Albany RapidRoll 355 User manual

PART NUMBER 350016-0000
RAPID-ROLL DOOR OWNER’S MANUAL
MODEL 355 VersionNovember 2006
975-A OLD NORCROSS ROAD
LAWRENCEVILLE, GA 30045
[phone] TEL
[phone] FAX
[phone] TOLL FREE

2 Nov. 2006
WARNING
DO NOT INSTALL, OPERATE, OR SERVICE THIS PRODUCT UNLESS
YOU HAVE READ AND UNDERSTAND THE SAFETY PRACTICES,
WARNINGS, INSTALLATION, AND MAINTENANCE INSTRUCTIONS
CONTAINED IN THIS MANUAL.

4 Nov. 2006
STATEMENT OF WARRANTY
RAPID-ROLL™ MODEL 355
EXCLUSIVE FIVE YEAR WARRANTY
ON BALANCE/TENSIONING SPRINGS
Albany Door Systems warrants to the original owner of the door that the
BALANCE/TENSIONING SPRINGS will be free of defects in materials and workmanship for a
period of FIVE (5) YEARS from the date of shipment.
ONE YEAR WARRANTY ON DOOR PANEL, MECHANICAL & ELECTRICAL
COMPONENTS
Albany Door Systems warrants to the original owner of the door that the door panel fabric,
mechanical and electrical components will be free of defects in material and workmanship for a
period of twelve (12) months from the date of shipment.
Only defects brought to the attention of Albany Door Systems during the warranty period will be
covered by this warranty.
Albany Door Systems will replace, or repair any component parts that are found to be defective upon
inspection by an Albany Door Systems representative.
This warranty does not cover damage caused by collision or other abuse of the product. Adjustments
made to the Control Panel or to the mechanical operation of the door without the authorization of
Albany Door Systems will void this warranty.
The replacement provisions shall be the limit of Albany Door Systems responsibility under this
warranty and Albany Door Systems shall not be responsible for any other losses or damages due to
the operation of any door or parts covered by this warranty.
No other oral or written representations made by Albany Door Systems or its agents are a part of this
warranty unless specifically set forth in writing by an authorized Albany Door Systems official.
THE ABOVE SET FORTH WARRANTY IS SELLER'S SOLE WARRANTY. SELLER MAKES NO OTHER
WARRANTY OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED; AND ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH
EXCEED THE AFORESTATED OBLIGATION ARE HEREBY DISCLAIMED BY SELLER AND EXCLUDED
FROM THIS AGREEMENT. USW-355-00

5 Nov. 2006
SAFETY PRACTICES
WARNING
THOROUGHLY READ THESE SAFETY PRACTICES PRIOR TO INSTALLING,
OPERATING, OR SERVICING A HIGH-SPEED, RAPID-ROLL™ DOOR. FAILURE TO
FOLLOW THESE SAFETY PRACTICES MAY RESULT IN PROPERTY DAMAGE,
PERSONNEL BODILY INJURY, OR DEATH.
1. Do not operate a RAPID-ROLL™ Door while you are under the influence of drugs or alcohol.
2. Do not use the door if any parts appear to be broken or damaged.
3. Stay clear of the door while it is operating.
4. Keep hands and feet clear of the door at all times.
5. Do not drive through the door opening unless door is completely open.
6. Maintain a clear door opening at all times. Keep the door opening free of any obstructions.
7. Remove power at the fused disconnect during all electrical or mechanical service. OSHA requires
a disconnect to be properly tagged and locked out during all maintenance or service of equipment.
8. All electrical troubleshooting or service must be performed by a qualified electrician or service
person and must meet all applicable local, state, federal, international, and other governing agency
codes.
9. USE EXTREME CAUTION when it is necessary to service the control panel while it is
energized.
10. If you have any questions, please contact your local Albany service provider for assistance.
Otherwise contact Albany Door Systems at 1-877-925-2468 for information on your local
distributor.

6 Nov. 2006
PACKING LIST
Before beginning the installation, thoroughly inspect the crate to ensure all necessary
components are there. The following list applies to a standard Model 355 door
(No optional parts are included unless ordered that way).
•Left Hand and Right Hand Side Columns with attached Covers (1 set)
•Top Roll Assembly (1)
•Drive Unit w/torque arrestor bracket (1)
•Electrical Control Panel (1)
•Safety Photocells (1 set)1
•Bottom Rail Profile (1)
•Counterbalance Springs (2)
•Tensioning Ropes (2)
•Width Gauge
•Assembly Hardware
OPTIONAL PARTS
•Motion Detector
•Floor Loop
•Transmitters
•Auxiliary Pushbuttons Stations
•Pull Cords
SUGGESTED TOOLS REQUIRED
•5mm allen wrench •Water Level
•6mm allen wrench •Carpenters Level
•8mm allen wrench •Hammer
•18mm open end wrench •Wrench set (SAE)
•Screwdriver •Screwdriver Set
•Tape Measure
•Come-a-along •Wrench set (METRIC) •Drill bits

7 Nov. 2006
MODEL 355 MECHANICAL INSTALLATION
Step 1 . Unpack crate and inventory parts, comparing against the packing list in the front of this manual,
to verify all parts are on site.
Step 2 . Using a tape measure, determine the clear opening width. Compare this measurement with the
door ordered width. See crate label for door ordered dimensions.
NOTE
THE CLEAR OPENING WIDTH MUST BE THE SAME AS THE DOOR
MANUFACTURED WIDTH IN ORDER FOR THE RESET SYSTEM TO
FUNCTION PROPERLY. THIS MEANS THE DISTANCE BETWEEN
THE SIDE FRAMES AT THE TOP, MIDDLE AND BOTTOM MUST
EQUAL THE DOOR WIDTH.
Step 3 .Verify that the opening is
plumb and that the floor slab is
level. Shimming may be required
to level the side columns but no
more then ½”. Refer to approval
drawings for this door to confirm
drive side mounting (left or right-
hand).
Step 4 . Remove the side
columns from crate (one at a
time). Remove covers from both
side columns and set aside.
Remove springs and inner covers
from both side columns. Erect
both columns and place them in
position against the wall with
inner edges in line with the door
jambs. Verify the width per door
specification.
Step 5 . Plumb both side
columns and secure them to the
wall using proper anchoring
hardware. The anchor holes are
slotted to allow for adjustment of
door width and centering over the
door opening. (Figure 1 and
Figure 2)
Slotted Holes
Figure 1

8 Nov. 2006
Step 6
. Attach width gauge to the rear of door at both head plates. Removal of the black plastic funnels
on the head plates will make installing the width gauge easier along with the routing of the photocell
cables. Run wires under the back funnel and inside width gauge, from non-drive side to drive side of
door. These wires are for photocells, contactless safety edge photocells, and SRD2™ sensors.
Figure 2
Slotted Holes

9 Nov. 2006
Step 7. Using an approved lifting device, place a lifting strap around the top roll assembly, lift and
remove from shipping crate. Raise the top roll assembly into position and lower it slowly onto the top of
both side columns. Ensure the bearing housings are located outside the head plates. Secure the top roll at
both head plates on each side of door. (Figure 3)
Step 8
. Slide the drive unit onto the drive side stub axle. Attach torque arrestor bracket to the head
plate.
Step 9 . Remove straps holding door fabric in place. Disengage the drive unit brake by pulling down on
the brake release lever and rotate the top roll until the bottom edge of the fabric is approximately 30 mm
(1.25 in) below the head plates.
Figure 3

10 Nov. 2006
Step 10
. Attach and place 2 pre-wraps of tensioning rope on both rope pulleys and allow rope to drape
down over the front of the side columns. (Figure 4)
Special instructions for rope
The white rope does not so readily fit into the groove of the take up spool and requires a special step to
allow for this. You must pull the single inner core of the rope out about 4 inches and cut it. This will
help in reducing the diameter of the rope at the leading end. Then use a lighter to heat the end of the
rope and roll it between your fingers to slightly shrink the end of the rope. This will give the rope some
rigidity so that you can now thread it into the take up spool. Be careful not to burn your figures when
doing this.
DO NOT DRILL HOLE IN TAKE UP DRUM FOR ROPE.
Knot
Top Roll
–
2 Prewraps
Figure 4
FRONT OF DOOR FRONT OF DOOR

11 Nov. 2006
Step 11. Slide the bottom rail profile into the base of the curtain and center. Once the bottom beam is
centered, then locate the 2 predrilled holes on each end of profile, drill through the fabric and use the
provided slotted screws and acorn nut to secure the bottom beam in place.
Step 12 . Run the tensioning rope through the appropriate pulleys in the counterbalance system
corresponding to the drawing placed inside the side columns. Ensure the rope is run through the sliding
part of the CSE block. (Figure 4) Run the rope through the hole in the aluminum bracket on bottom
profile.
While running the rope for the door try to ensure that there are no twists or kinks in the rope.
DO NOT CUT EXCESS ROPE UNTIL STEP 15 HAS BEEN DONE.
Step 13 . Re-install both inner side column covers. Re-install counterbalance springs inside side
columns. Take note that the springs must be attached so that the spring is sitting against the short section
of brush that is on the inner cover. This brush dampens the movement of the spring allowing for a quiet
function. The spring will be noisy if this step is not performed correctly.
Step 14 . Using a come-a-long or similar pulling device, stretch the springs to the horizontal arrows
marked on the diagrams located on the side column covers. Remove slack from the tensioning rope and
secure rope in place by tying a knot in it (Figure 4).
Step 15 . When the counter balance system has been fully installed, disengage the drive unit brake and
manually move door over its entire range of motion. Ensure that the fabric and windclips go behind the
inner cover. NOTE: The door must be cycled 20-30 times to allow for the rope to stretch. This will
require you to make additional adjustments to the spring tension. Once the stretching has settled, you
can then put the door into operation. Be very sure that this is done before cutting the excess rope.
Step 16 is detailed in the following two pages
Step 16
. Run cable for bowden lever (emergency disengagement lever pre-mounted on drive side, side
column cover) through pre-drilled hole in the head plate. Pull enough slack thru so that you can now
slide the 2’ section of the cable sheating on. Run cable down through the brake realease lever on the side
of the motor. Loop the cable thru the grid on the bottom of the motor fan cover and use the barrel clamp
supplied to fix the cable to the fan cover. Do not extra cable until final adjustments are made. (Figure 6)
Additional adjusting may be required once the sideframe cover is installed so that the brake release
works properly. Attach the other end of cable (with spring) to the bowden lever while installing drive
side cover profile at the same time. Secure cover profile at the top and bottom using supplied bolts
(Figure 7). Check and ensure that when you pull on the disengagement handle the door releases and can
be pulled up or down.
Step 17 . Install the remaining cover profile on the other side of the door using supplied bolts.
Step 18 . Attach barrel cover to both head plate mounting brackets using supplied screws and washers.
Place the side column covers over the head plates and attach using supplied screws.

12 Nov. 2006
Figure 6
Figure 7

13 Nov. 2006
INSTALLATION OF MANUAL DISENGAGEMENT LEVER
TOP ROLL BEARING BRACKET (TOP VIEW)
DRIVE UNIT
1. RUN BARE CABLE UP THROUGH SIDE
FRAME AND SMALL HOLE IN BEARING
PLATE. CABLE SHEATH
STARTS HERE.
RUN CABLE
FROM TOP OF
BEARING PLATE
OVER TO DRIVE
UNIT.
SECURE BARE CABLE TO
BOTTOM OF MOTOR COVER
USING SUPPLIED CABLE CLAMP.
ALSO REFER TO FIGURE 6
Figure 9

14 Nov. 2006
THRU-WALL DISENGAGEMENT LEVER INSTALLATION
Figure 10

15 Nov. 2006
ELECTRICAL INSTALLATION
The following instructions are recommended guidelines for electrically installing a typical Model 355
door. Actual wiring may be different based on what options, special instructions, special components,
etc. were ordered with the door. Consult the electrical schematics that are supplied with the door. These
should be located inside the control panel.
WARNING
CONTROL PANEL CONTAINS HIGH VOLTAGE. THE FOLLOWING
PROCEDURES SHOULD BE PERFORMED BY QUALIFIED ELECTRICAL
PERSONNEL ONLY. WIRING MUST MEET ALL LOCAL, STATE, FEDERAL,
INTERNATIONAL, OR OTHER GOVERNMENT AGENCY CODES. FAILURE TO
DO COULD RESULT IN SERIOUS INJURY OR DEATH.
NOTE
TO AID THE WIRING AND SERVICE OF ALL ELECTRICAL CIRCUITS, TAG OR
LABEL ALL WIRE ENDS DURING THE FOLLOWING ELECTRICAL INSTALLATION.
ALSO, ALL THREE PHASE POWER WIRES SHOULD BE RUN IN SEPARATE
CONDUIT FROM ALL OTHER CONTROL CIRCUIT WIRING (I.E. PULSE ENOCDER
WIRING).
1. Mount the control panel at a height of approximately four feet from the floor on the drive side of the
door.
2. Run electrical conduit and wires for: pulse encoder cable, drive unit power leads, and receptacle
cable. Plug all wires into the electrical receptacles located above the drive unit (Figure 11).
3. Install all the actuators and wire according to the electrical schematics supplied with the door.
4. Install a fused disconnect beside the control panel. The main supply to the All★Star drive system
can be from 208 VAC up to 600 VAC. The control panel is fused at 15 amps.
CAUTION
VERIFY ALL FIELD WIRING TO ENSURE TERMINAL CONNECTIONS ARE
TIGHT AND CORRECT.A FUSED DISCONNECT IS REQUIRED FOR EACH
ALBANY DOOR AS A MEANS OF DISCONNECTING INCOMING POWER FROM
THE CONTROL PANEL.THIS DISCONNECT IS NORMALLY SUPPLIED BY
OTHERS.

16 Nov. 2006
Label What Plug Location
X31 THERMAL SWITCH 3 WIRE BLK. WIRE MOTOR
X33 TOP OPEN PROX. 3 WIRE BLK. WIRE SIDE FRAME
X35 PHOTOCELL RECEIVER 3 WIRE LEFT SIDE FRAME
X36 PHOTOCELL TRANSMITTER 3 WIRE RIGHT SIDE FRAME
X37.1 CSE RECIEVER 4 WIRE RIGHT SIDE FRAME
X38.1 CSE TRANSMITTER 4 WIRE LEFT SIDE FRAME
WARNING
BEFORE APPLYING POWER TO CONTROL PANEL, CHECK LINE VOLTAGE AT
DISCONNECT WITH A VOLTMETER.
FIGURE 11

17 Nov. 2006
ELECTRICAL START UP
Step 1. Manually bring the door to the halfway closed position. This can be done by pulling down on
the bowden lever to release the drive unit brake and moving the curtain by hand (Figure 12).
Step 2. Check for correct line voltage at the disconnect with a voltmeter. Utilize the All-Star control
panel manual to make all field wire connections to the panel. Apply power to the control panel. Ensure
the POWER LED’s on both the PLC and frequency inverter are lit. Also ensure that the RUN LED is lit
on the PLC.
Step 3 . Push the SETUP button. The RESET light on the outside of the panel will come on and relay
CR-11 will be energized at this point. Using the OPEN/CLOSE JOG DOOR button located on the
control panel backplate (small rocker switch), jog the door in the close direction. If the door closes, go to
the next step. If the door opens, then the phase rotation on the drive unit is backwards. Swap two of the
three motor leads in the panel to change the motor rotation (terminals T11, T12, T13).
FIGURE 12
Disengaged

18 Nov. 2006
SETTING DOOR LIMITS
NOTE
IT IS IMPORTANT TO ENSURE THE DOOR IS MOVING WHEN THE RESET BUTTON IS PUSHED TO SET
THE CLOSE LIMIT. DO NOT RELEASE JOG SWITCH UNTIL DOOR HAS STOPPED.
Step 1. Press SETUP button. Reset light will turn on; this indicates that you are in the setup mode.
Close the door using the OPEN/CLOSE JOG DOOR button. When the door reaches the close limit,
press the RESET button while still jogging door. The door will stop automatically and the closed
limit will be set. The reset light should turn off at this point as well.
Step 2 . Press SETUP button. Open the door using the OPEN/CLOSE JOG DOOR button. When the
door reaches the open limit proximity switch, it will stop automatically and the open limit will be set.
The reset light should turn off at this point as well.
Step 3 . Actuate door and observe the door limits (open and closed). Repeat steps 1 and 2 as necessary
to finely adjust both door limits.
Step 4 . Check all actuators for proper operation.
Step 5 . Verify the automatic operation of the door. The time delay to close is adjustable via an
adjustment screw on the face of the PLC (see drawing # NONAUTO). If non-automatic mode is desired
for door operation, turn the adjustment screw fully counterclockwise. In non-automatic mode, the
actuator must be pulsed to open the door and pulsed again to close the door.
NOTE
NON-AUTOMATIC MODE CANNOT BE USED WITH MOTION DETECTORS,
LOOP DETECTORS, OR PRESENCE SENSORS.

19 Nov. 2006
Quick reference for setting limits
Press SETUP button
Reset Light turns on
Close door with ‘JOG’ switch
Door starts to CLOSE
When door reaches bottom
limit, press RESET button
while the door is still moving.
Door in the CLOSED
POSITION
When door reaches the open
limit proximity switch, it will
stop automatically
Press SETUP button
OPEN door with ‘JOG’ switch
Reset Light turns on
Door starts to OPEN
Door STOPS Moving

20 Nov. 2006