RCA Orca GarageAce Service manual

Installation Instructions
& Owner’s Manual
Orca™ GarageAce Remote Control Roller
Door Opener.
IMPORTANT
SAFETY
INSTRUCTIONS
Warning:
It is vital for the
safety of
persons to
follow all
instructions.
Incorrect
installation can
lead to severe
injury.
Save these
instructions.
NOTE: This unit is for roller doors only. See your local distributor
for ORCA tm GarageAce Door Openers designed for tilt and
sectional doors.
Thank you for purchasing the ORCA™ GarageAce. This unit
is easy to install and provided these instructions are followed,
will provide many years of smooth, trouble-free operation.
Important Information
Never let children operate or play with the door controls.
Keep the remote control away from children.
Always keep the moving door in sight - and keep people and
objects away until the door is completely closed.
NO ONE SHOULD CROSS A MOVING DOOR.
Do not operate the door opener manually with people or any
object (including motor vehicles) within the doorway.
The garage door must be well balanced. Sticking or binding
doors can falsely trigger the obstruction detection.
All maintenance must be carried out by a suitably qualified
person.
Test the door opener monthly. The garage door MUST reverse
on contact with a 5 to 10 cm high object on the floor. The
amount of force the door exerts is adjustable, and failure to
adjust the opener properly may cause severe injury or death.
Although GarageAce has an obstruction detector, it is a legal
requirement in some countries that a photo-electric sensor
be installed across the doorway. Please check this requirement
with your local distributor.
Read all instructions carefully.
SEE BACK OF LEAFLET FOR FEATURES, CONTROL
DEFINITIONS AND SPECIFICATIONS.
Contents
1 x Drive Unit
1 x Control Unit
1 x U Bolt and nuts
2 x Remote Controls
Cat. OGA-GDRD

SYMPTOMS POSSIBLE CAUSE REMEDY
Door will not operate Main power not turned on Turn on
Door is obstructed Remove obstruction
Fuse blown Replace fuse
Door will not operate Door reversing sensitivity not Re-adjust reversing sensitivity
adjusted properly (Ref installation instruction step 7)
Door moves downwards Door reversing sensitivity not Re-adjust reversing sensitivity
and reverses itself upwards adjusted properly (Ref installation instruction step 7)
Door operates from drive Indicator on transmitter Battery flat of battery leads broken
unit but not from hand transmitter not lighting
Transmitter has not been learnt Refer to installation
instructions - step 8
Drive unit aerial wire not extended Extend aerial wire
Battery flat Replace battery
Door does not close fully Limit micro switch Re-adjust limit switch
incorrectly adjusted (refer to intallation
instructions step 6)
Door does not open fully Limit micro switch Re-adjust limit switch
incorrectly adjusted (refer to intallation
instructions step 6)
lights not functioning Bulb blown Replace bulb
Bulb keeps blowing Incorrect bulb Replace with 24V 5 Watts
Festoon bulb
FAULTS AND REMEDIES
Specifications
INPUT VOLTAGE:
110/220V AC 50Hz
Single Phase.
Current Required 1 Amp
TRANSFORMER SPEC:
Primary Voltage 110/220 VAC
Secondary Voltage 24V AC/100VA
MOTOR SPEC:
Motor type Permanent Magnet DC Motor
Torque 150kg cm at 4 Amps
OPENER LIFTING CAPACITY: 30kg
CONTROL BOARD SPEC:
Relay Contact Rating 12 Amp/30V DC
Relay Coil Voltage 24V DC
Control Board Voltage 24V DC/5V DC
Light Globe Voltage 24V DC 5 Watts
Receiver Specification Receiver Type FSK AM
RF Frequency 433.92 MHz
Code Storage Capacity 6 different codes
Control Distance >50m
TRANSMITTER SPEC:
Carrier Frequency 433.92 MHz
Current Consumption 50mA (approx.)
Battery Voltage 12 Volts
Coding Format Rolling Code (7.38 x 1019 Code Combinations)

19
18
18
17
17
16
15
14
13
12 11
10
9
8
7
6
5
4
3
2
1
CONTROL DEFINITIONS
Control Definitions
(DIY installation points are in bold. Other points are of interest to qualified
electrical installers only)
1 . O/S/C Button, is used during installation to open, stop and close the
opener.
2. EXT Push Button, is for connecting the wall switch, with the same
function as the 0/S/C Button.
3. EXT ALARM, is for connection the extra alarm siren, accomplish the anti-
theft function via the A-SW input at the CONTROL TERMINAL.
4. +24V, PB and GND, is for connecting the 2-wire or 3-wire Photo Electric
Beam.
5. A-SW and GND, is for connecting the anti-theft sensor, broken at the
full close position will activate the EXT. ALARM output.
6. PUSH and GND, is for connecting the PUSH BUTTON, with the same
function as the 0/S/C button.
7. LEARN LED, to indicate the learn/working status of the transmitter(s).
8, LEARN BUTTON, is used for storing or erasing your selected security
code from your transmitter(s) into the openers memory device.
9. RF RECEIVER Board, 433.92MHz AM FSK mode receiver,
10. ANTENNA, do not cut antenna wire or coil up.
11. UPWARD FORCE Adjustment. (Model A only), is for adjusting the
open obstruction force. Turning the shaft in a clockwise direction increases
the force that is required to restrict the door before it stops when opening.
Turning anti-clockwise will decrease the force that is required to stop the door.
12. DOWNWARD FORCE Adjustment, is for adjusting the close safely
obstruction force. Turning the shaft in a clockwise direction increases the force
that is required to restrict the door before it reverses when closing. Turning
anti-clockwise will decrease the force that is required to reverse the door.
13. AC POWER, is for connecting the main power supply. AC 24V. 50-
60Hz.
14. LAMP, the courtesy light, with the rating 8W/24V.
15. TO DC MOTOR, is for connecting the opener, the DC motor output.
16. OPENICLOSE limits connector, Pin 4-5, the open limit input and pin 5-
6, the close limit input. Normal contact and activate while the switch opens.
17. BATTERY BACKUP CONNECTION, for use with 24V battery back
up.
18. FUSE. 5 x 20mm normal Blow Glass Fuse, 7A 240V.
19. BEEPER, on Board Beeper when in operation.

Weight Bars
Figure 2
Curtain Control Unit
Remote Control
Power Cord
Drive Unit
Bracket
U Bolt
Plate
Spring
Washer
Nut
Side Room Requirements
Fig 1 shows the side room required. The minimum distance between
the edge of the door curtain and the inside of the bracket is 85mm
(11Omm is recommended). The distance between the edge of the
door and the outside of the bracket is 135mm (160mm is
recommended).
Installing the Orca™ GarageAce
Figure 1 Figure 1 Minimum 135mm
(160mm recommended)
Minimum 85mm
(11Omm recommended)
2. Fixing the door weight bars
Weight bars can improve the door's perfomance. If you have been
supplied them with your door it is advisable to fit them. The Orca™
GarageAce will, however, function without thembut if you encounter
the door sticking during closing contact Figure 2 your door supplier
for information about adding weight bars. Figure 2 shows the weight
bars attached. If the door feels heavy it may require extra tension to
be added to the door springs. Refer to the door manufacturer's
installation instructions on how to tension the door.
Right Hand Left Hand
Green Red Green Red
Red Yellow Red
Yellow
Figure 3
1. Before beginning the installation, check
operation of the door.
The door must be well balanced and be in a reasonable operating
condition. You should be able to lift the door smoothly and with little
resistance. It should stay open at around 900mm to 1200mm above
the floor. The door should not stick or bind in the guide tracks.
Weight Bars
3. Left or right hand installation
The GarageAce opener can be installed on either the left or right side
of the door. Looking from the inside Weight Bars of the garage, it the
opener is to be installed on the RIGHT hand side, go to step 4. If the
opener is to be installed on the LEFT side, the motor wire connectors
will need to be adjusted. Remove the connectors and swap them as
shown in Fig 3.

4. Fixing the drive unit to the door
(Fig 4, 5, 6)
The drive unit can be fixed to the door in a number of ways. The
following is one way that we recommend.
THESE INSTRUCTIONS ARE FOR A RIGHT
HAND INSTALLATION, (LEFT HAND
INSTRUCTIONS ARE IN ITALICS).
a) Make sure there is enough room (135mm from the end of the door
shaft to the wall) toslide the drive unit onto the shaft.
b) Check that the door shaft U bolt is securely tightened on the left
{right} side of the door.
c) Raise the door and tie a rope around the middle to secure the roll.
d) Support the right {left} hand side of the door with a suitable prop
- use soft padding.
WARNING: Do not allow children or other people
under the door when propped. Serious personal
injury and/or property damage can result if the
prop is disturbed or Support gives way.
e) Double check working distance [Step a) above] then carefully loosen
and remove the right {left} door U bolt.
f) Make sure the prop is secure then remove the right {left} hand door
mounting bracket from the wall.
g) Remove the drive unit from packaging. Cheek that the black drum
rotates freely. It it does not, then manual mode has to be selected -
pull the red string handle down to disengage gears and release slowly.
The black drum should now rotate. (Pulling the green cord will re-
engage the gears.)
h) Slide the drive unit over the door axle making sure that the forks
in the black drum extend into and over one of the spokes of the door
drum wheel.i) Refit the door mounting bracket to the wall. Make sure
the door will still be level - in some cases the bracket Red Cord may
have to be repositioned.
j) Straighten the drive unit and position over the wall bracket. Refit
the original U bolt through the slots in the drive unit and into the
bracket.
k) If the original U bolt does not fit through the slots, discard it and
use the supplied U bolt instead. You may have to drill new holes in
the bracket for this
to fit through. When you are sure everything will fit, remove the prop,
reposition unit and shaft on the bracket then tighten the U bolt. Untie
the rope Untie Rope from the door.
5. Installing the control unit (Fig 7)
a) Position the control unit in a convenient place. It should be close
enough to the drive unit so that the connecting cord will reach. A
standard three-pin outlet should be installed close enough so that
the power cord will easily reach. The control unit also has a courtesy
light, so the unit should be positioned where the light will give the
best unimpeded illumination.
b) Screw a fastener into the wall and slip the control unit recess over
the fastener.
c) Remove the cover. Be careful lifting oft the cover -the control button
cord is plugged into the board. (Fig 8) This can be unplugged for
convenience and re-plugged later.
d) Plug the control cable from the drive unit into the appropriate slot
on the board (Fig g). Position the cord into the recess at the base of
the unit. Do not switch on yet.
Courtesy Light
O/S/C Button
Support
Rope
U Bolt
Right Bracket
Figure 4
Red Cord
(Disengage)
Green Cord
(Re-engage)
Drive Unit
Figure 5
Refit Right
Bracket
Refit U Bolt
Untie Rope
Remove
Support
Figure 6
Figure 7

6. Setting the limit switches
Instructions are for right hand installation {left hand installation in Italics}
a) Set unit in manual mode [see 4 g) above] and move door up by hand to the
desired OPEN position.
b) Remove the switch cover . Loosen the three black screws holding the cams
in place (Fig 10). The UP LIMIT cam is the inner-most cam. Move this around
clockwise {anti-clockwise} until it fully engages the UP LIMIT switch.
c) Move the door down by hand to the desired CLOSE position. The DOWN
LIMIT cam is the outer-most cam. Move this anti-clockwise {clockwise} until
it filly engages the DOWN LIMIT switch. Tighten the three black screws.
d) Turn the power on and re-engage the drive gear (pull the green cord).
Up Limit Switch Open limit adjustment
e) Press the 0/S/C button on the uncovered board. The door should
start opening. If the door stopped at the desired OPEN position the
limit adjustment is complete. If not, the UP LIMIT cam will have to be
adjusted as detailed above To open the door more, adjust the cam
clockwise {anit-clockwise}
To open the door less, adjust the cam anti-clockwise
Close limit adjustment
f) Press the 0/S/C button on the board again. The door should start
closing. It the door stopped at the desired CLOSE position the limit
adjustment is complete. If not, the DOWN LIMIT cam will have to be
adjusted as detailed above. To close the door more, adjust the cam
anti-clockwise {clockwise} To close the door less, adjust the cam
clockwise {anti-clockwise}
Figure 8
Control Button
Cord
Figure 9
Courtesy Light
Cord
Down Limit Cam
Up Limit Cam
Up Limit Switch
Down Limit Switch
Figure 10
7. Setting force levels for open/close
obstruction detection (Fig 11)
The settings for the open/close obstruction detection force levels are
the most important adjustments in the whole installation procedure.
They are the same for right or left instailation. Failure to set these
levels could result in serious injury or property damage. Once made,
these settings should be tested at regular intervals - once a month
is recommended.
Obstruction detection force level for CLOSE
a) Fully open the door by pressing the 0/S/C button. The door will
stop automatically when the open limit position is reached.
b) Turn the DOWN FORCE knob fully clockwise. Press the 0/S/C
button again - the door should start closing. As the door is closing,
turn the DOWN FORCE knob slowly anti-clockwise until the door
stops momentarily then reverses.
c) Turn the DOWN FORCE knob 10 degrees clockwise. Press the
0/S/C button again to close the door. If the door reverses by itself,
readjust the DOWN FORCE knob a further 5 degrees clockwise. Keep
adjusting in this manner until the door can complete the full closing
cycle.
Obstruction detection force level for OPEN
a) Fully close the door by pressing the 0/S/C button. The door will
stop automatically when the close I limit position is reached.
b) Turn the UP FORCE knob fully clockwise. Press the 0/S/C button
again - the door should start opening. As the door is opening, turn
the UP FORCE knob slowly anti-clockwise until the door stops.
c) Turn the UP FORCE knob 10 degrees clockwise. Press the 0/S/C
button again to open the door. If the door stops by itself, readjust the
UP FORCE knob a further 5 degrees clockwise. Keep adjusting in
this manner until the door can complete the full opening cycle.
Obstruction detection test
The door now has to be tested for response to an obstruction while
it is opening and closing. With the door in the open position, press
the 0/S/C button. The door will start closing. When it reaches about
half way hold the bottom of the door with your hands. If the door
does not readily stop and reverse, the force load setting is too great
and will need adjusting. If the door is unable to reverse, discontinue
use and report the fault to your local distributor. Repeat the test for
the opening cycle.
8. Setting the remote control(s) (Fig 12)
The supplied Remote Control units can be programmed tor any
number of purposes. Although the unit has four buttons, only one is
needed to operate the GarageAce. The same button will open and
close the door. If you have other devices (such as a burglar alarm)
that can program a remote control, use the other buttons for this
purpose.
a) On the CONTROL UNIT board press the LEARN button for 2
seconds. The LEARN LED will turn on.
b) Press the preferred button of REMOTE CONTROL then release
and press again. The LEARN LED will flash about 8 times then turn
off.
c) Press the remote control to test the door open i ng/closing.
d) Repeat these steps for each Remote Control. A maximum of six
remotes can be programmed.
e) It you wish to delete the codes, press and hold the LEARN BUTTON.
The LEARN LED will turn on. Keep holding the LEARN BUTTON for
approx. 8 seconds until the LEARN LED turns off. All stored codes
are deleted. (Recommended if a remote is lost or stolen).
Remote Learn LED
light
Remote
Learn
Button
Figure 12
Downward
Upward
Minimum
Maximum
Figure 11

Operation
To operate the door simply press the hand held transmitter or
the control unit switch for two seconds and the door will
automatically open or close. The door can be stopped during
the opening or closing cycle by pressing the control unit switch
or handheld transmitter. The next actuation will move the door
in the opposite direction.
Safety Obstructive Reverse
While the door is in the closing cycle it will automatically reverse
if it hits an obstacle or is restricted in some way. The amount
of pressure the door applies before reversing is adjustable.
Similarly, if restricted whilst opening the door will stop.
Automatic Courtesy Light
The Courtesy Light on the opener comes on automatically
whenever the door is activated to do an opening or closing
cycle. The light will stay on for
approximately three minutes before turning off.
Security Code Store
The opener uses state of the art microchip 1 technology in
storing your Rolling Code Transmitter Security Code. Up to
20 different remote control codes can be stored in the non-
volatile memory device. To store any code simply press the
LEARN button on the opener and press the remote control
button twice. The codes can be deleted at any time. Security
is enhanced because the fixed and encrypted sections
combined increase the number of combinations to 7.38 x
1019. There are no Dip switches on the opener which can be
visually seen and copied.
Open and Close Drive Button
Another feature developed to aid in the installation of the
opener are the 0/S/C Buttons. These buttons are used to help
set the open and close limit positions. The quicker setting time
and a more precise limit position can be achieved using this
system.
Auto Close Mode
The opener can be programmed to automatically close
approximately thirty seconds after the door has opened. A
Photoelectric Beam must be installed if this mode is selected.
Auto Run Time
If the motor is left running in the disengaged mode for any
reason the Auto Run Time will turn the motor off after 30
seconds.
Photo Electric Beam
The opener has an input for a Photo Electric Beam to be
connected for extra safety protection.
Maintenance
No particular maintenance is required for the Motor Control
Unit. However, check at least twice a year that the unit is in
proper working order. Adjust if necessary the motor force.
Make sure that the safety devices are working effectively.
Check once a month that the drive reverses when an object
(40mm or higher) is placed in the door’s path.
If you experience any problems, contact ORCA on
Freephone 0800 ORCAHELP
Features
Your automatic roller door opener has many features which
you will appreciate. The components and materials used in
this control board are of the latest technology and highest
quality. Below are listed some of the features,

SafetyAce
Fire Extinguisher
Great for the home, garage, vehicle, caravan,
boat. A small sized extinguisher that packs a
powerful punch.
Designed for class A, B and E fires, the SafetyAce
is just what you need!
Cat. OSA-FE
Don’t forget these other great ORCA products . . .
SafetyAce
Smoke Alarm Range