Cal-Royal 8600 User manual

1
CAL-ROYAL PRODUCTS
8600 AUTOMATIC SWING DOOR OPERATOR
Operations & Installation Manual
These installation instructions detailed within are solely for professional installers
and are not intended to be handed over to the end user.
Ver. September 30, 2021
CAL-ROYAL PRODUCT INC.
#6605 Flotilla St. Commerce
CA, 90040, USA
Tel: [phone], Fax: [phone]
Web: www.cal-royal.com
Email: mailto:[e-mail]
CAL-ROYAL

8600 Installation Manual
2
WARNING
AVOIDANCE OF ELECTRIC SHOCK, INJURY, FIRE OR MALFUNCTIONS
Please read these instructions carefully before installing the door operator. We are not responsible for
any loss or damage if these precautions are not followed. These instructions should be followed to
avoid the possibility of injury and damage due to wrong installation or adjustment.
During maintenance and installation, the power to the control unit should be OFF.
Please use the correct power supply - Power Acceptance 90V-250V DC-50/60 Hz.
Make sure that the operator is grounded or connected to earth! The coating of the operator is made of
an electrically conductive metallic material which will easily induce electrical conduction. Make sure
the ground or earth wire is connected.
The operator housing is not completely sealed, therefore it should be noted that excessive moisture or
a corrosive atmosphere could destroy the electronic components contained within.
Do not remove screws and bolts from the structure of the Control Unit or Motor Gear Box. Do not
intend to open, repair, or alter any part of the operator unit. Failure to comply will result in loss of
warranty.
Installation and maintenance of this product can be performed by trained and authorized personnel
only.
Before switching ON the power supply, make sure that no objects obstruct the travel of the automatic
doors.
NATIONAL WIRING REGULATIONS AND STANDARDS MUST BE CONFORMED TO.
Follow all indicated instructions as improper installation could cause severe damage.
Correct equipment must be used in order to reach overhead area for installation and service.
KEEP FINGERS AND CLOTHING CLEAR OF ALL MOVING PARTS.
Please keep these instructions
WARRANTY
36 MONTHS FROM SHIPMENT. WARRANTY VOID IF REPAIR IS ATTEMPTED TO MOTOR GEAR OR
CONTROL ASSEMBLY.
Failure to observe the information in this manual may result in personal injury or damage to
the equipment. To reduce the risk of injury to persons, use this operator with single or
double pedestrian swinging doors only.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

3
TABLE OF CONTENTS
SECTION 1.0 - PRODUCT SUMMARY------------------------------------------------------------------------------------------------------------ 4
SECTION 2.0 - TECHNICAL SPECIFICATION----------------------------------------------------------------------------------------------------- 5
SECTION 3.0 - RECEIVING INSPECTION--------------------------------------------------------------------------------------------------------- 6
SECTION 4.0 - PRE-INSTALLATION INFORMATION ------------------------------------------------------------------------------------------- 7
SECTION 5.0 - OPERATOR INSTALLATION------------------------------------------------------------------------------------------------------ 9
SECTION 6.0 - PUSH AND PULL ARMS INSTALLATION---------------------------------------------------------------------------------------14
SECTION 7.0 - LEARNING CYCLE AND START UP ---------------------------------------------------------------------------------------------17
SECTION 8.0 - ELECTRONICS CONTROLLER PROGRAMMING------------------------------------------------------------------------------18
BASIC SETTINGS TABLE DESCRIBING THE CONTROLS FUNCTIONS, SETTINGS, VALUES AND DEFAULTS ---------------------------23
SECTION 9.0 - WIRING CONNECTIONS --------------------------------------------------------------------------------------------------------25
SECTION 10.0 - CHANGING HANDING OF OPERATOR --------------------------------------------------------------------------------------29
SECTION 11.0 - SAFETY SIGNAGE AND DECALS ----------------------------------------------------------------------------------------------33
SECTION 12.0 - TROUBLESHOOTING-----------------------------------------------------------------------------------------------------------34
SECTION 13.0 - DAILY SAFETY CHECKLIST-----------------------------------------------------------------------------------------------------36
SECTION 14.0 - ADDITIONAL INFORMATION -------------------------------------------------------------------------------------------------37
SECTION 15.0 - PRELOAD SPRING TENSION --------------------------------------------------------------------------------------------------38
SECTION 16.0 - DROP SPINDLE INSTRUCTIONS ----------------------------------------------------------------------------------------------39
SECTION 17.0 - MISCELLANEOUS/FUTURE USE----------------------------------------------------------------------------------------------40
SECTION 18.0 - WARRANTY POLICY------------------------------------------------------------------------------------------------------------41
8600 Installation Manual

4
Section 1.0- Product Summary
8600 is a universal, non-handed, electro-mechanical swing door operator which provides powered door opening upon
activation. The unit is designed to facilitate barrier free access into and within building through swing doors.
When properly installed and programmed, this product complies with ANSI/BHMA A156.19 Standard for Power Assist
and Low Energy Power Operated Swinging Doors.
8600 features enable the continuous automation of pedestrian doors while offering Low energy barrier-free access.
(THE 8600 INT) Designed to achieve the highest degree of safety while offering a long service life.
It is the responsibility of the installer and installation company to certify that the final completed operator is installed
in accordance with local building codes, applicable laws, and ANSI 156.19 standards governing this product.
Opening
When an open signal is received by the control unit, the door is opened at the factory set or pre-adjust opening speed.
Before the door is fully open, it will begin its back check, slowing automatically to low speed. The motor stops when the
selected full open angle has been reached. The open position is held by the motor.
In case the door encounters an obstruction during the opening cycle, once the maximum current limit is reached for at
least two (2) seconds, the door opening is then cancelled.
Closing
When the activation time has elapsed, the operator will close the door automatically using spring force and motor
power. The door will slow to latch speed before it reaches the full closed position. The door is kept closed by spring
power.
Power Failure
During power failure, the operator acts as a manual door closer with controlled closing speed.
8600 can be surface mounted or overhead concealedmounted on either side of the door header for left, right, pull, or
push applications. It is suitable for either single or double door opening being either hinged or center hung mounted.
ALL PRODUCT, PRODUCT SPECIFICATIONS AND DATA ARE SUBJECT TO CHANGE
WITHOUT NOTICE TO IMPROVE RELIABILITY, FUNCTION OR DESIGN OR
OTHERWISE. ... It is the customer's responsibility to validate that a particular product with
the properties described in the product specification is suitable for use in a particular
application.
8600 Installation Manual

5
Section 2.0 - Technical Specification
1.0
Model
8600
2.0
Application
Low Energy Swing Door Operator
3.0
Power Supply
100V - 240V AC, 50/60 Hz
4.0
Consumption
100W Max
5.0
Motor
1/4 Hp, Low revolution 24 DC, 3A Max
6.0
Rated Operation
Continuous opening and closing cycles
7.0
Reduction Gear
Enclosed Reduction Gear system
8.0
Control System
Microprocessor Digital Control
9.0
Operating Environment
Ambient temperature: -18~ +50
(no condensation or icing)
Ambient humidity 30% to 85% RH
(no hazardous materials must be present in the
atmosphere)
10.0
Operation During Power Failure
Low manual resistance when opened by hand. Door
closing by spring.
11.0
Operator Net Weight
17 kg, approx. 38 lbs.
12.0
Operator Dimensions
5½" (h) (140 mm) x 4½" (D) (115 mm)
13.0
Door Weight (max)
700 lbs. (318 kg) per leaf
14.0
Door Width Limits
29" up to 60" (consult factory for special sizes)
15.0
Operator Width
29" to 102"
16.0
Installation Types
Push, Pull, Overhead Concealed, Center spindle
17.0
Adjustable Opening Angle
80to 180
18.0
Auxiliary Power
500mA @ 24 vdc for accessories AND
1,000mA @ 12 vdc for accessories
19.0
Closing Force
Adjustable pressure by spring tension and optional
motor close
20.0
Product Standards
UL 325 Listed by ETL #5012330
ANSI 156.19 Compliant
UL10C Fire Door Rated Operator - 2 hours
8600 Installation Manual

6
Section 3.0 - Receiving Inspection
On receiving the package, please verify that the order was shipped complete and correct, including model number,
header width, door handing, arm and color.
If any of the below items are not correct, do not attempt to install the unit until all conditions are correct.
Report any incorrect items immediately.
NO CLAIMS FOR SHORTAGE WILL BE ACCEPTED UNLESS REPORTED WITHIN 24 HOURS OF RECEIPT OF SHIPMENT. THE
FOLLOWING ITEMS SHOULD BE SUPPLIED:
3.1 Exploded View
3.2 Parts List
No.
Description
Parts No.
1
8600 Header/Housing
HDR
2
End cover plate
ECPL-8600
3
Control Unit 8600 SW-CU-8600
4
Motor
n/a
5
Gear Box/Motor Assembly
SW-MGB-8600
6
Spindle
S-8600
7
Mechanical door stop
MDS-8600
8
Motor gear box end support bracket
MEB-8600
9
Motor gear box mount bracket
MGBMB-8600
10
Rev Counter/Encoder
SW-REV
1
2
3
4
5
6
7
8
9
10
2
8600 Installation Manual

7
Section 4.0 - Pre-Installation Information
4.1 Safety Precautions
Only trained technicians are authorized to carry out these operations.
Ensure all power is OFF to the unit before performing any work or maintenance.
Do not climb or put weight on any door or header parts.
Do not let children play with the operator or the electrical board.
Keep remote controls away from children.
To avoid bodily injury, material damage, and malfunction of the product, the instructions contained in this manual must
be strictly observed during installation, adjustment, repair, and service.
Training is needed to carry out these tasks safety.
4.2 Compliance Codes and Standards
It is the responsibility of the final installer and/or installation company to certify that the final completed operator is
installed in accordance with ANSI/BHMA A156.19 Standard for Power. Assist and Low Energy Power Operated Swing
Doors, local building codes and applicable laws.
Be sure to complete the site inspection and acceptance test before taking the door into operation.
All wiring must conform to standard wiring practice in accordance with national and local wiring codes.
Door must swing feely through the entire opening and closing cycle before beginning of installation.
Incorrectly installed or improperly adjusted door operators can cause property damage or personal injury.
All dimensions are given in inches (millimeters), unless otherwise noted.
Before installation, verify door frame is properly reinforced and is well anchored in the wall.
Concealed electrical conduit and concealed switch or sensor wires should be pulled to the frame before proceeding.
4.3 Electrical
The 115+/-5 VAC supply lines are connected into the Green Connector block located to the left hand side of the control
unit. Words clearly indicate its correct wiring. The ground wire is also connected into the Green Connector block.
The control board settings have been pre-set prior to shipment. It will be necessary for the door operator to be
functional while adjustments and settings are made. Please follow these instructions for a successful installation.
CAUTION
8600 Installation Manual

8
A black push actuator button indicated by "TEST/LEARN" is mounted to the lower left corner of the visual display to ease
in the adjustment process.
Once the unit is powered up and before the arm is installed, push the "TEST/LEARN: button in order to check the spline
drive shaft rotates in the correct direction.
Keep all wires away from moving parts and sharp edges that may cut into the outer casing of the wires.
Installation of any extra wiring for controls or accessories into the header unit shall be secured and away from any
moving parts.
If the motor is not plugged into the circuit board, there is no resistance against the spring when manually opening the
door. The door or arm will close very quickly if opened.
If an electrical access hole is added or knocked out of the end plates, code approved electrical transfers must be used.
Hole cannot be knocked out and unfilled.
4.4 Required Tools for Installation
Allen Wrench Set
Power Drill and Drill Bits
Level
Tape Measure
Wire Stripper
Screwdrivers: Flat, Philips, 5/16" Hex. Nut
Additional fasteners depending on surface
Shims
Hand Saw/Power Saw
4.5 Suggested Fasteners for Frame
#14 x 2-2/3" (70mm) long sheet metal screws for wood.
4.6 Suggested Fasteners for Door
#12, #14, Wood screws, Sheet Metal screws, Self-tapping screws of varying lengths depending on applications.
Typically, doors are hung on 4 1/2" (114mm) butt hinges or 3/4" (19mm) offset pivots.
The fastener components listed above are merely suggestions. A technician should use their best discretion to
determine what components they will need to complete the job.
8600 Installation Manual

9
Section 5.0 - Operator Installation
The following information gives a complete guidance to the correct installation on the 8600 operator.
5.1 Control Unit
No.
Description
1
Power Unit (90-250VAC 50/60hz)
9
3 Position Switch Input Connector
2
Motor Connector Plug in
10
Enter Button
3
Motor Encoder Connector Plug in
11
Down Button
4
LED Display Screen
12
Up Button
5
Sync/Comm Connector Plug in (Double Operator)
13
Menu Button
6
24VDC/12VDC Power Output Connector
14
Test/Learn Button
7
Activation/Safety Accessories Connector
15
Fuse - Replaceable
8
E-Lock Signal Connector
16
Battery Back-up Connection
5.2 Operator Handing and Orientation
Verify that the operator is the correct orientation. Left Push, Right Push, Left Pull, or Right Pull.
Note:
If the operator label is facing 'Down' to the floor, the handing is Left Hand Push/Pull.
If the operator label is facing 'Up' to the ceiling, the handing is Right Hand Push/Pull.
8600 Installation Manual

10
5.3 PUSH Arm Handing and Operator Orientation
RHR/LEFT Hand PUSH
LHR/RIGHT Hand PUSH
5.4 PULL Arm Handing and Operator Orientation
LEFT Hand PULL
RIGHT Hand PULL
8600 Installation Manual

11
5.5 Operator Installation
Step 1. Remove the cover from the assembly by gently pulling the cover down with minimal effort. Carefully set the
cover in a location where it will not be damaged.
Step 2. Remove the motor/gear box and control board from the back plate, make through holes on the back plate for
mounting header where appropriate.
Note: Can be installed without removal of motor/gear box and control board if preferred.
8600 Installation Manual

12
Step 3. Power Supply
Step 4. Fixing Operator in Place
Make sure all power is turned OFF before
handling the supply wires. This should be
done by a certified electrician and within
the guidelines of the enforced local
electrical codes.
Drill holes for the high voltage wires in
backing plate.
Pull the power supply into the header at the
same time as the header assembly is
positioned.
Be sure there is proper support in the wall
to secure the header at the vertical jambs
and behind the header at intervals between
the vertical jambs
A solid space material or filler may be
required to compensate for any gap
between the back of base rail and wall.
Ensure, before fixing base rail to the door
frame, that access holes for power supply
cables are in line, if required.
Secure the header box to the top of the
door frame with the appropriate
fasteners.
Holes can be made anywhere in header
to secure. All holes MUST be drilled
into substantial support (studs, blocks,
framing, etc.).
8600 Installation Manual

13
Step 5. Once the header back plate is in place, install the motor/gearbox and control board to the header back plate.
Slide the nuts (supplied with the operator) to hold the motor/gearbox and control board along the 2 parallel tracks on
the back plate.
Fasten the bolt to hold the motor/gearbox and control board in place.
The motor/gearbox needs to be installed so that the center of the spindle is 4 3/4" (120mm) from the end of the plate.
8600 Installation Manual

14
Section 6.0 - Push and Pull Arms Installation
Following these simple steps will allow the door to be set up quickly and correctly. Refer to installation drawings below.
6.1 Push Standard Scissors Arm for 0" - 14" Reveals
Note: Base rail to be mounted flush with the bottom of the door frame.
A solid spacer material or filler may be required to compensate for any gap between the back of base rail and wall.
Ensure, before fixing base rail to the door frame, that access holes for power supply cables are in line, if required.
Step 1. Without arm fitted, set 3-position switch to Hold Open (ii. The drive shaft will turn fully until hitting the in-built
fixed doorstop, so charging the spring.
Step 2. With door in closed position, install door shoe and rod to the door according to the installation drawing below at
13" to the first hole.
Step 3. Manually open the door to the full open
position (approx. 100open position).
Line up Rod with Push Arm, sliding Rod into Push Arm
and tighten bolts.
Fit PUSH arm to the drive shaft at the full open position,
close door and tighten arm.
Step 4. Set 3-position switch to manual
(0_ and allow door to close under
spring pressure.
Test and adjust arm at full closed
position as necessary so door closes
fully with frame.
Step 5. Press Test/Learn button to begin
the learning cycle. See Learning Door
Cycle.
8600 Installation Manual

15
6.2 Pull Standard Angle Arm With Track for 0" to 4" Reveals
Notes: Operator to be mounted so that base of drive shaft is clear above the door top. See Installation Drawings. A solid
spacer material or filler may be required to compensate for any gap between the back of base rail and wall. Ensure,
before fixing base rail to the door frame, that access holes for power supply cables are in line, if required.
Step 1. Without PULL arm fitted, set 3-position switch to Hold Open (II). The drive shaft will turn fully until hitting the
in-built fixed doorstop, so charging the spring.
Step 2. Manually open the door to
full Step 2. Manually open the door to
full open (approx. 100open position).
Fit PULL arm to the drive shaft at the full
open position so the roller touches the
door.
Mark the open position where roller
touches the door.
Step 3. Set 3-position switch to manual
(0) and allow the door to close under
spring power.
Mark the closed position where the
roller touches the door.
Step 4. Position slide track horizontally
within 1st and 2nd mark, then fix it to
the door.
Slide the roller along the channel,
followed by fitting end caps.
Step 5. Turn 3-position switch to automatic (I).
Press Test/Learn button to begin the learning cycle.
See Learning Door Cycle.
8600 Installation Manual

16
THIS PAGE INTENTIONALLY LEFT BLANK
8600 Installation Manual

17
Section 7.0 - Learning Cycle and Start Up
"TEST/LEARN" button is currently used for two functions.
a. TEST - if the "TEST/LEARN" button is pressed for less than 3 seconds and released, an activation will be
generated.
b. LEARN - if the button is pressed for at least 4 seconds and released, a door re-learn is selected.
Re-learn is confirmed by pushing the "ENTER" button.
Re-learn can be cancelled by pushing the "TEST" or "MENU" or "UP" or "DOWN" button.
Step 1. Place a heavy item or your
foot at the desired full open position
at approx. 90open position.
Step 2. Press Test/Learn button for 3
seconds and release to begin the
learning cycle.
Step 3. Incorporating a unique
electronic stop, the door will learn the
full open position during a one-time
open/door cycle.
The door will open until it touches the
object at the desired full open
position.
Back-check and latching position are
automatically calculated and do not
need setting (unless adjustment is
required).
On the next activation, the door will
open, slow at back check, then stop at
the learnt opened position.
The door will not hit the in-built fixed
doorstop.
Note: The built-in mechanical doorstop should only act as a limiting device should the door be pushed past its pre-
set electronically selected open position.
8600 Installation Manual

18
Section 8.0 - Electronics Controller Programming
Programming is quick and simple via the visual LED display.
Each FUNCTION is clearly shown on the display in text, words, and symbols.
The VALUE or APPLICATION can easily be adjusted using the buttons on the face of the controller.
Changed menu values will automatically be saved during the next opening cycle.
SPECIAL WARNING
All Menu Values and Settings must comply with ANSI/BHMA A156.19 Standard
for Power Assist and Low Energy Power Operated Swing Doors.
8.1 Opening Speed (05-12 for Low energy) or (05-20 for Full Automatic)
This setting is the door "Opening" speed from the fully closed position to the back-check position.
Use the "UP" and "DOWN" buttons to select the desired door opening speed.
Active the door to check the speed is correctly adjusted.
8.2 Back-check Speed (01-05)
This setting is speed when the door reaches the back-check position to the full door opening.
Use the "UP" and "DOWN" buttons to select the desired door back-check speed.
Activate the door to check the speed is correctly adjusted.
8.3 Safety Speed (Hold/Crawl)
This setting is door speed when "Safety 2" is active during the opening cycle.
Use the "UP" and "DOWN" buttons to select either Hold or Crawl speed.
8.4 Closing Speed (01-15
This setting is the door "closing" speed from the fully opened position to the Latch area.
Use the "UP" and "DOWN" buttons to select the desired door "Closing" speed.
Activate the door to check the speed is correctly adjusted.
8.5 Latch Speed (01-05)
This setting is the door "Closing" speed in the Latch area until fully Closed.
Use the "UP" and "DOWN buttons to select the desired door "Latching" speed.
Activate the door to check the speed is correctly adjusted.
8600 Installation Manual

19
8.6 Current Limit (01-20)
In case the door encounters an obstruction during the Opening cycle, once the maximum Current limit is
reached for at least 2 seconds, the door Opening is then cancelled.
Use the "UP" and "DOWN" buttons to select the desired "Current" limit strength.
Activate the door to Open. During the Opening cycle, physically apply pressure to stall the door for at least 2
seconds.
Check the force needed to reach the limit at which the door Opening is cancelled.
Increase or Decrease this setting to achieve the correct strength needed.
 Note: Setting of 10 is sufficient for most all applications.
8.7 Activation Time (01-60 seconds)
This setting is the duration of the door Open cycle in seconds.
The timer starts when the door starts to activate.
Use the "UP" and "DOWN" buttons to select the desired "Opening" time.
8.8 Hold On Manual Open (No or 01-05 seconds)
This setting is the length of time the door will be physically held Open, when the door is "Manually" pushed or
pulled open by a pedestrian.
The door must be opened at least 60% of the door swing for this feature to activate.
Use the "UP" and "DOWN" buttons to Enable or Disable this feature and set the timer value to keep open.
Caution: Do not set timer for more than 1.0 seconds unless requested by the end user.
8.9 Electronic Door Stop (Yes/No)
This feature is always Enabled even if you select Disabled.
8.10 Electric Lock (Yes/No)
This setting is to Enable or disable the electric Lock/Strike through the Control unit.
Select No when there is not an electric Lock.
Use the "UP" and "DOWN" buttons to set the proper Electric Lock.
8.11 Electric Lock Delay (0.2-2.0 seconds)
This setting is the length of time in seconds for the Delay between activating the Electric Lock and the Start of
the Opening cycle.
Use the "UP" and "DOWN" buttons to Disable or Enable the electronic Delay/Output.
Note: Setting of 0.2 seconds is sufficient for most applications.
8.12 Latch Position (2%-30%)
This setting will adjust the door Latch position during the Closing cycle.
Use the "UP" and "DOWN" buttons to set the starting point for the Latch position.
Activate the door. During the Closing cycle, check the Latch starting position where the door begins to slow
down.
Check this setting is correctly adjusted.
If stack pressure is preventing the door from Fully Closing, set at 30% and activate the Power Close feature.
8600 Installation Manual

20
8.13 Back-check Position (70%-98%)
This setting is to adjust the door Back-check position of the Opening cycle.
Use the "UP" and "DOWN" buttons to set the starting point for the Back-check position.
Activate the door. During the Opening cycle, check the position where the Back-check begins and the door
starts to slow down.
Check this setting is correctly adjusted.
In windy conditions, set to 70%.
8.14 Push & Go (Yes/No)
This setting is to Enable or Disable the Push & Go feature, also known as Manual Activation, when the door is
Manually pushed or pulled open by hand.
Caution: Do not activate this feature without training and specifically requested by the end user.
Use the "UP" and "DOWN" buttons to Disable or Enable this feature.
8.15 Push & Go Active Time (01-30 seconds)
This setting is to adjust the duration of the door Open cycle in seconds from when the door is Manually pushed
Open to when the Push & Go feature is enabled.
Use the "UP" and "DOWN" buttons to select the desired Opening time.
8.16 Power Close (Yes/No)
WARNING: You should always install a Presence Safety sensor when Enabling this feature.
This setting is to Enable or Disable the Power Close Assist feature.
When Power Close is "ON", should the door reach the Latch position and cannot fully Close after 3 seconds,
the motor will assist the spring in order to fully Close the door.
This feature is used when the pressures on the door prevent the door from fully Closing
Use the "UP" and "DOWN" buttons to Enable or Disable this feature.
8.17 Power Close Force (01-05)
This setting will allow you to increase or decrease the amount of Closing Force needed to fully Close the door
at the Latch position.
This feature is used to counter act Stack or Wind pressures.
IMPORTANT: When using the Power Close Force feature, we strongly recommend to wire a Presence Safety
sensor into the input (PC Cancel" on the control board terminal that Cancels out this feature when a pedestrian
presence is detected. PC = Power Close.
Use the "UP" and "DOWN" buttons to select the desired Closing Force. Use the lowest Force setting needed to
ensure positive Latching in these conditions.
Check this setting is correctly adjusted.
8.18 Door Seal (Yes/No) Not an Active Function.
8600 Installation Manual