Assa Abloy Albany RR1000 User manual

© ASSA ABLOY Entrance Systems AB 2014. All rights reserved.
Lodjursgatan 10, 261 44, Landskrona, SWEDEN
800-252-2691 www.albanydoors.us
Albany RR1000 Owner’s Manual
Albany RR1000
6410T0030
Revision: EN01

6410T0030_EN01 2014-08-01 Page i
© ASSA ABLOY Entrance Systems AB 2014.
ASSA ABLOY, ASSA ABLOY Entrance Systems, Albany, RapidRoll, RR1000 as words and
logos are registered or unregistered trademarks belonging to ASSA ABLOY Entrance
Systems AB or other companies within the ASSA ABLOY Group. All rights reserved.
All rights to the door and the related operating instructions are protected. Legal action
will be taken in case of imitation or copying of the door system.
These operating instructions may not be reprinted or otherwise reproduced without the
written consent of ASSA ABLOY Entrance Systems.
The general terms and conditions of ASSA ABLOY Entrance Systems are applicable.
ASSA ABLOY Entrance Systems reserves the right to make technical changes.
These operating instructions are an integral part of the door.
Manufacturer:
ASSA ABLOY Entrance Systems
High Performance Door Solutions
975-A Old Norcross Road
Lawrenceville, GA 30046
USA
Internet: www.albanydoors.us
Email: [email protected]
Phone: 1 (800) ALBANY1

Albany RR1000 Owner’s Manual
6410T0030_EN01 2014-08-01 Page ii
Table of Contents
INTRODUCTION ...........................................................................1
SAFETY DEFINITIONS ...................................................................2
GENERAL SAFETY INFORMATION ....................................................3
PRODUCT DESCRIPTION ...............................................................5
TECHNICAL INFORMATION ............................................................7
MAINTENANCE SCHEDULE .............................................................9
ADJUSTMENTS FOR CHAIN DRIVE DOORS ..................................... 11
INERTIA BRAKE RESET PROCEDURE.............................................. 12
CURTAIN REPAIR........................................................................ 15
CURTAIN CLEANING ................................................................... 16
MANUAL HOIST USAGE ............................................................... 16
ELECTRICAL ADJUSTMENTS......................................................... 17
TECHNICAL SUPPORT CONTACT INFORMATION............................... 18
PARTS LIST ............................................................................... 19
RIGHT SIDE FRAME ASSEMBLY...............................................................19
LEFT SIDE FRAME ASSEMBLY .................................................................21
DRUM TUBE ASSEMBLY .........................................................................23
CURTAIN ASSEMBLY .............................................................................24
BOTTOM BEAM ASSEMBLY .....................................................................25
HEADER ASSEMBLY (Direct Drive) ..........................................................27
HEADER ASSEMBLY (Chain Drive) ...........................................................29
TOP ROLL & MOTOR COVERS (Direct Drive) .............................................33
TOP ROLL & MOTOR COVERS (Chain Drive)..............................................35

6410T0030_EN01 2014-08-01 Page 1
Introduction
These operating instructions are intended for use with Albany RR1000 doors with the
associated control system. They constitute part of the product and describe how to
use the product properly and safely throughout the product lifecycle. The operating
instructions are only valid in combination with the operating instructions for the con-
trol system and associated electrical schematics which are supplied on delivery.
The information contained in these instructions constitutes the technical specifica-
tions applicable at time of print. Keep these operating instructions inside the control
system electrical cabinet or in another safe and accessible storage location. If own-
ership of the door is passed to a third party, these operating instructions must also
be supplied to the new equipment owner.
These operating instructions are intended for trained, qualified and authorized staff.
Only employees of the original equipment manufacturer or other staff trained by the
original equipment manufacturer may install, commission, inspect, maintain, repair
and dismantle the door.
This product has been designed and manufactured under consideration of a risk
analysis according careful selection of the standards to be observed and other tech-
nical specifications. It is therefore state-of-the-art and guarantees the highest pos-
sible degree of safely. However, this level of safety can only be achieved in practice
if all the necessary measures are taken. In particular, when the door is operated, all
persons that use the door must have been instructed in the use of the door and the
potential danger involved in walking under the closing door must be highlighted.
Warning notices refer to dangers to the life and health of people or to the
machine, equipment or the environment. The notices applied directly to
the door must be followed and kept in legible condition.

Albany RR1000 Owner’s Manual
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Safety Definitions
The contents of this manual are designed to help you maintain Albany RR1000 high
performance doors. DO NOT execute any maintenance procedures on the high
speed door unless you have read through the instructions in this manual.
The safety alert symbol is used to identify safety information about haz-
ards that can result in personal injury. A signal word (DANGER, WARN-
ING, or CAUTION) is used with the safety alert symbol to indicate the
likelihood and the potential severity of injury. In addition, a hazard sym-
bol may be used to represent the type of hazard.
DANGER indicates a hazard that, if not avoided,
will result in death or serious injury.
WARNING indicates a hazard that, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazard that, if not avoided,
might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in damage
to the door.
NOTICE is used to inform you of a method, refer-
ence, or procedure that could assist with specific
operations or procedures.
Other symbols that may be used in this manual are:
Lock Out /
Tag Out
Crushing Fire Shock Read Manual

6410T0030_EN01 2014-08-01 Page 3
General Safety Information
Special personal protection equipment is not required for use of the
door. Nevertheless, the door may only be used by trained and au-
thorized staff. Additional site-specific conditions pertaining in the
operation where the door is used may also apply.
The Albany RR1000 door is designed and manufactured under consideration of safe-
ty technical specifications. This meets the highest standard of safety. However, this
safety can only be reached in operational practice if all necessary measures are met.
It is the duty of the operator of such door system to ensure all these measures and
check it’s status. Please read the operation manual carefully and keep it in a safe
place.
The operator of the door is held to ensure especially that:
 Installation, first operation, inspection, servicing, repair work and dismantling
are only done by personnel that have been trained by the manufacturer.
 Only to be operated by personnel that have been sufficiently assigned and au-
thorized to operate this door system.
 The door must only be used for its intended purpose.
 The door must be only operated in a functional perfect state and especially the
safety features must be checked for function in regular intervals.
 Keep the working vicinity and the opening of the door in clear of obstructions.
Maintain a clear door opening at all times. Obstructions may cause accidents.
 The operation manual should be kept at the site of the fitted door system in
readable condition.
 All safety and warning labels should not be removed from the machine and
should also be kept readable.
 Do not drive through the door opening unless door is completely open.
 Do not run through the door opening. Go upright and with normal pace.
 Do not climb or hang on the door.

Albany RR1000 Owner’s Manual
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 During operation of the door, do not stick your hands in the side frames. Keep
hands and feet clear of the door at all times. Stay clear of the door while it is
operating.
 Never reach into the area of the top roll when the door may be energized.
 Do not operate the door when excessive wind load is present. Refer to applica-
ble specifications for “operational wind load”.
 Only operate the door at the approved supply voltage and mains frequency.
 Only use accessories or attachments that have been approved by the manu-
facturer for use with this door.
 The STOP Button on the front of the panel is a momentary stop ONLY with the
ACS-50 and MCC control panels. The door will only stop for that cycle; motion
detectors, floor loops, or any activating device can activate the door! To en-
sure that the door keeps from being activated, use the rotary disconnect on
the front of the panel.
 When damage occurs to the door (mechanically or electrically) turn off opera-
tional power immediately. This is especially true if you have damage of the
curtain or drive system.
 For all kind of work on the door the main switch (main disconnect) must be set
to the OFF position and secured from being re-energized by unauthorized per-
sons by following proper lock-out tag-out procedures.
 Do not ever use petroleum-based products on the door curtain. If done, this
voids all warranty on the curtain material.

6410T0030_EN01 2014-08-01 Page 5
Product Description
Albany RR1000 doors are vertically opening, rapid roll doors. They comprise two side
frames, a top roll with an electric drive, the door curtain and a bottom profile.
Side Frames
The side frames guide the bottom profile and flexible door curtain that is rolled
onto the top roll when the door opens. These side frames are constructed from
continuous extruded steel profiles and segmented aluminum and polymer curtain
retention profiles which retain the wind lock edges of the door curtain.
Curtain
The flexible door curtain is made from high tensile strength underlying weave
coated with a resilient textured SBR or EPDM rubber material. Additional features
of the curtain including the wind lock are made of similar materials and friction-
limiting coverings.
Bottom Beam
The bottom beam assembly is made from impact-resistance fiberglass pultrusion
profiles bolted to the front and rear face of the curtain. A reversing edge sensor
profile is connected to the bottom edges of the fiberglass and is surrounded by a
rubber bottom edge weather seal.
Top Roll
The top roll drum and idler are made from steel tubes with welded axle plates.
The idler tube also has welded axle shafts, though the top roll drum has forged
steel axles bolted to the ends.
Drive Unit
The drive unit contains an electric motor, gear reducer, limit switch and electronic
position encoder.
Control System
The electrical control system will either be the ACS50 contactor control system or
MCC variable frequency control system, depending on configuration. The MCC
control system facilitates a gentle acceleration and braking of the door with high-
er overall speeds, while the ACS50 operates the door in a more abrupt manner
and is meant for shorter lifecycle periods without required maintenance.

Albany RR1000 Owner’s Manual
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Operation and Safety Systems
Albany RR1000 doors contain one open button, close button, and stop button in-
tegral to the control system which can be used to operate the door. This is the
minimum activation devices; however, many types and quantities of accessory
activation items may be added such as auxiliary push button or palm button sta-
tions, pull cords, motion sensors, presence sensors, photo eyes, inductive loop
detectors, laser scanning sensors, building control and security systems, or other
various switches and sensors. Incorporation and operation sequences for these
various types of sensors may be found in the control system manual provided
with the door.
Without respect to how the door is activated, once commanded to open, the drive
unit will turn to draw up and wrap the flexible curtain around the top roll drum
until it reaches the set open position. When the door closes, the curtain is rolled
off the top roll and descends under the weight of the bottom profile and the cur-
tain itself.
All Albany RR1000 doors are fitted with compliant protection of the main bottom
edge. The electric safety edge is tested prior to initiating downward movement
and monitored permanently while the door closes. The door will not initiate down-
ward movement if a fault is detected. If a fault is detected during downward
movement, the drive unit reverses and opens the door immediately.
All doors are also fitted with an integrated safety photocell or an integrated light
curtain in the side frames. The stationary safety photocell or light curtain moni-
tors the closure area of the door. If the light beam is broken, the door is prevent-
ed from closing. If the door is closing and the light beam is broken, the door im-
mediately returns to the open position.
Self-Repairing Breakaway
Albany RR1000 doors are designed to allow the curtain to break away from the
side frames upon impact without damage to the door. Sensors integral to the
curtain wind lock detect such an event and are transmitted wirelessly to the con-
trol system. The control system immediately stops all movement of the door and
requires a user to press the “open” button to initiate the automatic repair se-
quence. The door then opens to the upper repair limit position resetting itself

6410T0030_EN01 2014-08-01 Page 7
Technical Information

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DIMENSIONAL SPECIFICATIONS
Min Width 6  (1,829 mm)
Max Width 30  (9,144 mm)
Min Height 6  (1,829 mm)
Max Height 35  (10,668 mm)
Side Frame Clearance 5 in (127 mm)
Side Frame Projecon 5 in (127 mm)
Headroom Clearance 22.94 in (582 mm) - 26.81 in (681 mm) (door height dependant)
Headroom Projecon 33.28 in (845 mm)
PERFORMANCE INFORMATION
Opening Speed up to 60 in/sec (door size dependent)
Closing Speed ≈24 in/sec
Stac Wind Load up to 130 mph (100 mph @ max size)
Stac Pressure Load up to 43psf (26psf @ max size)
Operang Wind Load 40 mph
Operang Pressure Load 4 psf
Self-Repairing Breakaway YES (push buon)
Applicable Agency Approvals UL508A
MATERIALS & FEATURES
Door Curtain Construcon 1/4" Thick Rubber - Black SBR, *Tan SBR, *Blue EPDM, *Grey EPDM
Reversing Edge Type wireless electric contact edge
Photo Safety Type through-beam photoeye or *light curtain
Counterbalancing none
Life Length of Counterbalance N/A
Side Frame Construcon self-supporng heavy duty 3/8" painted steel
Boom Beam Construcon high strength berglass pultrusion
(mulple layers depending on door width)
Top Roll Construcon 8-5/8" diameter steel tube drum
6-5/8" diameter steel idler barrel
Roll Cover Construcon 18 gauge steel powder-coated black (RAL 9005)
Motor Cover Construcon 18 gauge steel powder-coated black (RAL 9005)
Control Panel MCC All-In-One
Voltage Opons **208V 3Ø (± 10%), **230V 3Ø (± 10%), 460V 3Ø (± 10%), **575V 3Ø (± 10%)
** - with transformer internal to control panel
Motor Size up to 3.35hp helical-worm gearmotor
Warranty Terms 1-year parts & labor w/ACS50
5-year, 1 Million Cycle w/MCC
ENVIRONMENTAL LIMITS
Operang Temperature Range Standard 14 °F - +104 °F (-10 °C - +40 °C)
*Extended -20 °F - +140 °F (-29 °C - +60 °C)
Controls Environmental Rang NEMA-4
Motor Environmental Rang IP-55
(*) - indicates oponal item

6410T0030_EN01 2014-08-01 Page 9
Maintenance Schedule
Before starting work on the door, the power must be disconnected by switching off the
main power disconnect and then locked out. Then the control box needs to be checked
to verify that voltage has been eliminated from the panel. Please observe that all used
ladders, scaffoldings, or such, correspond with the valid safety regulations.
The working area must be blocked for both vehicle and foot traffic. Lubrication oil on
the floor, tools and other material should be removed from the floor when work has
been finished.
The necessary maintenance inspections, check-up and time intervals are listed in the
Inspection section.
Daily Inspection
1.Inspect the door curtain for obvious wear or damage.
2.Operate the door through several openings and closing cycles. Verify that the door
seats against the floor and that the door fabric remains tight and does not wrinkle.
Verify that the door opens fully, slightly beyond the wall opening, and does not open
too far.
If the door does not seat against the floor properly or opens to the wrong posi-
tion, refer to “Setting Door Limit Adjustments” in the applicable controls man-
ual.
If the door fabric has diagonal wrinkles, the door fabric roll at the top of the
door is not level and perpendicular to the side rails. Leveling adjustments
should be made as soon as possible to prevent wear or damage. Refer to the
installation instructions or contact Technical Support.
3.With the door closing, place an object through the light curtain, or photo eyes, on
each side of the door. Verify that the door stops immediately.
4.While the door is closing, tap the bottom of the door edge wand verify that the door
stops and reverses to a fully open position.
5.See the applicable control panel or installation manual for operation details pertain-
ing to the controls.
Do not stand under the door when performing the following
inspection. If the bottom bar reversing switch is not function-
ing correctly injury can occur.

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Installation Mounting
Inspect and tighten mounting hardware annually
Check welding seams 6 months or 50,000 cycles
Drive
Inspect assembly of the torque arm and isolation bushings
6 months or 50,000 cycles
Inspect brake condition and function of break release lever
Check the chain, adjust and possibly tension and lubricate (if applicable)
Check function and condition of the torque arm during operation
Drive shaft
Check screws to drive shafts and flange bearings 6 months or 50,000 cycles
Chain drive: check fastening of locking element (if applicable)
Door curtain
Check curtain for cracks and traces of scrapes or shavings in the guides
6 months or 50,000 cyclesCheck connection of door curtain at the top roll and at the bottom profile
Check winding performance of door curtain and ropes/belts
Bottom profile
Check condition of the safety edge and the cable
6 months or 50,000 cycles
Check battery level in wireless transmitter (should be 3.6V)
Check the condition and function of the crash system
Check opening and closing position of the bottom profile
Side Frame
Check mounting hardware and condition of the profiles with attachments annually
Remove dirt from the photocell optics clean if necessary
Check condition and installation of the springs and the spring mounting, if
applicable check for easy movement of the axial bearing 6 months or 50,000 cycles
Check for wear & tear on guiding rails annually
Control box and additional attachments (e.g. impulse activator)
Check for full number/completeness of circuit
annually
Check main switch and control box lock
Inspect for presence of water or moisture inside control cabinet
Check mounting hardware
Electrical components
Visual inspection for mechanical damage
6 months or 50,000 cycles
Check function of safety edge, photocell, additional safeties and actuators
Check activation devices for mechanical damage and ensure they function
properly

6410T0030_EN01 2014-08-01 Page 11
If the Chain tension needs to be adjusted, loosen the (4)
bolts that attach the operator to the header assembly.
Using the threaded adjustment bolts located on the bottom
of the attachment bracket, either raise or lower the operator
to achieve the proper tension.
Retighten the (4) bolts that attach the operator to the head-
er assembly when finished.
Drive Chain Tension Adjustment
The drive chain tension is preset from the factory. This setting should be checked af-
ter the door is cycled a few times. The drive chain is to be tensioned so the deflec-
tion of the slack side of the chain is equal to 2% of the distance between the shafts,
or about 3/8” (9.5 mm).
Installing the Inertia Brake
A safety inertia brake is supplied on all chain drive doors. This device engages and
locks the top drum from turning if the maximum operation speed is exceeded.
The brake must be installed on the bracket on the non-drive side of the header as-
sembly after the phase rotation has been verified. This must be installed with the
correct rotation direction. Installing backwards can cause the brake to engage.
The smaller inertia brake shown below on the left is a one-
time use only device. If it has been engaged it must be re-
placed (P/N 6622T001).
The larger inertia brake shown below to the right might be reset dependent upon how
hard of an activation has taken place. If this brake has been engaged, consult the fol-
lowing instructions to properly inspect, repair or replace this brake. Repair parts may
be required.
ENGAGED
Adjustments for Chain Drive Doors
SMALL
LARGE

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Inertia Brake Reset Procedure
In the event that the resettable inertia brake becomes engaged, it locks the drum shaft
and must be reset before normal door operation can continue. Conditions that caused
the inertia brake to engage must first be understood and rectified as additional compo-
nents may need to be replaced or adjusted.
An engaged inertia brake is indicated by the protrusion of the red indicator tab shown in
the image below to the right.
NORMAL POSITION ENGAGED BRAKE
Lock-Out Tag-out all electrical power supplied to the door be-
fore making any electrical installations or connections. Also
Lock-out Tag-out any equipment near the installation site if that
equipment may be inadvertently operated into the area used to
assemble and install the door. Failure to properly de-energize
electrical circuits and disable equipment during maintenance
could result in serious injury or death.

6410T0030_EN01 2014-08-01 Page 13
If the brake is engaged, the magnitude of engagement must be determined in order to
proceed with the proper reset procedure sequence.
First rotate the drum approximately 90degrees in the direction that lifts the door cur-
tain upward. This may be accomplished using the manual chain hoist connected to the
drive unit. Then once in this position, remove the two M10 bolts and clamping spacers
shown being removed in the image below.
Next, use the following diagrams to determine the proper course of action.
Damping Elements OK
Safety Brake OK
Proceed to Step #13
Damping Elements Damaged
Safety Brake OK
Proceed to Step #8
Damping Elements Damaged
Safety Brake Damaged
Replace Entire Safety Brake

Albany RR1000 Owner’s Manual
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The picture to the right shows all the parts that are in-
cluded in the dampening plate repair kit (order P/N
6622T0023). Situation (6) shown on the previous
page would be the only time that a repair kit would be
needed.
Finally, when all component replacements and adjustments have been made, reset the
inertia safety brake indicator in accordance with steps (14) and (15) as follows.

6410T0030_EN01 2014-08-01 Page 15
Curtain Repair
In order to work on the ripped or perforated area, the curtain must be taken out of
the guides and lowered to the floor. Then, either work on an area supported by the
floor or alternatively, a solid, level surface provided by a heavy table, for example.
1) Using a utility knife, set it to a depth that will penetrate the rubber down to the ny-
lon cord center of the curtain and cut a rectangular section approximately 2" wider
than the sides of the rip or perforation. Be careful not to cut the nylon cord itself.
2) Using a screwdriver and pliers and starting at one corner of the cut, peel the sur-
face from the nylon cord center within the perimeter of the cut.
3) Using coarse sandpaper or a wire brush, remove loose rubber particles from the
nylon cord center; however, it is not necessary to have the fabric 100% bare.
4) Flip the curtain over to the other side of the rip or perforation and repeat steps 1-3
5) From the 1/8" thick piece of repair rubber, cut some pieces to inlay into the pre-
pared areas. Using a grinder with a sanding disc or a wire brush, roughen-up the
inlay surfaces for bonding.
6) Mix the adhesive as per the manufacturer's instructions and apply a liberal coating
to the nylon cord fabric and the rough surfaces of the inlay rubber segments. Al-
low pieces to dry to the touch (about 15 to 20 minutes) and apply a second coat-
ing. Allow to set until tacky. Place the inlay segments into position and, using a
rubber or rawhide mallet and a steel buckler, impact the entire area of the patch
repeatedly. A high degree of impact ensures proper adhesion. Clamping is not ac-
ceptable. Allow the cement to fully cure for 24hrs before moving the curtain.
7) Finally, raise the curtain to an open position, reassemble the guides, and resume
normal operation.

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Manual Hoist Engagement
A manual hand chain is pro-
vided to move the door
without power. Lightly pull
the red handle of the hoist
disengagement until it
stops. The control circuit is
now interrupted and the
door can be opened or
closed with the hand chain
only.
Manual Hoist Disengage-
ment
By lightly pulling the green
handle until it stops, the
control circuit is re-made
and the door is electrically
operational and the hoist is
disengaged from the drive.
Manual Hoist Usage
Curtain Cleaning
 DO NOT EVER USE PETROLUM BASED PRODUCTS ON THE CURTAIN, IF DONE
THIS VOIDS ALL WARRANTY ON THE CURTAIN MATERIAL.
 Clean curtain with a citrus based cleaner or a cleaner specifically designed for
cleaning SBR / EPDM rubber materials. All cleaners are to be petroleum free
and non-caustic.
 Dust may be removed with a cloth. Harder dirt may be removed with water.
Dirt, grease, or oil on metal may be removed with a citrus cleaner.
Lock-Out Tag-out all electrical power supplied to the door before cleaning the door
curtain. Also Lock-out Tag-out any equipment near the installation site if that equip-
ment may be inadvertently operated into the area used to clean the door. Failure to
properly de-energize electrical circuits and disable equipment during cleaning and/or
maintenance could result in death or serious injury.

6410T0030_EN01 2014-08-01 Page 17
Lock-Out Tag-out all electrical power supplied to the door before making any electri-
cal installations or connections. Also Lock-out Tag-out any equipment near the in-
stallation site if that equipment may be inadvertently operated into the area used to
assemble and install the door. Failure to properly de-energize electrical circuits and
disable equipment during installation and/or maintenance could result in death or se-
rious injury.
Electrical Adjustments
A qualified electrician must make all electrical mountings
and connections in accordance with all applicable regulat-
ing authority electrical codes and standards.
Consult the control system manual supplied with the door for additional specifications
and detailed instructions for installation and troubleshooting. A full set of electrical
schematics are supplied with each door as well. These will either be located inside the
control system enclosure, or included packaged with the product manuals. Standard
products will utilize one of the two systems shown below.
Albany ACS50 Controller Albany MCC Controller