Richards-Wilcox DYNA-HOIST DC Series User manual

PB 1
DC Direct Drive Commercial
Door Operator
Installation Manual and
Setup/User Instructions
FOR USE ONLY WITH PROPERLY BALANCED
SECTIONAL DOORS AND ROLLING STEEL
Dyna-Hoist DC Installation
Manual and Setup/User Instructions-R0
Engineered for Life
www.rwdoors.ca/dynahoist
DYNAHOIST
DC SERIES

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 21
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 22
Set Calibration .........................................................................................................................................................Page 23
Set Maintenance Schedule...................................................................................................................................Page 23
Set Red Flashing .....................................................................................................................................................Page 23
Set Advanced Red .................................................................................................................................................. Page 23
Set Open Limit Switch........................................................................................................................................... Page 23
Set Close Ramp-Up Time .....................................................................................................................................Page 23
Set Motion Detect Time......................................................................................................................................... Page 24
Set Factory Reset....................................................................................................................................................Page 24
Exiting ADVANCED Menu.....................................................................................................................................Page 25
Power Outage Operation................................................................................................................................................... Page 25
Battery Information .............................................................................................................................................................. Page 25
Car Wash/Water Resistant Applications ....................................................................................................................... Page 25
Components .........................................................................................................................................................................Page 26
Troubleshooting Guide ....................................................................................................................................................... Page 27-29
Replacement Parts List ......................................................................................................................................................Page 29
Warranty.................................................................................................................................................................................Page 30
FOR DYNA-HOIST DC SERIES TECHNICAL SUPPORT
PLEASE CALL 1-833-785-7332

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GENERAL OVERVIEW
Thank you for purchasing this Dyna-Hoist 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 soft-start/soft-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 Dyna-Hoist 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 Dyna-Hoist 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. Shaft Collar and Shaft Key
6. Reversing Device – Reflective Photo-eye (Thru-Beam Photo-Eye included on Dyna-Hoist 1000/2000)
7. Two 12V, Lead-Acid Rechargeable Batteries (3 Batteries fo Dyna-Hoist 2000)
In case any of the above items is missing, please contact Richards-Wilcox and provide us with details of the
missing part(s), as well as the serial number of your operator.
OPERATOR TECHNICAL OVERVIEW
Motor
HORSEPOWER: DC500 = ½ HP DC750 = ¾ HP DC1000 = 1 HP DC2000 = 2 HP
SPEED: 1750 RPM
CURRENT (FLA): ½ HP = 5A ¾ HP = 7.6A 1 HP = 10A 2 HP = 10A(208-240Vac)
OUTPUT TORQUE: Dyna-Hoist500 = 54Nm,Service Factor 1.6
Dyna-Hoist750-1 = 80Nm, Service Factor 1.1
Dyna-Hoist750-1.25 = 108Nm, Service Factor 2.0
Dyna-Hoist1000 = 147Nm, Service Factor 1.5
Dyna-Hoist 2000 =

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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
r edundancy.
Maximum Recommended Counter balance Sectional Door size
Dyna-Hoist 500: up to 200 Square Feet
Dyna-Hoist 750: up to 350 Square Feet
Dyna-Hoist 1000: up to 500 Square Feet
Dyna-Hoist 2000: over 500 Square Feet
IMPORTANT
WARNING – These instructions are intended for experienced personnel trained for service and in-
stallation 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 ft) or more above the floor: or
b. If the operator must be installed less than 2.44m (8ft) 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 ft) 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.

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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 DYNAHOIST OPERATORS, BUT MUST BE INSTALLED PRIOR TO OPERATION.
Operator Mounting Requirements
Dyna-Hoist operators are mounted directly on the door shaft. Before installing the operator, please ensure follow-
ing 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 shaft 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 shaft), and
24” vertically below the shaft. 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 ft. from ground level, within clear sight of the
door but far enough away as to prevent users from
contacting moving parts).
Left Hand Mounting:
The factory default mounting as shown
(Shown in Fig: 2) is for left-hand side of the
door, hence no modification is required.
FIGURE: 1
FIGURE: 2
Magnet on
this side
Encoder
FIGURE: 1A

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Right Hand Mounting:
The software 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 left-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 shaft from
the right side of the gearbox and gently tap out the
encoder magnet assembly wedged in the left side of the
gearbox hollow shaft.
Align the key and insert the magnet assembly into the
right side of the hollow shaft and gently tap with a
rubber mallet until it is slightly recessed 1 mm (1/32”) in the hollow shaft (level with the inner bevel edge of
the hollow shaft). 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 Shaft Off-set.
FIGURE: 3
FIGURE: 4
Magnet on
this side
Encoder

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TORQUE ARM POSITION IN RELATION TO OPERATOR

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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 after 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
Shaft Collar/Key Installation
The Shaft Collar serves as an end-stop for the gearbox on the shaft 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 shaft keyway is facing up (you may have to
open/wedge/clamp the door open slightly to achieve this).
Loosen the Shaft Collar set screw and slide it over the shaft
approximately 3 ½” from its end.
Insert the 3 inch long key (provided with operator) into the door shaft
keyway with one end flush to the end of the shaft.
Slide the collar back so that it touches the key, which should still be flush with the shaft end on its opposite side (the key
sits in the keyway between the collar and the end of the shaft), see Fig: 5.Firmly tighten the set screw of the collar onto
the shaft. 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 shaft to an appropriate length.
FIGURE: 5

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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 Shaft Collar/Key Installation on previous page) located on the
mounting side of the shaft.
Slide the gearbox onto the shaft until it makes contact with the Key
Shaft 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 ft. 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 (after 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