RYTEC PredaDoor NXT User manual
TABLE OF
CONTENTS
PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOLS AND EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
2
FLOOR LOOP EQUIPMENT
REQUIREMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . .
.
2
BASIC JOB REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
2
ELECTRICIAN’S RESPONSIBLITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
2
GENERAL ARRANGEMENT OF DOOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .
.
2
ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
3
Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
3
Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
3
Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
3
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . .
.
3
LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
4
SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
5
SPREADER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
6
Door without Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
6
Door with Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
7
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
7
BOTTOM
BAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
10
ENCODER MAGNET, ENCODER AND WIRELESS ANTENNA. . . . . . . . . . . . . . 10
Install the encoder magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install the encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
11
Install the wireless antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
11
Wire the encoder to the System 4 controller . . . . . . . . . . . . . . . . . . . . . .
.
11
PHOTO EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
12
Testing Photo Eye Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
13
ELECTRICAL WIRING ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
14
CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . .
.
14
DOOR OPEN- AND CLOSE-LIMIT POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . .
.
14
Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
14
Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
15
PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . .
.
15
Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . .
.
15
Reversing Edge Switch Sensitivity
Adjustment
. . . . . . . . . . . . . . . . . . . .
.
16
PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . .
16
Kill Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
16
Kill Switch Air Bleed
Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
17
Kill Switch Sensitivity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
17
RESETTING BOTTOM BAR
ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
18
PHOTO EYE
ADJUSTMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
18
ALUMINUM HOOD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
19
ABS HOOD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
19
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
21
1
Right Side
Column
INTRODUCTION—DOOR SERIAL NUMBER(S)
INTRODUCTION
The information contained in this manual will allow you
to install your
Rytec
PredaDoor NXT® Door in a manner
that will ensure maximum life and trouble-free
operation.
Any
unauthorized
changes in
procedure,
or failure to
follow the steps as outlined in this manual, will
automatically void the warranty. Any changes to the
working parts, assemblies, or specifications as written
that are not authorized by Rytec Corporation will also
cancel the
warranty. The responsibility for the
successful operation and
performance
of this door lies
with the owner of the door.
IMPORTANT: When installing multiple doors
of the same model but in
different sizes, verify the serial
number on the control panel
with the one on the side column.
Left Side Column
Drive Motor
DO NOT OPERATE OR PERFORM MAINTENANCE
ON THIS DOOR UNTIL YOU READ AND UNDER-
STAND THE INSTRUCTIONS CONTAINED IN THIS
MANUAL.
If you have any questions, contact your Rytec representative
or call the Rytec
Technical
Support
Department
at 800-628-
1909. Always refer to the serial number of the door when
calling the representative or Technical Sup- port. The serial
number plate is located on the small edge of the left side
column. (See Figure 1.)
Rytec
System 4
Control Panel
Serial Number
Location
NOTE: Left side column shown.
Figure 2
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader of potentially hazardous
situations, or situations where additional information to
successfully perform the procedure is presented:
Serial Number
Decal
A7700034
Figure 1
The wiring connections in this manual are for general
information purposes only. A wiring schematic is pro-
vided with each individual door specifically covering the
control panel and electrical components of that door.
That schematic was shipped inside the control panel.
DOOR SERIAL NUMBER(S)
Your DOOR SERIAL NUMBER information can be
found in three universal locations. These are at the
small edge of the left side column
(shown
in figure 1), on
the drive motor, and on the System 4 control panel.
(See Figure 2.)
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
that is CRITICAL to the suc
cessful
completion
of
the
procedure.
NOTE: NOTE is used to provide additional
information to aid in the performance of
the procedure or operation of the door, but
not necessarily safety related.
2
INSTALLATION—TOOLS AND EQUIPMENT REQUIRED
INSTALLATION
TOOLS AND EQUIPMENT REQUIRED
1. Socket and wrench set.
2. Concrete anchor bolts (1/2-in. diameter).
(See “ANCHORING METHODS” on page
3.)
3. Threaded rod (1/2-in. diameter).
(See “ANCHORING METHODS” on page
3.)
4. Two ladders (taller than the door opening height).
5. Forklift.
6. Carpenter’s level (4-ft. minimum length).
7. Carpenter’s square.
8. Hammer drill.
9. Masonry drill bit (1/2-in. diameter).
10. Three or four bar clamps (1-ft. length).
11. Hammer and mallets.
12. Crowbar or pry bar.
13. Assorted hand tools (pliers, tape measure, etc.).
14. Assorted shim stock.
15. Water level, line level, or transit.
3. The customer must guarantee 100% access to the
door opening during the installation. No traffic
should be allowed through the door during the
installation.
4. If an electrician is used, that person must make all
electrical connections. The electrician should be
present one hour after installation begins.
5. The Rytec control box and a fusible disconnect
should be installed prior to the start of the door
installation. (See Figure 1 for layout.)
ELECTRICIAN’S RESPONSIBLITIES
For complete details on the responsibilities of the
electrician, refer to the Rytec System 4 Drive & Control
Installation & Owner’s Manual.
GENERAL ARRANGEMENT OF DOOR PARTS
Figure 3 shows the location of the major components
of your
PredaDoor
NXT. This
illustration
should be
used as reference only and should not be used as part
of the installation instructions.
Drive Motor/Gearbox
Left Side Column
FLOOR LOOP EQUIPMENT REQUIREMENTS
1. Wet-type concrete saw.
2. Wet vac.
3. 200–500 feet of 16-gauge, 19-strand, type XLPE,
copper, crosslink polyethylene jacket wire (or
equivalent). The length of wire is determined by the
size of the loop.
4. Bondo® P606 flexible embedding sealer (or
equivalent) — required to fill grooves in floor. For
cold temperature sealing applications, Bondo P610
speed set must be added to the P606 to ensure
proper curing of the filler.
5. Water supply and garden hose (for concrete saw).
NOTE: For complete floor loop installation
instructions, refer to the installation
instructions provided with your floor loop.
BASIC JOB REQUIREMENTS
1. A forklift must be supplied by the customer, dealer,
or installer.
Fused
Disconnect
Rytec
System 4
Control Panel
Photo Eye
(Left)
A7700040
Bottom Bar
Figure 3
Fabric Roll
Photo Eye
(Right)
Right Side
Column
2. Two installers are required.
NOTE: One installer must be a qualified electrical
technician, and all electrical work must
meet applicable codes. If the installer is
not qualified, an electrician must be
present during installation.
NOTE: The above illustration shows the front side
of the door. Left and right are determined
when viewing the front side of the door.
3
(Front and Back Side — Full Length)
Through Bolt or
Threaded Rod
Side Column
INSTALLATION—ANCHORING METHODS
ANCHORING METHODS
Correct anchoring of the side columns to the wall and
the floor is important for the smooth and safe operation
of the door. The wall material should be strong enough
to support the weight of the door and all wall anchors.
Figure 4 through Figure 7 show anchoring methods for
various types of walls. Use the method that is best
suited for your particular installation site.
All necessary anchoring hardware and material
required
for the installation of this door is the responsibility of the
door owner. If you have any questions, call your Rytec
representative or the Rytec Technical Support
Department at 800-628-1909.
Insulated Walls
Through Bolt
or Threaded Rod
Insulated Wall
Aluminum-Clad Lumber
Side
Column
NOTE: Use 1/2-
in.
diameter threaded through
bolts
or 1/2-
in.
diameter threaded rods to anchor
the door to all wall applications. Use 1/2-in.
diameter concrete anchor bolts to anchor
the door to a concrete floor or wall.
If expansion anchors are used, a quarterly
inspection should be implemented for safe
and secure door operation
A0500039
Figure 6
Insulated
Wall
Concrete, Block, or Brick Walls
Concrete Wall
Expansion
Anchor
Side
Column
A0500038
Aluminum-Clad Lumber
(Back Side — Full Length)
Figure 7
A0500005
Figure 4
LOCATING CENTERLINE OF DOOR OPENING
NOTE: Accurate
measurements
are critical for the
proper installation and operation of your
Rytec door. Verify all measurements.
1. Measure the width of the door opening.
Wood Walls
Figure 5
Side Column
Crush Plate
(1/2-in. Thick,
6-in. x 8-in. Steel)
Through Bolt or
Threaded Rod
Wood Wall
4
INSTALLATION—LOCATING SIDE COLUMNS
Half of Door
Production
Width
Centerline of
Opening
Centerline of
Opening
Overall Width
of Door Opening
A0500001
Half Width of
Door Opening A0500002
Figure 8
Extend and Mark
Edges of Door Along Floor
Figure 9
LOCATING SIDE COLUMNS
1. Locate the layout drawing of the door. It should be
attached to the small parts carton packed inside the
shipping crate. This drawing identifies the
production width of your door.
2. Using the centerline as a reference point, lay out
and mark half of the door’s production width along
the floor. (See Figure 9.)
This door is equipped with a breakaway
bottom bar assembly. To ensure that it
works properly, the width of the door
opening must not be smaller (narrower)
than the production width of the door.
If the width of the opening is narrower than
the width of the door, do not proceed with
the installation. Contact your Rytec
representative or Rytec Technical Support
Department at 800-628-1909.
3. With a carpenter’s square placed against the wall,
mark both sides of the door along the floor. Extend
the line along each edge.
4. Check the floor for level across the door opening.
The floor must be level within 0.12 in. from side to
side. If one side of the opening is higher than the
other, a shim under the side panel will be required.
Figure 10 and Figure 11 show two methods that
can be used to ensure level side columns.
NOTE: Contact the Rytec Technical Support
Department if the floor is more than 1 in.
out of level.
Line Level
This Dimension Must Be
Equal on Both Sides of
Door Opening
A0500003
Shim Plate
(If Required)
Figure 10
5
Production Width Line
(Side Column Must Be
Located on Outside
Edge of Line)
Left Side Column
Anchor Holes
(Two Anchors
Required)
This Dimension
Must Be Equal on
Both Sides of Door
Opening
INSTALLATION—SIDE COLUMNS
Motor Mount Side
Column Has Wire
Access Hole
Water Level
A0500004
SIDE COLUMNS
Figure 11
Shim Plate
(If Required)
A7700020
Figure 12
NOTE: The standard mounting location for the
motor/gearbox assembly on a PredaDoor
NXT door is on the left but can be ordered
to be mounted on the right. DO NOT
change the location of the drive motor
without first contacting your Rytec
representative or the Rytec Technical
Support Department at 800-628-1909.
The PredaDoor NXT has only one access
hole in each side column.
1. Remove the drive motor side column from the ship-
ping crate. The drive motor side column is identified
by the wire access hole along its outside edge.
(See Figure 12.)
2. Stand the drive motor side column on the floor and
tight against the wall. To determine on which side of
the door to place the side column, be sure that the
access holes are facing away from the door opening.
3. Align the inside edge of the side column with the
production width line laid out earlier on the floor.
The side column must be located on the outside
edge of the layout line. (See Figure 13.)
Anchor Holes
(Three Anchors
Required)
Anchor Hole for
Door Opening
Over 9 ft. 6 in.
A7700021
Figure 13
6
INSTALLATION—SPREADER ASSEMBLY
It is critical that the side columns are
mounted level and square to the wall and
floor, both vertically and horizontally. A
4-ft. level and carpenter’s square are
recommended for this procedure.
The use of bar clamps to secure the side
columns to the wall during installation is
recommended, as these hold the columns
securely in place, while allowing for slight
adjustments of either side column during
the installation of the head assembly.
NOTE: All necessary anchor hardware and material is
the responsibility of the door owner.
Serrated-Flange
Hex Screw
(Two on Each End)
Spreader
Extrusion
L-Shaped Support
Bracket (Mounted to
Top of Header
Extrusion)
4.
Once
the side
column
is
properly positioned,
secure
it to the wall using the appropriate anchors. (See
“ANCHORING METHODS” on page 3.) Anchor
holes have been provided in the side column. (See
Figure 13.) DO NOT tighten the anchor hardware at
this time.
A8500004
Figure 14
Serrated-Flange Hex
Nut (Two on Each End)
NOTE: Use 1/2-in. diameter expansion shell
stud- type anchors for concrete walls or
1/2- in. diameter threaded through bolts
for brick walls and other applications
where expansion bolts are not acceptable.
Use a tape measure to ensure that proper
width alignment is maintained between
the side columns, at the top and bottom
ends of each column. DO NOT tighten the
anchors at this time.
5. Mount the other side column to the wall in the same
manner as outlined above for the first side column.
SPREADER ASSEMBLY
Door without Hood Assembly
1. Attach an L-shaped support bracket to each end of
the spreader extrusion using two 3/8
-16
x 1 1/4-in.
serrated-flange hex screws and nuts. The brackets
and mounting hardware were shipped in the small
parts carton. (See Figure 14.)
2. Attach the spreader assembly to the inside face of
each side column using two 3/8
-16
x 1 1/4-in
.
serrated-flange hex screws and nuts at each end of
the assembly. Face the spreader so the brush is
toward the front of the door. (See Figure 15.)
L-Bracket (Fits
Behind Inside
Face of Side
Column)
Serrated-Flange
Hex Nut (Two
on Each End)
Serrated-Flange
Hex Screw (Two
on Each End)
Inside Face of
Side Column
A7700025
Figure 15
3. Check that the side columns are plumb and square
with the floor and wall.
4. Tighten all anchor hardware securing both side
columns (or pullouts) to the wall.
7
Header
Extrusion
INSTALLATION—HEAD ASSEMBLY
5. Remove any bar clamps that may have been used
to temporarily hold the side columns (or pullouts) to
the wall.
Door with Hood Assembly
NOTE: DO NOT change the location of the drive
motor without first contacting your Rytec
representative or the Rytec Technical
Support Department at 800-628-1909.
3. Attach the spreader assembly to the U-brackets
using two 3/8-16 x 1 1/4-in. serrated-flange hex
screws and nuts at each end of the assembly.
Face the spreader so the brush is toward the front
of the door. (See Figure 17.)
Serrated-Flange
Hex Screw
(Two Each Side)
1. Identify the drive motor side column by the wire
access holes along its outside edge. This is
important for the proper installation of the spreader
assembly.
2. Attach a spreader assembly U-bracket on the
outside face of each side column using two
3/8
-16
x 1 1/4-in
. serrated-flange
hex
screws
and
nuts for each bracket. The U-brackets and
mounting hardware were shipped in the small parts
carton. (See Figure 16.)
IMPORTANT: Attach the large U-bracket to the drive
motor side column with the screw hole
located 6-3/4 in. from the end of the
bracket, nearest to the outside face of
the side column. (See Figure 16.)
Support
Bracket
A8500153
Serrated-Flange
Hex Nut
(Two Each Side)
Left Side Column
Large
U-Bracket
6-3/4 in.
Small
U-Bracket
Large U-Bracket
(Drive Motor
Side Column)
Figure 17
4. Check that the side columns are plumb and square
with the floor and wall.
5. Tighten all anchor hardware securing both side
columns (or pullouts) to the wall.
6. Remove any bar clamps that may have been used
to temporarily hold the side columns (or pullouts) to
the wall.
HEAD ASSEMBLY
1. Before removing the head/fabric roll assembly from
the shipping crate, locate four
¹/₂
-13
x
1
¹/₄
-in.
serrated-
flange hex screws, four
¹/₂
-13
serrated-flange nuts,
and the flange bearing assembly in the small parts
carton.
NOTE: On a door configured with pullouts, the
Serrated-Flange
Hex Screw (Two
Each Side)
A8500152
Serrated-Flange
Hex Nut (Two
Each Side)
Figure 16
four 1 1/4-in. long serrated-flange hex screws
mentioned above in step 1 were not shipped
with the door. Instead, the longer 1/2-13 x 6-in.
hex screws that were installed earlier will be
used to attach the head assembly to the side
columns.
8
INSTALLATION—HEAD ASSEMBLY
Also, some oversized doors (with or with- out
pullouts) require a steel spacer between both side
columns and the head assembly. If your door is
oversized, locate two 9-in. x
1 3/4-in.
steel spacers
shipped in the small parts carton. (The spacers are
further identified by a hole at each end.)
If spacers were included in the small parts
carton but the door does not include
pullouts, four 1/2
-13
x 2-in. serrated-flange
hex screws were substituted for the slightly
shorte4 1/2-13 x
1 1/4-in.
screws mentioned
above in step 1. The 2-in. screws were
shipped in the small parts carton.
2. Remove the head/fabric roll assembly from the
shipping crate.
Before lifting the roll assembly, secure
both side columns to the building wall.
Secure the roll assembly to the forklift
before lifting. Failure to secure the side
columns or the roll assembly can result in
serious injury and property damage. DO
NOT remove the forklift until the assembly
is secured to both side columns.
IMPORTANT: If your door is oversized, two
large spacers were included in
the small parts carton. Failure to
install a spacer between the
motor mounting bracket and
flange bearing assembly could
result in damage to the door.
(See Figure 18 and Figure 19.)
5. Attach the motor mounting bracket to the side
column using two 1/2
-13
x
1 1/4-in.
serrated-flange
hex screws and nuts (or two 1/2
-13
x 2-in. screws
and nuts). Doors with 3 or more windribs will have
spacers for the drive and non-drive side to shim the
drum roll assembly away from the rear spreader.
Failure to install these spacers (if supplied) will
cause the drum roll to jamb against the rear
spreader due to the diameter of the drum roll.
Doors with 2 windribs or less will not have the shim
material. DO NOT tighten the hex nuts at this time.
(See Figure 18.)
Motor Mounting
Bracket
IMPORTANT: Install spacer between
motor mounting bracket and side
column (if spacer is supplied).
Side Column
Use care when handling the fabric roll to
ensure that the fabric is not torn or dam-
aged. DO NOT remove the shipping bands
holding the fabric to the roll.
IMPORTANT: The fabric and bottom bar, un-roll
from the back of the drum
assembly.
3. Using a forklift, lift the head/fabric roll
assembly in place.
4. Position the head assembly in front of the pair of
holes near the top of each side column. Align the
holes in the motor mounting bracket with the
holes in the side column. (See Figure 18.)
A7500247
Figure 18
Serrated-Flange
Hex Screws and Nuts
(Hex Nuts Only If
Pullouts Were Used
6. Slide the flange bearing assembly over the drum
shaft at the non-drive end of the head/fabric roll
assembly. (See Figure 19.)
IMPORTANT: If your door requires spacers, be
sure to install a spacer between
the flange bearing assembly and
the side column. (See Figure 19.)
9
INSTALLATION—HEAD ASSEMBLY
Figure 19
7. Bolt the flange bearing assembly to the side column using
two 1/2-13 x 1-1/4-in. serrated-flange hex screws and nuts
(or two 1/2-13 x 2-in. screws and nuts if spacers are
required, or nuts only if 6-in. screws were installed earlier).
DO NOT tighten the hex nuts at this time.
IMPORTANT: If the drum/fabric roll assembly
cannot be made level by adjusting the flange
bearing mounting bracket up or down, verify that
the side columns are plumb, square and level and
make any necessary adjustments.
8. Place a carpenter’s level along the length of the
drum/fabric roll assembly and adjust the flange
bearing mounting bracket up or down, as required,
until the drum/fabric roll assembly is level.
Tighten the hardware securing the motor and the
flange bearing mounting brackets to the side
columns. Then tighten the set screw to lock the
flange bearing to the drum shaft. (See Figure 20
and Figure 21.
For a door with pullouts, verify that the two hex nuts
threaded on each 6-in. screw are tight against their
associated side column and mounting bracket.
Failure to tighten all eight nuts could result in
damage to the side columns. (See Figure 21.)
Figure 20
Figure 21
DO NOT remove the shipping bands holding the
fabric material to the drum roll assembly at this
time.
9. Do not remove the shipping bands securing the
fabric material to the drum roll. Only remove the
fasteners securing the drum assembly to the forklift.
Then lower and move the forklift out of the way.
IMPORTANT: Install spacer between flange
bearing assembly and side column (if spacer
is supplied).
Serrated-Flange
Hex Screw
(Two Required)
Serrated-Flange
Hex Nut
(Two Required)
Flange
bearing
assembly
Head/Fabric
Roll assembly
Tighten Each
Set of Nuts on
6-in. Screws
Pullout
Mounting
Bracket
Side
Column
Tighten Hex Screws
(Tighten Hex Nuts If
Pullouts Are Used)
Tighten Flange
Bearing Set Screw
Adjust Bracket Up or
Down as Required
Level
10
INSTALLATION—THE BOTTOM BAR
THE BOTTOM
BAR
1. Check the brake release lever located on the motor/
brake assembly. The brake must be in the UP
engaged position. (See Figure 22.)
Figure 22
NOTE: When released, the motor brake will default to
the ENGAGED position.
2. Cut and remove the shipping bands holding the
fabric to the roll.
3. Insert the plastic tabs on the bottom bar into the slot
of each side column. (See Figure 23.)
Figure 23
THE ENCODER MAGNET, ENCODER AND
WIRELESS ANTENNA
Locate the wireless antenna parts box (labeled part
number H1060612-1A) in the crate. The box holds the
encoder magnet, the wireless antenna, and the
encoder. The wireless antenna is pre-installed on its
mounting bracket, and the encoder is pre-installed on
its white mounting plate.
Figure 24
The wireless antenna and the encoder are
connected by a pre-installed wire. Make sure the
antenna is supported while the encoder is installed.
Excess tension can damage the wire.
Install the encoder magnet
1. Remove the two hex set screws from the magnet
and apply a mild thread lock to each.
Figure 25
2. Slide the magnet over the drum shaft. Re-install
and tighten the set screws. (See Figure 25.)
Manual
break
release
Crank-mounting location
Plastic Tabs on Bottom Bar
Fit into Slot in Side Column
11
INSTALLATION—ENCODER
Install the encoder
1. Locate two (2) M10 x 25 hex screws in the small
parts hardware bag. Also, locate the two hex
mounting screws for the wireless antenna, which
are in the bag taped to the antenna mounting
bracket. You will need them for the next step.
2. Slide the encoder and white mounting bracket over
the encoder magnet. (See Figure 26.) Make sure
the wireless antenna is supported during this step
so that excess tension is not put on the connecting
wire.
Figure 26
3. Install and tighten the two screws.
Install the wireless antenna
The wireless antenna is fragile.
1. Lift the wireless antenna assembly into place and
install the two hex mounting screws
(See Figure 27.)
Figure 27
Wire the encoder to the System 4 controller
1. Locate the encoder cable in the small parts box
and connect to the encoder.
2. Route the encoder cable to the System 4 controller
and connect per the provided schematics.
12
INSTALLATION—PHOTO EYE
PHOTO EYE
The photo eye is a safety measure and therefore
needed
for
proper
door
operation. When installing
photo
eyes on the back side of the door, make sure the
installation is
opposite
from the front. The end result
would be photo eye beams that crisis cross. (See
Figure 29 and Figure 30.)
The transmitter and receiver can be identified two ways.
The transmitter is designated SMT 3000 on the white
label or by a single green light that comes on at the clear
end of the transmitter. (See Figure 31.) The receiver is
designated SMR 3215 on the white label or by a yellow
light that illuminates only when it is in proper alignment
with the transmitter. (See Figure 32.)
NOTE: When the cable is connected to the photo
eye, there is only a 1/4-inch window to
see the green or yellow LED light. (See
Figure 32.)
Photo Eye
Transmitter
Transmitter
Module
Designation
Power Light
(Green)
A7700040
Photo Eye
Receiver
Figure 29
A2500258
IMPORTANT: When installing the rear set of
photo eyes, be sure that the
assembly is installed in reverse
order from the front. This is to
prevent crosstalk between the
photo eyes. (See Figure 30.)
Figure 31
Receiver
Module
Designation
Alignment Light
(Yellow)
A2500259
A7700046
Figure 30
Figure 32
13
INSTALLATION—PHOTO EYE
1. Install the photo eye assembly on the motor mount
side column with two 1/4-
20
x 3/4
-in.
serrated-
flange hex screws. The mounting holes are located
approximately 40 in. from the floor. (See Figure 33.)
NOTE: Photo eyes and mounting hardware are
shipped in the small parts carton. The two
sets of photo eyes provided must both be
properly installed. (See Figure 29.)
Photo Eye
Cable
Serrated-Flange
Hex Screw
(Two Required)
A7500316
Cord
Grip
A7500315
Figure 33
Assembly
Photo Eye
Figure 34
4. Install photo eye assembly on the non-drive side
column with two 1/4
-20
x 3/4-
in.
serrated-flange
hex screws.
5. Feed photo eye cable through the cord grip.
Remove all slack in the cord between the photo eye
and grip. Tighten the cord grip.
NOTE: Mounting hardware for the second set of
photo eyes has been provided. If this hard
ware will not work for your application, any
additional required hardware becomes the
responsibility of the installer.
2. Install the cord grip in the side column, just below
the photo eye assembly. (See Figure 34.)
3. Feed photo eye cable through the cord grip.
Remove all slack in the cord between the photo eye
and grip. Tighten the cord grip. (See Figure 34.)
6. Mount the second photo eye assembly on the wall
adjacent to the back of the door. The photo eye
emitter and receiver are to be mounted at the same
height as the photo eye assembly on the front of the
door, but as close to the door as possible.
Testing Photo Eye Modules
When power is on, the green light indicates the photo
eye module is powered up. When the yellow light on
the receiver module is also lit, the transmitter and
receiver modules are properly aligned.
Placing
your hand in front of the
receiver
breaks the light
path and causes the yellow light to go out. Removing
your hand causes the yellow light to go back on.
14
INSTALLATION—ELECTRICAL WIRING ROUTING
ELECTRICAL WIRING ROUTING
1. Locate the Rytec control box and fused disconnect
as shown in Figure 35.
Fused Disconnect
(Supplied by Door
Owner)
Plastic Cap
Rytec
System 4
Control Panel
4 ft.
Side Column Cover
Encoder Wire
Note: Conduit to floor
loop (if required) is
supplied by door owner
A7700039
Figure 37
A7700040
Figure 35
IMPORTANT: Never run high and low voltage
wires together.
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec
The fused disconnect must be in the OFF
position and the fuses removed before
wiring of the control box begins.
2. Locate and remove the access covers and hole
plugs from the side column to gain access to the
wires. (See Figure 36.)
Access Cover
A7700020
Figure 36
3. Run wires from the encoder and over the top of the
motor mount side column cover. Run wires down
to the
access hole in the side column cover. (See Figure 37.)
System 4 Drive & Control Installation & Owner’s Manual
for information on control panel installation, electrical
connections, door limit settings, and initial door start-up
procedure.
NOTE: If a floor loop is used, all wiring from the
fused disconnect to the control box and
from the control box to the motor mount
side column, as well as conduit running
from the control box to the floor, is pro-
vided by the door owner/installer or the
electrician. All wiring and conduit must
meet all local and state codes. Wires pro-
vided with the door are labeled with
terminal or contact numbers.
DOOR OPEN- AND CLOSE-LIMIT POSITIONS
See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The door open- and close-
limit positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that the
door travel
allows
the yellow vinyl loop on the bottom bar
to gently seal against the floor. (See Figure 38.)
DO NOT allow the rubber reversing edge, enclosed in
the yellow vinyl loop, to come in contact with the floor.
15
INSTALLATION—PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT
Damage to the rubber reversing edge or
other bottom bar parts can occur if the
door seal is allowed to seal too tightly
against the floor.
PNEUMATIC REVERSING EDGE SWITCH
ADJUSTMENT
Do not stand under the door panel when
making check. If reversing edge switch is
not working properly, panel could strike
person performing check.
Fabric Panel
Rubber
Reversing
Edge
Yellow
Vinyl Loop
A7500195
Open-Limit
Position
Figure 38
¹/₂
to 1 in.
To check the reversing edge switch operation, run the
door through the down cycle. As the door is lowering,
tap the bottom of the reversing edge. If the reversing
edge switch is operating properly, the door should
immediately reverse and run to the full open position.
Push the control box push-button to close the door after
the check is completed.
If the door does not reverse, check the air bleed and
sensitivity of the reversing edge switch. The switch is in
the bottom bar on the side opposite the door motor.
Reversing Edge Switch Air Bleed Check
1. The reversing edge switch is located inside the bot-
tom bar assembly. To inspect and/or adjust the
switch, remove the access cover from the face of
the bottom bar assembly. (See Figure 40.)
The open-limit position should be adjusted so that the
door travel allows the bottom bar
assembly
to stop at the
position shown in Figure 39.
NOTE: It is important that the plastic breakaway
tabs on the ends of the bottom bar are
above the black plastic tab on the side
column. This open-limit setting height
allows the door to be jogged to the proper
height to allow for the re-setting of the
bottom bar if the door is broken away.
Bottom Bar
Access Cover
Plastic Tabs on Bottom Bar
Fit into Slot in Side Column
A7500201
Figure 40
2. Make sure the clear PVC hose is in tight contact
with the air input post so that air leakage cannot
occur and that vibration will not cause the hose to
fall off. Make sure the hose is not kinked.
(See Figure 41.)
3. The air bleed has been set at the factory and should
not require adjustment. To check the air bleed, turn
the air bleed
adjustment
screws located on the front
and back of the switch fully clockwise, but do not
overtighten.
Then turn the screws counterclockwise
one full turn. (See Figure 41.)
A7700006
Figure 39
16
INSTALLATION—PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT
Reversing
Edge Switch
(On Side
Opposite
Door Motor)
Air Bleed
Adjustment
Screw
PNEUMATIC KILL SWITCH
CHECK AND ADJUSTMENT
A kill switch has been mounted in the bottom bar
assembly. The purpose of this switch is to prevent the
door from being operated if the breakaway bottom bar
becomes separated from either side column.
Kill Switch Check
PVC Hose Must Be Tight
on Lower Input Hose
A7700042
Figure 41
Reversing Edge Switch Sensitivity Adjustment
1. The reversing edge switch is a normally open con-
tact. The PVC hose is on the lower air input post. To
adjust the switch, first remove the wires and resistor
from the contact terminals and attach an ohmmeter
across the two terminals. (See Figure 42.)
2. Turn the adjustment screw, located on the face of the
switch, clockwise or counterclockwise until continuity is
achieved. Then
turn the screw two full turns
counterclockwise. The ohmmeter should no longer show
continuity. Turning the screw counterclockwise decreases
sensitivity. Turning the screw clock- wise increases
sensitivity. (See Figure 42.)
Reversing
Take precautions to prevent the door from
being opened or closed while performing
the following procedure.
1. Raise or lower the door to approximately head or
chest height and stop the door.
NOTE: It should not be possible to restart the door
until the door has been reassembled and
the control system reset.
2. Push the breakaway bottom bar out of the side
column. Door should not operate until control box is
reset. (See Figure 43 and Figure 44.)
If the kill switch did not operate properly: Adjust
the kill switch and then recheck it. (See “Kill Switch
Air Bleed Adjustment” on page 17.)
If the kill switch operated properly: Reinstall the
bottom bar into the side column. (See “RESET-
TING BOTTOM BAR ASSEMBLY” on page 18.)
Edge Switch
Sensitivity
Adjustment Screw
Resistor
Remove Wires
to Test and
Adjust Switch
Air Switch Bladder
Plastic Tabs Out
of Side Column
A7700042
Figure 42
3. Reattach resistor and wires and then replace the
access cover on the bottom bar.
NOTE: If the reversing edge is set too sensitive,
the door may reverse direction during the
closing cycle, without the reversing edge
coming in contact with an object. If this
occurs, readjust the reversing edge
switch.
A7700007
Figure 43
Bottom Bar
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