMI related issues. The Electrical Box can either be mounted above the header or to the side of the Motor. WARNING! MOUNT BOX OUT OF THE DOOR S TRAVEL PATH! Please refer to the Mechanical Drawing, if supplied for proper distances and spacing when building your own Header Board. All Therm-L-Tec supplied Header Boards are already pre-drilled for you specific application. Page 3 of 16
Further Requirements for Control Box: 1. Interim Board, M-1000 or M-1000s Controller 2. 24 VDC Power Supply 3. Omron MX2 Drive 230 VAC or 440/480 VAC 3 Phase 50/60 Hz Page 4 of 16
Wiring the Motor: 1. Connect the supplied yellow 16-4 SOOW type cable to the leads on the electrical box on the motor. Wire #1: T1 (U) black Wire #2: T2 (V) red Wire #3: T3 (W) white Green Wire: attach to stud which has two nuts 2. Drill a 7/8" Hole on the side of the Electrical Enclosure 3. Insert the Strain Relieve into the hole and secure with nut 4. Insert the SOOW Cord and strip insulation leaving enough length to reach the VFD Terminals U, V, W with some extra reserve. 5. Attach the 3 Wires: T1, T2, T3 to the VFD on the lower side Terminals labeled U/T1,V/T2,W/T3 and the Green Wire on the Ground bar (Green Screw). 6. Power Electrical control box and turn both Power Switches on. 7. Push the small Push button on the M-1000 Boards briefly. 8. The door should move in the Open direction. IF DOOR MOVES IN THE CLOSE DIRECTION STOP! REMOVE POWER TO DOOR THEN SWITCH WIRE U/T1 AND V/T2 ON THE VFD! REAPPLY POWER VERIFY THAT DOOR OPENS NOW, BY PRESSING THE SMALL PUSH BUTTON AGAIN BRIEFLY! 9. The Motor is now wired correctly Wiring the Pull Cord Switches: 1. Install the Pull Cord Switches at your desired location. Use Appendix B: Pull Cord Location Guide for reference. 2. Run a conduit to each Pull Cord with 2 14 or 16 ga wires. Connect Wires inside the Pull Cord according to Appendix A: Wiring Diagram DO NOT RUN THESE WIRE WITH ANY HIGH VOLTAGE [100 VAC and above] IN THE SAME CONDUIT! THIS MAY CAUSE INTERFERENCE PROBLEMS! 3. Connect the wires to the rolled up, above the 24 Volt Power Supply, Pruple and Orange 18ga wires as shown in Appendix A: Wiring Diagram Connect the Blue Wire if you have a Heated Pull Cord Switch only as shown in Appendix A: Wiring Diagram Page 5 of 16
Wiring the Safety Reversing Edge: 1. Drill a 5/8" Hole on the side or on the bottom of the Electrical Enclosure 2. Mount the 4 PIN Female Receptacle in the hole 3. Use the following two of the four wires and connect them as follows: White: Terminal 6 on the M-1000 Board Brown: Terminal 9 or 10 on the M-1000 Board Blue: Not used ( cut off or roll up and secure ) Black: Not used ( cut off or roll up and secure ) 4. Attach the grey 22-4 CMX cable with the male connector to the female receptacle. 5. Move the door to the Close position 6. Insert the 22-4 CMX Cable into the Cantilever by means of a strain relieve, leaving a slight sag in the cable. Drill a 7/8" Hole if the Cantilever Cover does not have a hole for the strain relieve. 7. Remove the insulation of the CMX Cable inside the Cantilever and connect each of the two wires White and Brown to the each of the 2 wires which are inside the cantilever so that the wire match up as follows: White Wire from Safety Edge: Orange Wire from Safety Edge: White Wire CMX Cable Brown Wire CMX Cable 8. Install the safety reversing edge on the other side of the door. 9. Connect the two wires on the safety reversing edge with the two wires which run inside the door to the cantilever. 10. If the two wires inside the door plug are missing, run the CMX Cable on top of the door connecting the two wires from the safety reversing edge as follows: White Wire from Safety Edge: White Wire CMX Cable Orange Wire from Safety Edge: Brown Wire CMX Cable Not used: Blue Wire CMX Cable ( Cut Off ) Not used: Black Wire CMX Cable ( Cut Off ) 11. Verify operation by testing Terminal 9 [10] and 6 for continuity with a continuity tester. The tester should respond for 1 to 3 seconds when the safety edge is depressed. 12. The safety reversing edge upon verification of continuity is now operational Page 6 of 16
Installing the Photoeye s: The Photoeye Sensors are installed on the Header. There is one Sensor for the Open Position and one for the Close Position. The sensor s can be installed in between the Drive belt, but care should be taken that the Belt does not touch the Photoeye Bracket or the Cable. Positioning of the Photoeye s: The Photoeye s need to be mounted that they sense the door before the door reaches it s full position. Recommendation: All adjustments should be made when the surrounding area of the door has reached it s desired Operating Temperature. This means that the cooler/freezer Temperature should be at the normal operating temperature on both sides of the door. This will prevent drifting of the door. Note: The adjustment will drift with temperature change. As an example: Door was set at 65 F and opens and closes to the desired End Points Ambient Temperature Increases Ambient Temperature Decreases Travel of door will increase by about 1" for every 40 F positive Temperature Change Travel of door will decrease by about 1" for every 40 F negative Temperature Change Page 7 of 16
Installing the Sensor Extension Cords: Your Photoeye Conversion Kit comes with two control cable s. A short control cable for the Open Position Sensor which is to be mounted close to the control cabinet and a long control cable for the Close Position Sensor which is going to be mounted farther away from the control cabinet. Each control cable has a connector attached on one side. This connector has to be in the proximity of where the Sensor is going to be mounted. If you have a TLT Logic Board, M-595 or M-596 Board then those will have to be replaced with a M- 1000 Board or a M-1000s Unit. Please follow the particular Manual for installing those Units / Boards before installing the Sensors. M-1000 Board / Interim Board M-1000s Unit The new Power Supply will replace the existing control Transformer. Please follow the Manual for installing the Power Supply Unit. Page 8 of 16
Installing and wiring the control cables: 1. Drill a 7/8" Hole on the side of the Electrical Enclosure 2. Insert the Strain Relieve into the hole and secure with nut 3. Insert the two new control cables with the open wire ends through the strain relief in the Control Cabinet. 4. Run the control cables with their connector sides to the approximate Sensor location 5. Mount the control cable with Mounting ties to the top of the header Do not fully close the tie end of these ties yet Leave some slack so you have enough cable to move the Sensor around Secure all these cable ties after the sensors have been installed and adjusted 6. Cut the control cables inside the Control Cabinet, leaving app. 1' to 2' of slack. 7. Cut off the white wire from the control cables. This wire is not needed. 8. Twist the two brown wires from each control cable together and connect them to Terminal #9 or #10 (+24VDC) on the M-1000 Board or to Terminal #15 On the M-1000s Unit 9. Twist the two blue wire from each control cable together and connect them to the upper header Terminal #10 (0VDC) on the M-1000 Board or to Terminal #13 On the M-1000s Unit 10. Insert the black wire of the Open Limit Sensor into Terminal # 7 on the M-1000 Board or to Terminal #14 On the M-1000s Unit 11. Insert the black wire of the Close Limit Sensor into Terminal # 8 on the M-1000 Board or to Terminal #16 On the M-1000s Unit 12. Secure the control cables with cable ties after the sensors have been installed and adjusted This concludes the wiring Installation of the Photoeye s Please make sure that you have finished the Chapter Installing and wiring the control cables and Changing the VFD Parameters in this manual before proceeding. Open Position Sensor Note: The Open Position requires more breaking distance for the door to come to a complete stop! Make sure your belt tension is correct before proceeding! 1. Move the door to your desired Full Open Position 2. Mark the position in between the belt on the header, extending the end of the Leading Door Edge Trolley Angle with a marker. 3. Measure 6" with a tape into the door travel and make an other mark 4. Mount the Open Sensor on this second mark with the mark being in the center of the slots with the enclosed Mounting Position Adjuster, assembled with Keyence Parts OP-87404, PZ-S20A and Photoeye LR-ZB250CP as shown in the picture below. Adjust the Sensor so that the light beam hits the shroud as shown in the pictures below. Assemble the close position sensor in the same way. Page 9 of 16
Assembled Photo Eye with Mounting Bracket 5. Attach Sensor Cable to the extension cable previously installed. 6. Apply Power to the System so the LED Display of the sensor comes on 7. Push and hold UP Button for 3 seconds until the display will either display: Lon or don Select Lon by pushing the UP Button until Lon flashes. Lon will flash for a few seconds and then the display will go back to normal operations. Lon will turn the Output of the Sensor ON (Normally Open) and the Orange Indicator Light will also be ON when the target is sensed. Selecting don will invert the Output (Normally Closed) and the Orange Indicator Light. It is important to select Lon for the correct operation of this system! Location of the different Buttons and Light Indicators on the Laser Sensor Page 10 of 16
7. Move the door so the light beam meets the end of the Trolley Angle. If the light beam hits the leading edge trolley angle like this adjust the sensor by loosening the set screw on the Bracket and aligning the beam by moving the sensor in or out until the beam hits the trolley angle like in this picture. 8. Push the SET Button once. The Display will flash Set and a Number and the Green Spot Indicator Light should be ON and the ORANGE INDICATOR LIGHT should be ON. 9. Move the Door so the light beam is no longer on the Trolley Angle and the Green Spot Indicator Light should be OFF and the ORANGE INDICATOR LIGHT should be OFF. 10. Push the SET Button again once. The Display will now flash - - - a few times and then display a number. 11. Verify correct operation of the sensor by moving the door several times in and out of the light beam. Every time the door is detected by the Sensor the Orange Indicator Light should come on and has to go Off when door is not detected. 12. Verify with a Voltmeter that the Terminal #8 is at +24VDC when the Orange Indicator Light comes on and is below 1 VDC when the Orange Light is Off Close Position Sensor The Close Position Sensor is essentially installed and setup in the same way as the Open Sensor. However, the distance is about 3" which the sensor has to be moved into the door travel and the Photo Eye should detect the Trailing Door Edge Trolley Angle. Check Terminal #7 for +24VDC when the door is detected for the closing Input. Page 11 of 16
Final Adjustment, fine tuning After finishing the preceding steps and having installed the Sensors, operate the door. 1. Pull the Pull Cord. Door should Open 2. Check the offset between your desired position and the actual position This door is not fully open. The desired Open Position is that the Safety Edge is flush with the Door Seal. The door opening is short by about 1" in this example. 3. Measure the distance on the door of how much the door has over/under traveled 4. Adjust the Sensor now as follows: Door does not open far enough: Move the Sensor in door open [close] direction by the measured inches. Door opens to far: Move the Sensor in the close [open] direction by the measured inches. 5. Repeat the same steps above for the Close Position [direction]. Your Door is now ready for operation. The Sensor will not need to be re calibrated unless the drive parameters have been changed or the door has been hit or damaged. We also recommend that you check your belt tension on a weekly or monthly basis. Page 12 of 16
M 1000 I/O Ports Upper Header Pos# Description I/O Type X1 24 VDC Supply Power 9 0 VDC Supply Power X2 On/Off Switch or Wire Bridge to X3 Input X3 On/Off Switch or Wire Bridge to X2 Input 10 0V - for Blue Wire from Photo Eye s Power G GND Protective Earth Ground PEG Float 11 Door Open Out 12 0V all Drives Out 13 0V all Drives Out 14 Door Close Out Lower Header 1 Door Open / Pull Cord s Input 2 Partial Door Open [ if installed ] Input 3 Loop Detector [ if installed ] Input 4 Not Used Input 5 Speed [ not used ] Input 6 Safety Edge Input 7 Open Limit Input 8 Close Limit Input 9 +24 VDC Supply Power 10 +24 VDC Supply Power Page 13 of 16
Appendix A: 230 VAC 3 Phase Wiring Diagram Page 14 of 16
440/480 VAC 3 Phase Wiring Diagram Page 15 of 16
Appendix B: Page 16 of 16