Model 3050 Electric Wall Installation Procedure Effective August 2017
Special tools needed: Bondus type hex ball point tip Allen 7/32 Roller Chain tensioner Roller Chain breaker 1 7/8 open end wrench 15/16 Bent Wrench for trolleys Steel Banding Snips. Chop Saw 15 Makita or substitute. Install track: Note all drop rod locations brackets and mounts. Include square nuts for all attachments Install track sections A, E, F, and D in that order. D section is a trim to fit. You will need a 15 Chop saw. Caution slide steel band out of the way of cut and trim with snips. If you do not have a 15 saw, cut face of track first and follow with a top cut to smooth even cut. Do not use an abrasive blade or band saw! Install #50 roller chain glide(s). Look for holes on side of track opposite of reference side. Install #50 roller chain. Loosen the trunnion bolt on drive sprocket and slide sprocket assembly toward middle of wall. Loop chain over the lead end of wall, pulling toward the middle of track. Tie off with wire on a threaded rod so chain does not fall back towards ground. Install paddle link facing outboard toward the reference side. Pull other end of chain over the glide rod(s), the return sprocket, and over lap the staring end of chain. Using a chain puller pull chain tight to where it hangs less than 12 inches under track throat. Break chain install master link and add pin to paddle link. Tighten chain using trunnion bolt and lead sprocket to where chain is hanging at least 1 inside of throat of track. Lead sprocket should reside approx middle of slot. Temporarily set limit switches at location noted on shop drawing. See instructions on page 9 for Model 3050 Half Panel Interlock Limit Switch Installation Instruction. Note service location of ceiling dropouts on both ends of wall. See drawings for recommended size. You will need to have access to both ends of the wall above track to finish installation of panels. Take field measurements. 2
Wiring: All wiring would be by others and a qualified Electrician will need to provide correct power supply, conduits, and gang boxes per wire diagram of wall. A separate disconnect is required for operator, optional automatic closure, and optional guardian systems as required. Please see print as noted. Optional Guardian unit, lead edge, mats will be shipped from Kwik-Wall with panels. Install ½ panel: Use laser to mark X location for bearing plate. Oblong slots and set screws are for left or right side plumb adjustment. Install wiper sweep per orientation of print. Position bearing plate directly under center pivot arm and bolt to floor. Lift ½ panel into place with pivot arm bolt sliding into top of panel, bottom pivot adjustment shaft will set into bearing. Adjust threaded shaft raising bottom of panel to 2 above finished floor. Lock adjustments and replace ½ round cap. Swing pivot to insure that it moves freely. Install panels: Lower escapement drop out. Load panels one at a time into track in reverse order. Note lead trolley orientation with extra length point away from stack. All floating trolley panels must be oriented with the slot of floating trolley is facing towards the lead edge of the panel. Reversing this orientation will cause the wall to bind. (If lead panel has an automatic floor seal then mark screw locations bottom seal and remove automatic bottom seal prior to placing panel in the track.) Replace escapement section of track. Pin adjacent panels together, one at a time, starting with ½ panel in stack. With panel flat in stack remove trolley wire. See page 12 for the wire hook removal. Check for smooth operation, sliding trolley forward, roll and adjust trolley height. Repeat for all panels. Attaching chain to lead trolley: See page 5 Model 3050 Installation Instructions for Extend & Retract limit switch Positions. This also covers chain location and lead trolley attachment. 3
Install # 40 chain: Pull wall and operate manually. Return wall to stack. Test limit switches prior to installing chain to insure that they are wired correct. Make sure limit switch for extend shuts down extend function and limit switch for retract function shuts down the retract function. Attach the #40 roller chain from the gear box to the drive sprocket. Do not install tight and taunt. 2 free movement up and down. This chain requires a loose fit so that manual or automatic closures will have enough slack to close wall. Operate Wall Electrically: Fine tune limit switches careful not to over extend or over compress wall. Keep in mind there is some travel of 2 to 3 inches as wall coasts when shut off. Adjust compensating closure: Measure distance from lead edge of bulb seal to wall. Mark location for edge of saddle with masking tape. Adjust expander saddle out to match distance. Optional Cut to fit Automatic floor seal (if required): Position wall approx 6 away from closing. Unpin hinges of lead panel. Set automatic bottom seal into lead panel with the nose of seal aligning with the trail edge nose of the aluminum astragal. Mark the wall contact point on opposite end of the aluminum bottom seal. Add 6 1/16 for amount of push for the rock over bottom effect. This is the location where you trim the edge. Cut aluminum bottom and install roller and pop rivets. Install bottom into panel noting the locations of screws previously marked prior to removal. The trail edge of auto bottom should be in direct line with the trail edge of the panel. Replace hinge pins attaching lead panel to wall. Place strike plate on opposite end of wall for smooth durable contact point. Test wall for bottom operation. 4
Optional Lead sensor edge and transmitter (if required): Set location of lead sensor seal base on the bottom lead edge of lead panel adjustable compensating extrusion and attach to compensating closure. The sensor base will cover the adjusting nuts of the compensating closure. Since closure is previously adjusted this will be fine. Slide seal into base and attach the two leads of the sensor with the two leads from the transmitter with wire nuts provided. (Wire transmitter is already installed in panel and wire leads are ran to edge of compensating closure.) Pressure test the sensor edge. Alarm should sound. Reset the fault bottom on the Guardian Box and test with wall running. Wall should stop operation if sensor has been activated. Model 3050 Installation Instructions for Extend & Retract Limit Switch Positions Setting the Extend & Retract Limit Switch 1. The Retract limit switch is located towards the Hydraulic or Speed Reducer Drive Unit. The switch should be located approximately 2'-3" [686 mm] (Speed Reducer Drive) or 2'-10" [864 mm] (Hydraulic Drive) away from the Lead End of the track. (The limit switch bracket assembly can be positioned between the first two (2) drop rod locations, if required.) 2. At the Key/Dual Push Button Switch station insert the key and rotate to the "On" position then press both Retract push buttons until the operator shuts off. This should place the paddle link chain member with 2" [51 mm] bolt Limit switch lever arm. Retract Limit Switch. Limit switch trip pin #8 x 2" [51 mm] bolt. attached right at the Retract limit switch arm. (See Illustration #1). Illustration #1 Paddle link. Place a mark on lever arm at point of contact. 5
3. Place a mark on the Retract limit switch lever arm at the point where the Trip Pin makes contact. (See Illustration #1). 4. All of the panels should be in the STACKED position. Make sure the panels are stacked as tight as possible. 5. Now take a measurement from the front of the LEAD carrier to the front of the 10" [254 mm] escapement section. This will be Dimension A as indicated in Illustration #2. Now take a dimension from the lead carrier to the opposite permanent wall (or Lead Panel if stacking at both ends). This will be Dimension C as indicated in (Illustration #2). Lead Carrier 10 " [254 mm] Escapement Dim. "A" Dimension "C" Illustration #2 6. To "Retract" Limit Switch. set Centerline Lever Arm of track. Limit switch bracket. Contact Point. Limit Switch Trip Pin. Dimension "B" = "A" Illustration #3 Dimension B turn the key to the "On" position at the Key/Dual Push Button station then press both Extend push buttons until the Limit Switch Trip Pin backs off equal to the distance of Dimension A. (See Illustration #3). 6
New Attachment Method 7. Remove the 10" [254 mm] escapement sections of track. Pull the Lead panel out into the 10" [254 mm] escapement area. Remember to put a spacer under the lead panel before the carrier is disengaged from the track. A side bolt attachment method eliminates the need to break the chain to install lead trolley. Place bracket over top of chain and install screws into side of bracket at drop out. Connect the LEAD carrier to the #50 roller chain w/ master links. 8. Re-install the LEAD carrier back into the track and, re-attach the 10" [254 mm] escapement sections of track. 9. At the Lead Panel take a dimension from the centerline of the track to the LEAD EDGE of the panel. This will be Dimension D as indicated in Illustration #4. From Dimension C subtract Dimension D. This dimension equals Dimension E. (See Illustration #5). 7
Dimension "D" Centerline of track. Illustration #4 "Extend" Limit Switch. "Retract" Limit Switch. Dimension "E" Illustration #5 10. From the mark on the Retract limit switch measure back to the Extend limit switch. This is Dimension E. (See Illustration #5). 11. The "Extend" limit switch should be set to shut the operable wall off as shown in photo #6. At this point the operable wall system should still be serpentine as shown in photo #7. Photo #6. Extend Limit Switch. Photo #7. Half panel closure. 12. The limit switches may require a final adjustment. By loosening the cap screw that holds the bracket assembly to the track you can slide the assembly as needed. IT IS VERY IMPORTANT TO MAKE SURE THE WALL SYSTEM IS SHUT DOWN BY THE LIMIT SWITCHES AND NOT ALLOWED TO STALL IN THE EXTEND OR RETRACT POSITIONS. 8
Model 3050 Half Panel Inter-Lock Limit Switch Installation Instructions. Introduction: The half panel inter-lock limit switch is used to prevent the operable wall system from being Retracted before panels #1-3 are partially opened (folded). The inter-lock switch should only be installed on operable walls that contain the Manual Closure system. Step 1.) Before starting the installation make sure the operable wall is in the fully extended position. (Note: panels #1 3 should be completely flat.) At the Stack end of the operable wall open the access panel to expose the top flange of the track. 1 1/4 diameter steel shaft. Hex head bolts and flat washers. Step 2.) At the end of the track system is a steel plate with a 1 1/4 diameter steel shaft protruding 9/16 wrench. thru the plate. Using a 9/16 wrench remove the two (2) front hex head bolts and washers from the plate. Step #2. 1/2 Flat Washers. Step 3.) Place a 1/2 flat washer on each hole where the hex headed bolts were removed from the steel plate. (The flat washers are used as a spacer for the inter-lock limit switch bracket.) Step #3. 9
Step 4.) Place the aluminum inter-lock limit switch bracket over the two (2) steel 1/2 flat washers and secure the bracket to the track using 3/8 x 1/12 socket flat head machine screws supplied. Use a 7/32 hex-key to tighten bolts in place. Socket flat head machine screws. Inter-lock limit switch bracket. Step #4. Step 5.) Remove shaft collar from the 1 1/4 diameter steel shaft. Once the collar is off of the steel shaft remove the 3/8 x 3/8 set screw and install the 3/8 x 2 1/2 set screw supplied. Place the 1 1/4 PVC spacer measuring 3 1/4 long over the 1 1/4 diameter steel shaft. Now slide the 1 1/4 diameter shaft collar back on the steel shaft. (Note: Make sure the 1 1/4 diameter steel shaft did not slip down when the shaft collar was removed earlier. Try pulling up on the shaft to make sure it is tight.) Rotate the 1 1/4 shaft collar so the 3/8 x 2 1/2 set screw lines up with the keyway grove machined in 1 1/4 diameter steel shaft. Tighten set screw to steel shaft using a 3/16 hex-key. Keyway groove cut in 1 1/4 diameter steel shaft. Step #5. Remove 1 1/4 shaft collar. 1 1/4 shaft collar with 3/8 x 2 1/2 set 1 1/4 x 3 1/4 PVC spacer. Step #5. 10
Note: Make sure the operable wall panels are fully extended across the opening and panels # 1 3 are completely flattened out before proceeding. If this is a track only installation and the panels will be shipped at a later date DO NOT install the limit switch unit the panels have arrived. Installing the limit switch without the panels may result in damage to the limit switch as the lower closure arm can rotate 180 degrees without the panels in place. Step 6.) Place the limit switch on the aluminum bracket as shown in photo, secure the limit switch to the bracket using #6 x 1 1/2 machine screws. Place a #6 flat washer under the head of the machine screw before installing the screw thru limit switch. Now place the limit switch as far to the RIGHT edge of the bracket as possible to begin with. Place #6 wing nut on each bolt to hold limit switch in place. Step #6. Limit switch positioned to far RIGHT. #6 x 1 1/2 machine screws. Step 7.) With the operable wall fully extended and panels #1 3 completely flattened out slide the limit switch over to the LEFT until the arm on the limit switch contacts the 3/8 x 2 1/2 set screw, at this point the limit switch should CLICK when the arm contacts the set screw. The limit switch is adjustable within the slots of the aluminum limit switch bracket. Try opening (folding) panel #1 to Arm of limit switch contacting 3/8 x 2 1/2 set screw. see if the limit switch CLICKS. Now try flattening the wall out by closing panel #1 to see if the 3/8 x 2 1/2 set screw contacts the limit switch arm and the limit switch should click. (Note: The end user has to remember to open (fold) panel #1 as far as possible for the system to operate correctly.) 11
Step 8.) The final step is to wire the Half Panel Inter-Lock Limit Switch into the system. Please refer to the wiring diagram included with shipment for this part of the installation. Wire Hook Removal Note: Each panel except the Lead and Half Panel shall contain a Floating Carrier. Each floating carrier is shipped with a wire hook that holds the carrier in the center of the panel. The wire hook must be left in place until each panel is hung in the track system and hinged to the adjacent panel. At this point the wire hook should be removed. Repeat this procedure for each panel that contains a floating carrier. Wire hook attached to Floating Carrier. 12
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Operable, Moveable Glass and Accordion Wall Systems 1010 East Edward Street Springfield, IL 62703 Phone: 217-522-5553 Fax: 217-522-1170 Website: ww.kwik-wall.com E-Mail: kwinfo@kwik-wall.com Distributed By: 16