RYTEC System 4 Operating instructions

System 4
Drive & Control
RY-WITM SYSTEM
RYTEC HIGH PERFORMANCE WIRELESS TECHNOLOGY
Installation & Owner’s
Manual
[Revision: Dec. 19, 2011, 00152000, ©Rytec Corporation, 2011]
®

TABLE OF CONTENTS
PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrician’s Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SHIPPING CRATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTROL PANEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Scrolling Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plug-In Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SYSTEM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Power Supply Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External Emergency Stop Switches (N.C. Contacts) . . . . . . . . . . . . . . . . .12
Breakaway Bottom Bar (Input 1 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . 13
Photo Eye — Front (Input 2 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . .13
Photo Eye — Rear (Input 3 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . . . 13
Alternate-Action Activator (Input 4 — N.O. Contact) . . . . . . . . . . . . . . . . .14
Auto-Close Activator 1 (Input 5 — N.O. Contact) . . . . . . . . . . . . . . . . . . . .14
Auto-Close Activator 2 (Input 6 — N.O. Contact) . . . . . . . . . . . . . . . . . . . .14
Open (Input 8 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Close (Input 9 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Stop (Input 10 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programmable (Inputs 11 and 12 — N.O. or N.C. Contact) . . . . . . . . . . . . 14
DC Power Supply — Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
DC Power Supply — Auxiliary Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Reversing Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SYSTEM START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
AUTOMATIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
NON-AUTOMATIC MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Parameter Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
SYSTEM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
SERVICE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clock Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACCESSING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parameter Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Navigating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Accessing Service Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting Door Limits (Open, Intermediate, and Close) . . . . . . . . . . . . . . . . 23
Setting Automatic Delay Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SYSTEM RESET (MANUAL RESET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIRELESS REVERSING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parameters for Wireless System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SYSTEM PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
OPERATOR LEVEL PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE LEVEL 2 PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLOCK PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CLOCK INPUT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SWITCHING CLOCK PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GENERAL OPERATION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DOOR SAFETY/EMERGENCY FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . .42
REVERSING EDGE CIRCUIT FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DRIVE SYSTEM FAULT CODES (400-LEVEL CODES). . . . . . . . . . . . . . . . . . . . . 44
DRIVE SYSTEM FAULT CODES (500-LEVEL CODES). . . . . . . . . . . . . . . . . . . . . 45
DOOR POSITION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
WIRELESS SYSTEM FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DELAY TIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
MISCELLANEOUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
DOOR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
SPECIAL STATUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DOOR LIMIT MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DOOR JOG MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DOOR STATUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PROGRAMMABLE TEXT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
TROUBLESHOOTING WITH STATUS LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
PLUG-IN MODULES (OPTIONAL ITEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
GENERAL - INCOMING POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
GENERAL - ENCODER AND PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
GENERAL - RADIO CONTROL AND E-STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GENERAL - BOTTOM BAR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
GENERAL - CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
PARTS ORDERING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
How to Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
SERIAL NUMBER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Substitute Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Return of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
ELECTRICIAN’S QUICK GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CONTROL PANEL — STANDARD PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

INTRODUCTION—DOOR SERIAL NUMBER(S)
1
INTRODUCTION
NOTE: This manual is intended for the System 4
Drive & Control only. Installation and oper-
ation information specific to your door is
detailed in the installation and owner’s
manuals that were shipped with the door.
The installation and operation of the System 4 Drive &
Control®is not difficult, providing you follow the proce-
dures outlined in this manual. Any unauthorized
changes to these procedures, or failure to follow the
steps as outlined, will automatically void our warranty.
Any changes to the working parts, assemblies, or spec-
ifications as written, not authorized by Rytec Corpora-
tion, will also cancel our warranty. The responsibility for
the successful operation and performance of this drive
and control system lies with the owner of the door.
DO NOT INSTALL, OPERATE, OR PERFORM MAIN-
TENANCE ON THIS DRIVE AND CONTROL SYSTEM
UNTIL YOU READ AND UNDERSTAND THE
INSTRUCTIONS IN THIS MANUAL.
If you have any questions, contact your Rytec represen-
tative or call the Rytec Customer Support Department
at 800-628-1909. Always refer to the serial number of
the door that your control system is connected to when
calling the representative or Customer Support. Refer to
the installation manual or the owner’s manual provided
with your door for the location of the serial number plate.
The wiring connections and schematics in this manual
are for general information purposes only. A wiring
schematic is provided with each individual door, specif-
ically covering the control panel and electrical compo-
nents of that door. That schematic was shipped inside
the cardboard box containing the control panel.
DOOR SERIAL NUMBER(S)
Yo u r DOOR SERIAL NUMBER information can be
found in three universal locations. These are at the
inside of either side column (approximately eye level),
on the drive motor, and on the inside door of the System
4 control panel. (See Figure 1)
IMPORTANT: When installing multiple doors
of the same model but in differ-
ent sizes, verify the serial num-
ber in the control panel with the
one on the door assembly.
NOTE: Figure 2 shows a sample decal. Different
model doors have serial numbers that
start with different numerals.
Figure 1
Figure 2
A9500221
System 4
Left Side
Right Side
Control
Panel
Column
Column
Drive Motor
A5400013

INTRODUCTION—HOW TO USE MANUAL
2
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader of potentially hazardous situa-
tions, or situations where additional information to suc-
cessfully perform the procedure is presented:
WARNING is used to indicate the potential
for personal injury, if the procedure is not
performed as described.
CAUTION is used to indicate the potential
for damage to the product or property
damage, if the procedure is not followed
as described.
IMPORTANT: IMPORTANT is used to relay
information CRITICAL to the
successful completion of the
procedure.
NOTE: NOTE is used to provide additional infor-
mation to aid in the performance of the
procedure or operation of the door, but not
necessarily safety related.
REQUIRED TOOLS AND EQUIPMENT
1. Wall anchor hardware (¹₄-in. diameter).
2. Carpenter’s level.
3. Hammer drill and masonry drill bit sized for wall
anchors (to install anchor hardware in concrete).
4. Assorted hand tools.
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. An electrician is required for all electrical connec-
tions. (See “Electrician’s Responsibilities” below.)
IMPORTANT: All electrical work must be per-
formed in accordance with local
and state building codes.
2. 100% accessibility to the door opening during the
installation process. Traffic should not pass through
the opening during the installation procedure.
Electrician’s Responsibilities
1. Furnish and install fused disconnect(s).
2. Install Rytec control panel.
3. Install all necessary conduit.
NOTE: High- and low-voltage cables must be
routed in separate conduit. High voltage
must use metallic conduit.
4. Run electrical power lines to fused disconnect.
5. Run power lines from disconnect to control panel.
6. Run power and control lines from control panel to
door head assembly (and defrost system if used).
7. Install conduit from control panel to floor for floor
loop activators and wire activators (if used).
8. All cables must be cut to length. No excess of high-
or low-voltage cables should be present in the con-
trol panel.
SHIPPING CRATE
The control panel was shipped from the factory in a
cardboard box along with the contents of your Rytec
door.
NOTE: A door-specific electrical schematic is
located inside the control panel.

SYSTEM OVERVIEW—CONTROL PANEL
3
SYSTEM OVERVIEW
CONTROL PANEL
The Rytec System 4 Drive & Control is a solid-state,
microprocessor-based control system designed exclu-
sively to operate your Rytec high-performance door.
(See IMPORTANT below.) It combines an AC drive with
the latest in door control technology.
The AC drive system controls the drive motor through
soft accelerations and soft decelerations. The operating
parameters are accessed through the up (▲), down
(▼), and reset (●) keys located on the keypad on the
front of the control panel. A scrolling display shows all
corresponding control and door status messages.
NOTE: The RESET key also serves as the ENTER
key and the STOP key.
IMPORTANT: The System 4 control panel
allows for configurable supply
voltage. Voltages can range from
200–500 volts AC. The System 4
can also be configured to
receive both single- and three-
phase voltages. The supply volt-
age MUST match the voltage
andphase as listed on the electri-
cal schematic provided with the
control panel. Failure to provide
the required voltage and phase
may damage the controller. If
voltage and phase do not match
supply, contact the Rytec Cus-
tomer Support Department at
800-628-1909.

SYSTEM OVERVIEW—CONTROL PANEL
4
Figure 3
IMPORTANT: All conduit entering the control panel must enter from the bottom of the panel — High voltage
from the bottom left and low voltage from the bottom right. Installing conduit through the top
or sides of the control panel will void the warranty.
A5400011

INSTALLATION—CONTROL PANEL INSTALLATION
5
INSTALLATION
CONTROL PANEL INSTALLATION
IMPORTANT: The control panel must be
installed in an area having a tem-
perature range of –4°F to 149°F.
Consult the factory if the temper-
atures approach these limits.
IMPORTANT: The fused disconnect and the
control panel must be installed
within sight of the door.
NOTE: The control panel and fused disconnect
are generally located adjacent to the drive
end of the head assembly.
Install the System 4 control panel and the fused discon-
nect as shown in Figure 4.
The System 4 control panel has three mounting loca-
tions on the black plastic enclosure. One is on the top of
the enclosure in the center and two are at the bottom of
the enclosure ( See Figure 5). Use these mounting loca-
tions along with user-supplied hardware to securely
mount the panel at the chosen location.
IMPORTANT: The mounting surface must be
structurally sound and free of
mechanical shock or vibration.
IMPORTANT: All conduit entering the control
panel must enter from the bot-
tom of the panel — High voltage
from the bottom left and low volt-
age from the bottom right.
Installing conduit through the
top or sides of the control panel
will void the warranty.
Figure 4
Figure 5
A9500221
Fused
System 4
Control Panel
Disconnect
Bottom Mounts
Top Mount
A5400020
NOTE: Panel housing shown
.
disassembled for clarity.

INSTALLATION—CONTROL PANEL INSTALLATION
6
The System 4 panel door is hinged at the top for easy
access to the terminal blocks. To open the door, loosen
the six screws along the door face as shown in Figure 6
and lift the door slightly out to release screws. Then lift
the door up as shown in Figure 7. The door can be
removed from the controller by disconnecting the door
electrical harness and depressing the tabs at the top of
the controller to release the hinges from the controller
body as shown in Figure 8.
Figure 6
Figure 7
Figure 8
A5400033
Mounting Screw
A5400035
A5400037
Door Hinge
Electrical
Harness

INSTALLATION—CONTROL PANEL INSTALLATION
7
Grounding of the power supply is essen-
tial to the safety of personnel as well as the
operation of the System 4 Drive & Control.
A floating, ungrounded or open delta type
power supply can permit dangerously
high voltage between the chassis of the
drive and the internal power structure
components (see Figure 9). In many cases,
this voltage could exceed the rating of the
input MOV protection devices of the drive,
causing catastrophic failure of the System
4 Drive & Control. In all cases, the input
power to this controller must be refer-
enced to ground (see Figure 10). If the ser-
vice transformer cannot be grounded,
then an isolation transformer must be
installed with the secondary of the trans-
former grounded. Please consult the fac-
tory for additional information regarding
isolation transformers or service suitabil-
ity.
Figure 9
NOTE: Cables must be cut to length. There can-
not be any excess cable present in the
control panel or any excessive cable bun-
dles present on the outside of the control
panel.
Figure 10
WIRING NOTE: All wiring from the fused discon-
nect to the control panel, from the control
panel to the optional junction box and the
door, and from the conduit between the
control panel and the floor (if a floor loop is
used) must be supplied by the owner of
the door. The wiring and conduit must
meet all local and state building codes.
Wires leading from the door are labeled
with the terminal numbers that are associ-
ated with the control panel. The high and
low voltage lines must run in separate con-
duit — otherwise, the warranty will be void.
Use shielded wire as indicated on the
schematic. If a wire cable is to be
extended or spliced, a like cable must be
used throughout the entire length of that
cable. Likewise, if a shielded cable is to be
extended or spliced, a like cable must be
used throughout the entire length of that
cable as well — otherwise, the warranty
will be void.
All conduit entering the control panel
must enter from the bottom of the panel
— High voltage from the bottom left
and low voltage from the bottom right.
Installing conduit through the top or
sides of the control panel will void the
warranty.
A5500019
A5500020

INSTALLATION—CONTROL PANEL INSTALLATION
8
IMPORTANT: The System 4 panel conduit con-
nection locations are NOT knock-
outs. Do NOT use impact to
remove the conduit connection
bosses, or damage to the panel
housing can occur. A drill and
suitable drill bit should be used
to remove the plastic for conduit
connection. (See Figure 11.)
Figure 11
IMPORTANT: If your door is to be mounted on
a freezer, mount the control
panel and the fused disconnect
on the warm side of the wall. It
may also be necessary for you to
install more than one fused dis-
connect. To ensure the equip-
ment is de-energized during
maintenance or service, turn off
all disconnects.
IMPORTANT: Protect the components inside
the control panel from metal
chips when installing conduit.
Seal inside the conduit and
panel if the conduit entering the
panel is coming from an area
having a different temperature
(warmer or colder) than the area
where the panel is located.
IMPORTANT: The schematics shown through-
out this manual are for informa-
tion purposes only. Due to
varying requirements of each
customer, a schematic has been
prepared for your particular door
and it must be used for this
installation. That schematic was
shipped inside the control panel.
The disconnect must be in the OFF position
and properly locked and tagged before wir-
ing of the control panel begins.
IMPORTANT: All conduit entering the control
panel must enter from the bot-
tom of the panel — High voltage
from the bottom left and low volt-
age from the bottom right.
Installing conduit through the
top or sides of the control panel
will void the warranty.
High voltage is present inside this control
panel. Do not touch the circuit board, elec-
trical components, or wiring inside this
panel with power applied.
You must wait at least five minutes after
power is turned off before you can begin
work on the control panel or motor con-
nections. The drive control inside the
panel contains high-voltage capacitors
which take time to discharge once power
is turned off.
A5400021

INSTALLATION—CONTROL PANEL INSTALLATION
9
A small cardboard box has been shipped with the con-
trol panel. This box contains five ferrite core magnets.
These ferrite core magnets are to be installed on the
incoming L1, L2, and L3 supply voltage wires and also
on the T1, T2, and T3 motor connections. The ferrite
core magnets act as a filter for the incoming supply
power and voltage passing to the motor. These filters
help to reduce electrical noise in the power system. See
Figure 12 for proper installation of the ferrite core mag-
nets.
NOTE: Failure to install the ferrite core magnets
as illustrated will void the manufacturer’s
warranty.
Failure to install the ferrite core magnets
will void the manufacturer’s warranty and
potentially cause irreparable damage to
the System 4 control panel.
Figure 12
NOTE: It is not necessary to run the supply volt-
age ground wire (green wire) through the
ferrite core magnet.
A5400029-30
Motor Connection
Magnet Location
Supply Voltage
Magnet Location
Green
Ground Wire

INSTALLATION—CONTROLLER
10
CONTROLLER
Located inside the control panel is an electronic control-
ler. This controller includes a scrolling display, terminal
blocks and screws, and other miscellaneous electrical
components. (See Figure 13.)
Figure 13
Scrolling Display
All door commands and door status messages appear
on the scrolling display. Also displayed are the cycle
counter, timer settings, alarm conditions, program set-
tings, and other miscellaneous messages.
The display is located near the top of the controller and
can be viewed through the window on the front of the
control panel.(See Figure 13.)
USB Connector
The USB drive logs the function of the door and allows
for programming the door using a Rytec encrypted soft-
ware program. Removing the USB drive will affect the
operation of the door. DO NOT remove the USB drive
unless informed by the Rytec Customer Support
Department to do so.
Status LEDs
Located on the controller are various light-emitting
diodes (LEDs). These diodes are helpful when trouble-
shooting the door and control system. The LEDs indi-
cate the operating status of the control system, the door,
activators, safety devices, and any other input device
connected to the control system. (See Figure 14.)
For detailed information on troubleshooting the control
system using the status LEDs, see “TROUBLESHOOT-
ING WITH STATUS LEDS” on page 52.
Figure 14
A5400016
Scrolling
Terminal Block(s)
Terminal
Screws
Battery
USB Connector
Service Switch
Display
A5400016
Reversing
Edge LEDs
Input LEDs
Run LEDs
(Green)
Red
Green
Ajar LED
24 V Short
LED

INSTALLATION—CONTROLLER
11
Plug-In Modules
For a door set up to be operated by a radio control or a
floor loop, a corresponding plug-in module for each type
of activator is required. The connectors for these mod-
ules are located along the right edge of the lower printed
circuit board. (See Figure 15.)
Figure 15
NOTE: The induction loop module for the System
4 (part #00122000) is different from the
module for the System 3. The System 4
module is physically smaller. Therefore,
the System 3 loop module will not fit in the
System 4 control. (See Figure 16.)
Figure 16
Radio Receiver
Module
Induction L oop
Module
A5400016 A5400024
Loop Wire
Te r m i n a l B l o c k

INSTALLATION—SYSTEM INPUTS
12
SYSTEM INPUTS
The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
Input terminals 200 through 293 support
+24 VDC only. All remaining input termi-
nals are dedicated for specific devices.
Connecting any other voltage or device
other than those intended may result in
damage to the control system.
NOTE: If the expansion board is installed in the
controller, there are additional input termi-
nals 300 through 363.
All high-voltage connections (L1, L2, and L3 supply volt-
age wires and the T1, T2, and T3 motor connections)
are made on the lower left terminal blocks. These con-
nections need to be in mettalic conduit entering from the
bottom left corner of the control panel. All low-voltage
connections (+24 VDC) should enter the bottom right of
the control panel and terminate on both the top and bot-
tom circuit boards. (See Figure 17.)
Figure 17
Power Supply Lines
Connect the power supply lines from the fused discon-
nect to the control panel as shown on the schematic that
was shipped with the door.
Motor
Connect the motor wires to the control panel as shown
on the schematic that was shipped with the door.
NOTE: Motor cable cannot exceed 100 feet. Cut
all excess cable to desired length. Refer-
ence the electrical schematic that came
inside the control panel for proper ground-
ing.
Motor Brake
Connect the motor brake to the control panel as shown
on the schematic that was shipped with the door.
Encoder
Connect the encoder to the control panel as shown on
the schematic that was shipped with the door.
External Emergency Stop Switches (N.C. Contacts)
Factory-installed jumper wires are provided in the E-
Stop connections. Refer to the door-specific electrical
schematic for information regarding E-Stop connection.
E-Stop 1 terminals are located at block X24, terminals
240 and 241. E-Stop 2 terminals are at block X25, ter-
minals 250 and 251. E-Stop 3 terminals are at block
X26, terminals 260 and 261.
A5400016
Terminal Block(s)
Te r m i n a l
Screws

INSTALLATION—SYSTEM INPUTS
13
Breakaway Bottom Bar (Input 1 — N.C. Contact)
The breakaway bottom bar signal is incorporated with
the RY-WI wireless reversing edge signal. The break-
away electrical connections are connected to terminals
5 and 6 on the RY-WI mobile unit in the bottom bar. That
signal is then transmitted from the mobile unit to the
antenna located on the head assembly of the door. The
antenna then sends the breakaway signal down the red
wire (encoder cable) to terminal 271 in the controller.
See the schematic that was shipped with the door.
If the bottom bar becomes disconnected from either
side column, a loss of this input will immediately stop
the door and “Door Ajar” will appear on the display.
(See Figure 18.)
Figure 18
NOTE: If you find it necessary to reposition the
bottom bar in order to reattach it, the door
can be jogged up or down by pressing and
holding the up (▲)or down (▼)key.
Push and hold the Stop, Reset and Enter
buttons until the system resets.
Once the bar is reattached and the control
system reset, the up (▲), down (▼), and
reset (●)keys will automatically return to
their normal operation.
Photo Eye — Front (Input 2 — N.C. Contact)
Connect the front set of photo eyes to the control panel
(terminal 222 located on block X22) as shown on the
schematic that was shipped with the door.
An interruption of this input (object between photo eyes)
while the door is closing will reverse the door and move
it to the open position. Only after the object is removed
from between the photo eyes will the door be allowed to
close.
If the door was initially opened by a non-automatic
activator, the door must be closed with a non-automatic
activator. If the door was initially opened by an auto-
matic activator, the door will automatically close after
the auto-close delay timer (ACL1 or ACL2) times out.
(See Figure 19.)
Figure 19
Photo Eye — Rear (Input 3 — N.C. Contact)
Connect the rear set of photo eyes to the control panel
(terminal 232 located on block X23) as shown on the
schematic that was shipped with the door.
An interruption of this input (object between photo eyes)
while the door is closing will reverse the door and move
it to the open position. Only after the object is removed
from between the photo eyes will the door be allowed to
close.
If the door was initially opened by a non-automatic
activator, the door must be closed with a non-automatic
activator. If the door was initially opened by an auto-
matic activator, the door will automatically close after
the auto-close delay timer (ACL1 or ACL2) times out.
(See Figure 20.)
Figure 20
0
Er ro Jog
F06 rooarjA
rlynO
D
t
reld
yo r
O
e
oo pe
hPe
F
DnH
222
o
t
reld
yo r
O
e
oo pe
hPe
R
DnH
223
o

INSTALLATION—SYSTEM INPUTS
14
Alternate-Action Activator (Input 4 — N.O. Contact)
Connect the alternate-action activator to the control
panel (terminals 210 and 211) as shown on the sche-
matic that was shipped with the door.
If this input is enabled (momentary contact) with the
door closed, closing, or stopped between the door lim-
its, the door will open. When this input is enabled with
the door open, the door will close. Typical activators tied
to this input include pull cords, push buttons, and radio
controls.
Auto-Close Activator 1 (Input 5 — N.O. Contact)
Connect auto-close activator 1 to the control panel (ter-
minals 210 and 212) as shown on the schematic that
was shipped with the door.
If this input is enabled with the door closed, closing, or
stopped between the door limits, the door will open. The
door will remain open as long as the input is enabled.
Once the input is disabled, the auto-close delay timer
(ACL1) will start. When the timer times out, the door will
automatically close.
An activated timer will automatically reset when the auto
input is enabled. To disable a timer, set the time delay
parameter (P:010) to zero (0) to turn timer off.
Typical activators tied to this input include floor loops
and motion detectors. (This input is exclusive of the
inputs described in “Plug-In Modules” on page 11.)
Auto-Close Activator 2 (Input 6 — N.O. Contact)
Connect auto-close activator 2 to the control panel (ter-
minals 230 and 233) as shown on the schematic that
was shipped with the door.
If this input is enabled with the door closed, closing, or
stopped between the door limits, the door will open. The
door will remain open as long as the input is enabled.
Once the input is disabled, the auto-close delay timer
(ACL2) will start. When the timer times out, the door will
automatically close.
An activated timer will automatically reset when the auto
input is enabled. To disable a timer, set its time delay
parameter to zero (0) seconds. Parameter P:015 = 0 to
turn timer off.
Typical activators tied to this input include floor loops
and motion detectors. (This input is exclusive of the
inputs described in “Plug-In Modules” on page 11.)
Open (Input 8 — N.O. Contact)
Connect the open input to the control panel (terminals
200 and 201) as shown on the schematic that was
shipped with the door.
If this input is enabled (momentary contact) with the
door closed, closing, or stopped between the door lim-
its, the door will open. This input is ignored while the
door is opening.
Close (Input 9 — N.O. Contact)
Connect the close input to the control panel (terminals
200 and 202) as shown on the schematic that was
shipped with the door.
If this input is enabled (momentary contact), the door
will close if the door is open or stopped. This input is
disabled when the door is closing and ignored if the door
is closed or opening.
Stop (Input 10 — N.C. Contact)
Input 10 is equipped with a factory-installed jumper.
Refer to door-specific electrical schematics for informa-
tion regarding this connection.
Programmable
(Inputs 11 and 12 — N.O. or N.C. Contact)
Programmable inputs (if used) are connected to the
control panel (terminals 290 and 291 or terminals 290
and 292) as shown on the schematic that was shipped
with the door.
These inputs can be assigned various functions such as
a third set of photo eyes or an air lock activator.