RYTEC Sure-Seal User manual

R Y T E C
P.O. Box 403, One Cedar Parkway, Jackson, WI 53037
Phone: [phone] Fax: [phone]
Rytec Website: www.rytecdoors.com, Rytec On-line store: www.rytecparts.com
Rytec E mail: helpd[email protected], Parts E mail: [email protected]
[Revision: A (2020-03-01), R1170928-0, ©Rytec Corporation 2010]
Sure-Seal™
Installation Manual

TABLE OF CONTENTS
PAGE
INTRODUCTION ...……………………………………………………………………1
HOW TO USE MANUAL ............................................................................................1
DOOR SERIAL NUMBER(S).....................................................................................1
INSTALLATION................................................................................................... 2
MATERIAL, TOOLS, AND EQUIPMENT ...................................................................2
ADDITIONAL REQUIREMENTS ...............................................................................2
Labor and Site Requirements.........................................................................................2
Forklift Requirements .....................................................................................................2
Electrician’s Responsibilities.........................................................................................2
Fill-In Material Requirements..........................................................................................2
GENERAL ARRANGEMENT OF DOOR COMPONENTS ........................................3
UNCRATING..............................................................................................................3
ANCHORING METHODS ..........................................................................................3
Concrete, Block, or Brick Walls......................................................................................3
Wood, Block, Brick, or Insulated Walls ..........................................................................4
Insulated Wall
..................................................................................................................4
LOCATING CENTERLINE OF DOOR OPENING .....................................................4
LOCATING SIDE COLUMNS ....................................................................................4
SIDE COLUMNS .......................................................................................................5
BRUSH SEAL............................................................................................................7
HEAD ASSEMBLY....................................................................................................7
ANCHOR PLATES ....................................................................................................9
JUNCTION BOX ........................................................................................................9
WIRELESS ANTENNA..............................................................................................9
ENCODER ...............................................................................................................10
DOOR SEALING .....................................................................................................11
CONTROL PANEL AND ELECTRICAL CONNECTIONS ......................................11
DOOR OPEN & CLOSE LIMIT POSITIONS ...........................................................12
Close-Limit Position......................................................................................................12
Open-Limit Position ......................................................................................................12
REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT.........................12
Reversing Edge Switch Air Bleed Check ....................................................................12
Reversing Edge Switch Sensitivity Adjustment ..........................................................13
RESETTING BOTTOM BAR ...................................................................................13
PATHWATCH LED™ WARNING LIGHTS ...............................................................14
Rear................................................................................................................................15
PHOTO EYES ..........................................................................................................16

TABLE OF CONTENTS
PAGE
Front...............................................................................................................................16
Rear................................................................................................................................16
Testing Photo Eyes.......................................................................................................17
AIR BLOWER (DOOR OPENING HT ≤ 13 FT) .......................................................17
SIDE COLUMN HEATED BLOWER .......................................................................18
CLEAR SIDE COLUMN TOP COVERS ..................................................................20
FINAL CHECKS................................................................................................20

INTRODUCTION-HOW TO USE MANUAL
1
INTRODUCTION
The information contained in this manual will allow
you to install your Rytec Sure-Seal™ 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 in 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.
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 Support. The serial
number is located in several locations, see DOOR
SERIAL NUMBER section.
A wiring schematic is provided with each individual
door, specifically covering the control and electrical
components of that door.
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader to potentially hazardous
situations, or situations where additional information
to successfully 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
information to aid in the performance of
the procedure or operation of the door, but
not necessarily safety related.
DOOR SERIAL NUMBER(S)
To obtain your DOOR SERIAL NUMBER, there are
five universal locations where this information can be
found. These are on the outside bottom & inside the
door of the System 4 control panel, the left and right
side columns at approximately eye level, and the
drive motor/head assembly. (See Figure 1)
IMPORTANT: When installing multiple doors of
the same model, verify & match the
serial numbers of all the
components for each door (i.e.
control panel, side columns, head
assembly, etc.).
Figure 1
NOTE: The lifting pockets in the head assembly are
there for forklift handling only.
System 4
Control
Panel
Drive Motor
Gearbox Assembly
Lifting
Pockets
Optional
Blowers or
Air Curtain
Left Side Column with
optional Heated Blower
Right Side Column with
optional Heated Blower
Head
Assembly

INSTALLATION-MATERIAL, TOOLS, AND EQUIPMENT
2
INSTALLATION
MATERIAL, TOOLS, AND EQUIPMENT
1. Threaded rod ( ¹/₂ -in. diameter) and other various
wall anchor hardware and material. Concrete
Anchor bolts
( ¹/₂ -in. diameter). (See
“ANCHORING METHODS” on page 3)
2. Assorted shim stock. (See Figure 10)
3. Double-sided tape (to temporarily hold shims).
4. Carpenter’s or spirit level (4-ft. minimum length).
5. Carpenter’s square.
6. Fish tape.
7. Hammer drill.
8. Masonry drill bit (for
¹/₂ -in. diameter anchors).
9. Three or four bar clamps (48-in. long).
10. Four 12” C-clamps.
11. Pencil or Marker.
12. Hammer or mallet and blocks of wood.
13. Crowbar or pry bar.
14. Assorted hand tools (pliers, tape measure, etc.).
15. Socket and wrench sets.
16. Water level, line level, or transit.
17. Two ladders (taller than height of door opening).
18. Forklift (see “Forklift Requirements”).
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. Two installers.
2. An electrician is required for making all electrical
connections. (See “Electrician’s Responsibilities”)
NOTE:All electrical work must be performed
in accordance with local, state, and all
applicable building codes.
3. 100% accessibility to the door opening during the
entire installation process. No traffic should be
allowed to pass through the opening while the
door is being installed.
Forklift Requirements
A forklift supplied by the customer, dealer, or installer
is mandatory for the safe and proper installation of
this door. The forklift should have:
•4,000-pound lift capacity.
•minimum height ability — door height plus 18 in.
•side-shift capability (desired).
Electrician’s Responsibilities
For complete details on the responsibilities of the
electrician, refer to the Rytec System 4 Drive &
Control Installation, Owner’s Manual, & Door Specific
Electrical Schematic.
1. Install fused disconnect and Rytec control panel.
(See Figure 2 for typical installation)
2. Install all necessary conduit tubing.
NOTE: Separate conduit must be run for high and
low voltage wiring.
3. Run electrical power lines to disconnect.
4. Run power lines from disconnect to control panel.
5. Run power lines from control panel to junction
box(s) and door.
6. Run power lines from control panel to door motor.
7. Run low-voltage cables from control panel to
door.
8. Wire low-voltage safety devices and activators (if
used).
Run high and low voltage wires/cables in separate
metal conduit to the bottom of the System 4 control
panel.
All wires/cables must be cut to length. DO NOT leave
excess wire/cable loops on the door or in the control
panel. Excess wires/cables can cause problems.
Fill-In Material Requirements
Some
applications may require the use of a door pullout
(extension) to gain clearance of an existing obstruction
between the door and the door opening. The following
materials can be used to fill the space or gap between
the door and the door opening.
1. 16-gauge hot-rolled sheet steel.
2. 2-in. x 2-in. x
³/₁₆ -in. angle iron.
3. Insulated panels.
NOTE:If any pullout or build out is used in
the installation it must be insulated to
prevent frost and ice buildup on or in the
door. Failure to properly insulate the
pullout can affect the operation of the
Sure-Seal door.
It is very important to seal and caulk
around the pullouts to prevent frost and
ice buildup.

INSTALLATION-GENERAL ARRANGEMENT OF DOOR COMPONENTS
3
GENERAL ARRANGEMENT OF DOOR
COMPONENTS
Figure 2 shows the location of the major components
of the door and the general placement of the
associated subassemblies for a typical installation.
This illustration is provided to you for informational
purposes only. It should not be relied upon solely
during the installation of your door and its sub-
assemblies.
Figure 2
NOTE:Figure 2shows the front side of the door.
Left and right are determined when viewing
the front side of the door.
UNCRATING
Your Rytec door has been crated to allow for minimal
handling of assemblies during the installation
process.
NOTE:Remove parts and sub-assemblies
from the shipping crate in the order
directed throughout this manual.
1. Remove the top of the crate.
2. Remove the front of the crate. (See Figure 3)
Figure 3
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 are 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.
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.
If expansion anchors are used, a quarterly
inspection should be implemented for safe
and secure door operation.
Concrete, Block, or Brick Walls
Figure 4
Patchwatch LED™ is owned by Rytec High Performance Doors.
Expansion
Anchor
Side
Column
Concrete
Wall
A0500005
Head Assembly
(Includes Drive Motor
Gearbox Assembly)
Door Panel
Lifting Pockets
System 4
Control
Panel
Fused
Disconnect
Optional
blowers
Bottom Bar
Assembly
Left Side Column with optional heated blower
(Includes Serial Number Plat
e and optional
Patchwatch LED)
Right Side Column with optional heated blower
(Includes Serial Number Plat
e and optional
Patchwatch LED)
Center
Buck

INSTALLATION-LOCATING CENTERLINE OF DOOR OPENING
4
Wood, Block, Brick, or Insulated Walls
Figure 5
Insulated Wall
Figure 6
Figure 7
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.
2. Divide the measurement in half to locate the
centerline. Then mark the centerline along the
floor. (See Figure 8)
Figure 8
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. Verify the
dimension provided by measuring the width
(length) of the head assembly.
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)
To ensure that the breakaway bottom bar
assembly 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 the Rytec Technical
Support Department at 800-628-1909.
NOTE: the breakaway bottom bar assembly is an
optional feature of the Sure-Seal, and may not be
included in this installation of the door. Check the
door to verify.
Wood
Wall
Crush Plate
( ¹/₂ - in. thick,
6-in. x 8-in.
Steel)
Side
Column
Through Bolt or
Threaded Rod
A0500037
Insulated
Wall
Through Bolt or
Threaded Rod
Side
Column
Aluminum-Clad Lumber (Front
and Back Sides — Full Length)
A0500039
Insulated
Wall
Through Bolt or
Threaded Rod
Aluminum-Clad Lumber
(Back Side — Full Length)
A0500038
Overall Width of
Door Opening
Half Width of
Door Opening
A0500001
Centerline
of Opening

INSTALLATION-SIDE COLUMNS
5
Figure 9
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 low side column 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 Department if
the floor is more than 1 in. out of level.
Figure 10
5. Use a plumb bob or carpenter’s level to check the
wall for plumb in the areas where the side
columns are to be mounted. Also, inspect the wall
for any obstructions.
If the wall is not plumb, shims must be used as required
@ each side column fastener. If you find an obstruction,
remove it or shim the column to avoid the obstruction.
(See Figure 10 and Figure 11)
Figure 11
SIDE COLUMNS
The following procedure details the installation of the
side columns.
Side columns are heavy; use proper lifting
and support equipment when removing
from crate. Personal injury may result from
using improper handling procedures.
1. Remove the blocking from the head assembly
buck in the middle of the shipping crate to gain
access to the side columns. (See Figure 3)
2. Remove the side columns from the shipping
crate. Remove the covers from the side columns
by removing the screws that hold the covers in
place. Save all hardware and covers for
reassembly for each one. Do not mix the parts up.
3. Stand one side column on the floor. Place it
against the wall on the appropriate side of the
door opening (i.e. left on left side, right on the
right side), just outside the line indicating the
production width of the door. Use clamps as
needed. (See Figure 12)
Extend and Mark
Edges of Door Along Floor
Half of Door
Production Width
Centerline of
Opening
This Dimension Must
Be Equal on Both
Sides of Door Opening
Shim
(if required)
Line Level
Shim
(if required)
Water Level
This Dimension Must
Be Equal on Both
Sides of Door Opening
Shim
(if required)
Shim
(if required)
Shim
(if required)

INSTALLATION-SIDE COLUMNS
6
IMPORTANT: It is critical that the side columns
are mounted square and plumb with
the wall and level across the door
opening. Utilizing a 4-foot level and
carpenter’s square to check this
will help ensure the columns are
correctly set. Place shims as
necessary.
Additionally, using bar clamps to
temporarily secure the side
columns to the wall will allow you
make slight adjustments during the
installation process.
Before drilling any holes, ensure there
are no electrical wires, water pipes, or
gas lines, etc., buried in the floor or
hidden in the wall.
4. Once the side column is set plumb and square,
mark the center of the slot locations and the
column edges on the wall. Predrilled anchor
points have been provided in the side column.
Remove the side column and drill anchor holes in
the wall. Reset the side column plumb and
square. Anchor it to the wall. DO NOT fully
tighten the anchors at this time - they will be
tightened later in the installation after the head
assembly is installed. (See Figures 12 - 14)
NOTE: Use ¹/₂-in. expansion shell or stud-type
anchors for concrete walls. Use
through bolts or threaded rods for brick
walls and other applications where
expansion anchors are not appropriate.
Figure 12
Figure 13
5. Mount the opposite side column to the wall
in
the
same manner used for installing the previous
side column.
6. With both columns set and at least snuggly bolted
in place to the wall, once again check the overall
plumb and squareness of each column. (See
Figure 14)
7. Compare the diagonal measurements and the
upper and lower horizontal measurements across
the columns. The columns are square and
parallel when the diagonal measurements are
equal and the horizontal measurements are
equal.
Note: It is critical that the horizontal distance
between the mating surfaces of the side
columns which the head bolts to, match the
mating width between the head assembly
mounting plates. (See Figure 14)
8. If either column requires any slight repositioning
(when the difference of either comparison is
greater than
¹/₄ in.), use a block of wood and a
mallet to nudge the column(s) into the correct
position.
9. Choose one of the side columns at this point and
tighten all fasteners and set it in place. The
opposite side column will likely need to be
adjusted when installing the head assembly.
Wall
Foam
Insulation
Right side shown
Carpenter’s
Level
Right Side
Column
Production
Width Line
(Wall Edge)
Anchor Points
Side
Column
Floor
Mounting
Plate
Production
Width Line
(Wall Edge)