icontrols PULSE User manual

PB 1
18 - 50 West Wilmot Street, Richmond Hill, Ontario Canada L4B 1M5
905-597-8989 •www.icontrols.ca •[email protected]
PULSE TECHNICAL SUPPORT LINE: 1-833-PULSEDC (1-833-785-7332)
PULSE
Commercial Direct Drive Door
Operator for Balanced Sectional
and Rolling Steel Doors.
Installation Manual and
Setup/User Instructions
U.S. Patent No. 11105138

23
TABLE OF CONTENTS
General Overview................................................................................................................... Page 3
Meeting UL 325 Requirements...............................................................................................Page 3
Box Inventory...........................................................................................................................Page 3
Operator Technical Overview ...............................................................................................Pages 3-4
Pre-Installation Assembly Requirements ..............................................................................Pages 5-7
Mounting Installation Instruction ..........................................................................................Pages 8-10
Wiring Instructions...................................................................................................................Pages 11-12
Wiring Diagrams .....................................................................................................................Pages 13-17
Startup Procedure...................................................................................................................Page 18-20
Testing for Spring Balance............................................................................................ Page 18
Accessing STARTUP MENU .............................................................................................Page 18
Set Closing Timer ...........................................................................................................Page 18
Set Voltage......................................................................................................................Page 19
Set Motor Position ..........................................................................................................Page 19
Set Door Limits................................................................................................................Page 19
Set Door Speed..............................................................................................................Page 19-20
Jog Mode.......................................................................................................................Page 20
Exiting STARTUP MENU & Testing....................................................................................Page 20
ADVANCED MENU Programming ..........................................................................................Page 21
Set Reversing Timer........................................................................................................Page 21
Set PWM Frequency ......................................................................................................Page 21
Set Dynamic Brake........................................................................................................Page 21
Set Opening Force ........................................................................................................Page 21
Set Closing Force...........................................................................................................Page 22
Set Open Slow Speed ................................................................................................... Page 22
Set Close Slow Speed....................................................................................................Page 22
Set Open Rampdown Distance...................................................................................Page 22
Set Close Rampdown Distance................................................................................... Page 22
Set Open Limit Options (Push Button & Remote).......................................................Page 22
Set Output Relay............................................................................................................Page 23
Set Calibration ...............................................................................................................Page 23
Set Maintenance Schedule .........................................................................................Page 23
Set Red Flashing ............................................................................................................ Page 23
Set Advanced Red ........................................................................................................ Page 23
Set Open Limit Switch....................................................................................................Page 24
Set Factory Reset ...........................................................................................................Page 24
Exiting ADVANCED Menu ..............................................................................................Page 24
Power Outage Operation ...................................................................................................... Page 25
Battery Information.................................................................................................................Page 25
Car Wash/Water Resistant Applications............................................................................... Page 25
Components............................................................................................................................Page 26
Troubleshooting Guide ..........................................................................................................Page 27-29
Warranty................................................................................................................................... Page 30

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GENERAL OVERVIEW
Thank you for purchasing this Pulse Direct Drive Door operator. This dependable operator is
designed for continuous-cycle duty for your Commercial Door and can extend the life of your
counter-balanced sectional door with its integrated so-start/so-stop capability.
It also features adjustable opening speeds of up to approximately 24” per second, battery
backup that can operate the door in case of power failure, over-current protection, and
adjustable auto-reversing force monitoring, along with many other programmable functions.
MEETING UL 325:2017 REQUIREMENTS
The Pulse Operator is provided with a Polarized Reflective Photo-Eye or Thru-Beam Photo-Eye (1
& 2HP model only), which is connected into Terminal 1 of the ‘Reversing Devices’ input on the
Control Panel. Once the Close button is activated, the operator verifies that the Photo-Eye is
connected and functional, and it continues to monitor the sensor as the door closes.
A dedicated terminal (Terminal 2 Reversing Devices) is provided to operate with Monitored
Reversing Devices.
Input (Terminal 3 Reversing Devices) for non-monitored reversing devices (i.e. standard
pneumatic edge).
The Pulse Operator will initiate Push/Hold to CLOSE protocols should devices in Terminal 1 and
2 be found non-functional, misaligned or unconnected (at least one functional device must be
connected and verified in either Terminal 1 or Terminal 2). Note that during Push/Hold to Close
protocols, the door will reverse should it not fully reach the closed limit per UL 325.
BOX INVENTORY
Before beginning installation, please verify that all components are accounted for:
1. Motor, Gearbox, Encoder, Junction Box Assembly
2. Control Panel
3. Limit Brackets and Hardware (Angle Brackets for Stop Limit to mount on door tracks)
4. Torque Arm, Mounting Bolts, Mounting Bracket
5. Sha Collar and Sha Key
6. Reversing Device – Reflective Photo-eye (Thru-Beam Photo-Eye included on Pulse 1000/2000)
7. Two 12V, Lead-Acid Rechargeable Batteries (3 Batteries fo Pulse 2000)
In case any of the above items is missing, please contact iControls and provide us with details of
the missing part(s), as well as the serial number of your operator.
OPERATOR TECHNICAL OVERVIEW
Motor
HORSEPOWER: Pulse500 = ½ HP Pulse750 = ¾ HP Pulse1000 = 1 HP Pulse 2000 = 2 HP
SPEED: 1750 RPM
CURRENT (FLA): ½ HP = 5A ¾ HP = 7.6A 1 HP = 10A 2 HP = 10A(208-240Vac)
OUTPUT TORQUE: Pulse500 = 54Nm, Service Factor 1.6
Pulse750-1 = 80Nm, Service Factor 1.1
Pulse750-1.25 = 108Nm, Service Factor 2.0
Pulse1000 = 147Nm, Service Factor 1.5
Pulse 2000 =

45
Electrical
SUPPLY VOLTAGE: 110-130 or 208-240V Vac, 1ph Input (All incoming power to be
connected in provided junction box)
BATTERIES: ½ HP= 2 x 5Ah, ¾ HP= 2 x 7Ah, 1 HP= 2 x 9Ah, 2 HP= 3 x 9Ah
CONTROL VOLTAGE: 24Vdc, 1A Power/Connections supplied for activation and
reversing devices
AUX RELAY: 1 SPDT Programmable Relay (factory default to activate on Open
Limits)
Safety
PHOTO-EYE or THRU-BEAM Polarized Photo-eye Sensor/Reflector with Bracket or Thru-Beam
SENSOR: sensor provided with unit as non-impact reversing device protection.
POWER OUTAGE Battery Backup to open/close the door in case of power-outage.
OPERATION: 3/8” ratchet socket for manual crank open/close as added
redundancy.
Maximum Recommended Counter balance Sectional Door size
Pulse 500: up to 200 Square Feet
Pulse 750: up to 350 Square Feet
Pulse 1000: up to 500 Square Feet
Pulse 2000: over 500 Square Feet
IMPORTANT
WARNING – These instructions are intended for experienced personnel trained for service and
installation of sectional doors and operators. All safety precautions and local codes must be
followed.
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
2. Have qualified service personnel make necessary repairs to ensure door is operating
smoothly without any unusual noise. Install operator only on a smoothly operating and well
balanced door.
3. Remove all pull ropes and remove locks (unless mechanically and/or electrically
interlocked to the power unit) connected to the door before installing the operator.
4. A commercial/industrial door operator that has exposed moving parts capable of causing
injury to persons or employs a motor deemed indirectly accessible by clause 10.6 by virtue
of its location above the floor shall include:
a. Install the door operator at least 2.44m (8 ) or more above the floor: or
b. If the operator must be installed less than 2.44m (8) above the floor, then exposed
moving parts must be protected by covers or guarding; or
c. Both a. and b.
5. Do not connect the operator to the supply power until instructed to do so.
6. Locate the control station: (a) within sight of the door, and (b) at a minimum height of 1.53m
(5 ) above floors, landings, steps, or any other adjacent walking surface and (c) away from
all moving parts.
7. Install an Entrapment Warning Placard next to the control station in a prominent location.

45
PRE-INSTALLATION ASSEMBLY REQUIREMENTS
BEFORE INSTALLATION, ENSURE THAT YOUR DOOR IS PROPERLY BALANCED AND RUNNING
SMOOTHLY. ALSO ENSURE THAT THE LIMIT BRACKETS (SUPPLIED) ARE INSTALLED AND
SECURED PROPERLY. BUMPER/PUSHER SPRINGS MAY BE USED IN PLACE OF, OR IN ADDITION TO
LIMIT BRACKETS FOR PULSE OPERATORS, BUT MUST BE INSTALLED PRIOR TO OPERATION.
Operator Mounting Requirements
Pulse operators are mounted directly on the door sha. Before installing the operator, please en-
sure following criteria is met:
The door is well balanced, is tested for
smooth functioning without any unusual
noise.
Provided Limit Brackets must be installed
4"-5" past door's desired open position (and
within allowable maximum cable height) to
prevent the doors from over-travel. (See Fig.
1A)
The door has a solid keyed sha with a
minimum exposed length of 4.5” on the
operator side.
Clearance of at least 12” horizontally from
the side of the door (or 9” from end of sha),
and 24” vertically below the sha. There
is adequate structural support surface to
securely install the torque arm mounting
bracket, the torque arm and the junction
box. For more details, see mounting
installation instructions
Fig: 1 & 7.
Mounting space for the operator Control
Panel (Min. 5 . from ground level, within
clear sight of the door but far enough away
as to prevent users from contacting moving
parts).
Le Hand Mounting:
The factory default mounting as shown
(Shown in Fig: 2) is for le-hand side of the
door, hence no modification is required.
FIGURE: 1
FIGURE: 2
Magnet on
this side
Encoder
FIGURE: 1A

67
Right Hand Mounting:
The soware and hardware must be modified for right-hand side mounting.
Refer to “OPERATOR START-UP/SET-UP, MOTOR POSITION.
Field Adjustment of the Encoder for Right-Hand Mounting:
Instructions to adjust the hardware for right hand
mounting: See Fig: 3.
Remove the 4 bolts, spacers that secure the
encoder on the le-side of the gearbox and set
the encoder mounting plate, bolts and spacers
aside.
Remove the cable tie that secures the cable to
the gearbox. DO NOT ATTEMPT TO REMOVE/
DISCONNECT CABLE!
Insert a long screwdriver through the hollow sha
from the right side of the gearbox and gently tap
out the encoder magnet assembly wedged in
the le side of the gearbox hollow sha.
Align the key and insert the magnet assembly
into the right side of the hollow sha and gently tap with a rubber mallet until it is slightly
recessed 1 mm (1/32”) in the hollow sha (level with the inner bevel edge of the hollow sha).
ENSURE THAT THE MAGNET IS VISIBLE AND FACING OUTWARDS FIG: 3 PRIOR TO INSERTION.
Attach the encoder mounting plate to right-side of the gearbox, so that it covers the encoder
magnet assembly, ensuring that the cable is facing towards the bottom of the operator, use
existing bolts and spacers. Ensure that bolts are fully
tightened. DO NOT TWIST THE CABLE.
Please note that the face of the encoder should not
be more than 1mm (1/32”) from the magnet. If too
far, the encoder may not detect the magnet. If too
close, friction will lead to limit retention issues.
Assembling Torque Arm to Gearbox
The torque arm must be assembled onto the gearbox
on the opposite side of encoder using the enclosed
4 bolts. There are 6 possible positions for the torque
arm, and its optimal mounting position should be
pre-determined prior to assembly. Tighten bolts
appropriately. THE TORQUE ARM IS AN INTRINSIC
COMPONENT OF THE OPERATOR’S SAFETY AND
FUNCTIONALITY AND MUST BE INSTALLED SECURELY. See
Fig: 4
See Fig; 4A-F For recommendations on how
to mount Torque Arm to Operator/Mounting
Bracket in relation to Sha O-set.
FIGURE: 3
FIGURE: 4
Magnet on
this side
Encoder

67
TORQUE ARM POSITION IN RELATION TO OPERATOR

89
WARNING
• TO REDUCE THE RISK OF PERSONAL INJURY OR DEATH, DO NOT CONNECT ELECTRICAL POWER UNTIL
COMPLETE OPERATOR, JUNCTION BOX AND CONTROL PANEL ARE INSTALLED, SECURED AND PROTECTED PER
FOLLOWING INSTRUCTIONS.
• ENSURE THAT AREA IS CLEAR OF PERSONNEL AND CORDONED OFF TO ACCESS WHILE INSTALLING
OPERATOR.
• USE PROPER SAFETY PROTOCOLS ACCORDING TO INTERNAL, LOCAL AND FEDERAL REQUIREMENTS.
MANDATORY FIRST STEP - Limit Bracket Installation
If your door is not already equipped with bumper/pusher springs, it is mandatory to install the
supplied Limit Brackets. Mount one bracket to the top of each track (See Figure 1A) to prevent
over-travel of the door, and enable automatic encoder recalibration prior to setting limits and aer
a power-loss. These should be mounted inside the door-tracks at the door’s maximum allowable
travel point, and are required to be located at the same exact position on both tracks so that the
top rollers of the door rest against them in a level position.
To install, manually open the door to the uppermost opening position allowable by the cables,
clamp the door in place, and secure the brackets to the track as shown Figure 1A using the top
rollers as the reference points for the brackets.
IN THE ABSENCE OF BUMPER/PUSHER SPRINGS, INSTALLATION OF LIMIT BRACKETS IS
MANDATORY PRIOR TO OPERATOR INSTALLATION. WITHOUT PHYSICAL LIMITS, THE DOOR CAN
RUN OUT OF ITS TRACKS AND CAUSE SEVERE PERSONAL INJURY AND/OR CAUSE SEVERE DAMAGE
TO THE DOOR. FURTHERMORE, YOU WILL BE UNABLE TO SET THE LIMITS.
MOUNTING INSTALLATION INSTRUCTION
Sha Collar/Key Installation
The Sha Collar serves as an end-stop for the gearbox on the sha to prevent possible damage to the
encoder magnet. It is important that it is securely fastened prior to installation of the operator, and needs to
be mounted in conjunction with the key as shown in Fig: 5.
Adjust the door so that the sha keyway is facing up (you
may have to open/wedge/clamp the door open slightly to
achieve this).
Loosen the Sha Collar set screw and slide it over the sha
approximately 3 ½” from its end.
Insert the 3 inch long key (provided with operator) into the
door sha keyway with one end flush to the end of the sha.
Slide the collar back so that it touches the key, which should still be flush with the sha end on its opposite
side (the key sits in the keyway between the collar and the end of the sha), see Fig: 5.Firmly tighten the
set screw of the collar onto the sha. Fasten the Torque Arm to the gearbox on the opposite side as the
encoder, and at an appropriate position as suggested on Drawing Figs: 4A-F)
Please note that in order to keep this collar as close to the door frame as possible and to
accommodate fastening of the torque arm, you may be required to cut the sha to an appropriate
length.
FIGURE: 5

89
FIGURE: 5
WARNING
WARNING: THE OPERATOR ASSEMBLY IS HEAVY AND CAN CAUSE SERIOUS INJURY OR DEATH SHOULD IT BE
DROPPED DURING INSTALLATION. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID DROPPING THE
OPERATOR (I.E. TETHER/TIE DOWN) PRIOR TO ATTEMPTING INSTALLATION. SCAFFOLDING OR SCISSOR-LIFTS/
PLATFORM-LIFTS ARE ADVISED FOR OPERATOR INSTALLATION. NEVER ATTEMPT TO INSTALL AN OPERATOR
ABOVE EYE-LEVEL OR FROM A LADDER.
Operator Installation
ENSURE THAT PREVIOUS STEPS FOR SHAFT COLLAR/KEY INSTALLATION HAVE BEEN PROPERLY FOLLOWED
BEFORE PROCEEDING. FAILURE TO DO SO COULD RESULT IN DAMAGE TO THE ENCODER DURING
OPERATOR INSTALLATION.
Align the keyway of the gearbox with the pre-mounted
key (see Key Sha Collar/Key Installation on previous
page) located on the mounting side of the sha.
Slide the gearbox onto the sha until it makes contact with
the Key Sha Collar.
Assemble the Torque Arm Bracket to the Torque arm
using the fastener provided. NOTE: DO NOT TIGHTEN THE
NUT FULLY). Anchor the Torque Arm Bracket to the solid
structural support.
Fasten the torque arm to structural support by means of
the supplied bolt, locking nut and washers. The supplied
bracket may be required. If the torque arm does not align
with structural support, you may try adjusting the torque
arm position on the gearbox (see Assembling Torque Arm
to Gearbox) accordingly or use the Torque Arm Bracket.
Junction Box Mounting
The junction box contains terminals for power
connections, as well as battery/communication
connections for the control panel. Mount the junction box,
by means of the mounting flanges and in accordance
with the electrical code, in a conspicuous location
that will provide access for both electrical power and
control panel wiring connections. The junction box is pre-
wired with 2 feet of flexible conduit, if longer lengths are
required, consult with factory. Do not mount the junction
box near moving parts or in an inaccessible area.
FIGURE: 6
FIGURE: 7
FAILURE TO SECURELY FASTEN TORQUE ARM COULD RESULT IN DAMAGE, SERIOUS INJURIES OR
DEATH AND WILL VOID THE WARRANTY.

10 11
Control Panel Mounting
The control panel should be securely mounted at
or around eye level (minimum 5 . from floor) on
the same side as the operator/junction box. Ensure
that the control panel is mounted far enough away
from the door as to avoid user contact with the
door while in operation, but close enough that the
user has clear view of the door at all times. Four (4)
control mounting brackets are provided to facilitate
mounting. See Fig: 8
Photo-Eye or Thru-Beam Sensor Mounting
The included reflective photo-eye or thru-beam
sensor should be mounted so that it scans area
that spans the entire width of the door at a height
of no more than 6 inches from the ground. The
sensor (reflective photo-eye) or receiver (thru-beam)
should be mounted on the operator side (as it will
be wired into the control panel), while the reflector
or transmitter should be mounted on the opposite
side of the door, facing the sensor/receiver so that its
center meets the beam. Use the included mounting
bracket(s) to secure to either the door tracks or the
wall. Refer to the specific mounting details provided
with the sensor. For final alignment of the sensor, put
unit in STARTUP MENU (see page 18) to apply power to
the sensor (aer WIRING – see page 13 for additional
wiring diagram). Once properly aligned in STARTUP
MENU, the indicator will light up in confirmation. Note
that upon exit from the STARTUP MENU, the sensor will
only become active when the door is closing.
See Fig: 9 for mounting reference.
FIGURE: 8
FIGURE: 9