RYTEC Sure-Seal User 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)
INSTALLATION-BRUSH SEAL
7
Figure 14
BRUSH SEAL
1. Mount and secure the Top Rear Spreader Brush
Seal in between the side columns as shown.
Adjust to provide a proper door seal. Use
alternating fastener holes. (See Figure 15)
Figure 15
HEAD ASSEMBLY
2. Remove the head assembly from the crate. Using
a fork lift, guide the forks into the slots in the front
of the head assembly making sure that the forks
are below the panel and idler drum. The lifting
slots are provided to aid in lifting the head and
preventing damage to the foam panel, drum, and
head assembly. (See Figure 16 and Figure 17)
Figure 16
NOTE: Do not wrap the strap around the rear
spreader when securing to lifting forks.
This will damage it.
NOTE: Personal injury or equipment damage
may result from the head assembly not
being secured when being lifted.
The head assembly is extremely heavy;
use proper lifting and support equipment
when removing it from the crate. Personal
injury may result from using improper
handling procedures.
Secure the head assembly to the forklift
prior to lifting it to the top of the side
columns.
NOTE: To prevent damage to the door
components, use cloth or packing
material between the forks and the
head assembly. Pay close attention to
the foam door panel.
3. Secure the head assembly with C-clamps and a
strap around the front spreader, door panel
drum, and the idler drum to the forks of the forklift
or mechanical lift before lifting it into position. C-
clamps should be used on both sides of the front
spreader to secure the head in place. (See
Figure 17 - 18)
Horizontal Measurements
Must Be Equidistant.
Horizontal Measurements
Must Be Equidistant.
Diagonal
Measurements Must
Be Equidistant
Side Columns Must
Be Plumb On Both
Side and Front
Spreader Brush
Seal Assy.
Fasteners
A8700059
NOTE: Door/panel is shown with
a cross sectional view and the
panel is shown as transparent.
Self drilling Tek screws
Wall mounting
holes
Door Panel
Adjustment slot(s)
INSTALLATION-HEAD ASSEMBLY
8
Figure 17
Figure 18
Figure 19
4. Check if there are optional Photo eyes or
Pathwatch LED strips in the side columns.
If there are, Insert the grommet with the Pathwatch
LED and/or Photo eye wires running through it into the
slot in the side column as shown.
5. With the head assembly safely secured to the forklift,
raise it up above the door to mount to the side
columns. Guide the head in toward the wall while
keeping the side column edges clear of the head
assembly mating edges and wires exiting the top of
the side columns. Line up the mating holes on the
head assembly with the fastener holes in the side
columns. (See Figure 19 - Figure 21)
Figure 20
6. Fasten the head to the level and plumb side
column that’s locked in place with the specified
fasteners. DO NOT completely tighten the
fasteners. Adjustments will need to be made yet.
The hardware is located in the small parts carton.
(See Figure 21)
a. Install (4) ³/₈-16UNC x 1¹/₄-in. hex flange
machine screws and ³/₈-16 Uni-Strut nuts on
each side column/head mount (left and right
side). (See Figure 21)
7. Next align and fasten the head assembly to the
opposite side column just like in the previous
steps. DO NOT completely tighten the fasteners.
Adjustments will need to be made yet. (See
Figure 21)
Figure 21 (Broken out view for clarity)
8. With the head assembly snugly bolted in place to
the side columns, check the overall plumb and
squareness of the overall assembly (side
columns and head). 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. Check the
head for level and plumb.
Forks
Clamps
Block
Material
Optional Pathwatch LED
and Photo eye wires in
Grommet
3/8-16UNC x 1-1/4 LG
SERRATED FLANGE SCREWS
3/8-16UNC UNI-
STRUT NUTS
Holes for
securing
wires, etc.
Grommet
Plug, Top
Insulation
Forks
Straps
INSTALLATION-ANCHOR PLATES
9
9. Once the assembly is set plumb, square, and, finish
fully anchoring the loose side column to the wall.
10. Tighten the fasteners and secure the head
assembly to the side columns.
11. Unclamp the head assembly from the forklift,
remove the strap(s), and then remove the forklift.
Be sure to carefully remove the forks from the
head so no damage occurs.
NOTE: Anchor points in the head assembly are predrilled at the
factory for the load bearing cross-sectional area. Do not
add additional points for mounting. Please consult your
Rytec representative or call the Rytec Technical Support
Department at 800-628-1909 with questions.
12. Remove the bar clamps or other items that were
used to secure the side columns to the wall.
13. Route the (optional) Pathwatch LED and Photo
eye wires up between the rear spreader bar on
the head assembly and the wall to the top of the
spreader. Use zip ties or another similar fastener
to secure them to the spreader in the holes
provided. (See Figure 20)
Figure 22
ANCHOR PLATES
1. Insert the side column floor mounting plates into
the bottom of each side column. Make sure all
wires, power cords, and any other items are not
on or under the Anchor Plate. Damage could
occur if they are. (See Figure 22)
2. Secure the position of the side columns on the floor.
Using the holes of the side column mounting plates,
locate and drill holes for the anchors, install them, and
secure the plates to the floor.
3. Secure the side column mounting plates to the floor
through the 2 holes in each plate. (See Figure 22)
NOTE: If a stud-type anchor is used for the
bottom anchor, the anchor must not
extend more than
1
in. above the base
plate of the side column.
JUNCTION BOX
NOTE: the junction box is an optional feature of the Sure-
Seal, and may not be included in this installation of
the door. Check the crate to verify.
The junction box is shipped loose in the shipping
crate and needs to be mounted separate of the
door’s head assembly.
1. Locate, identify, & remove junction box from the crate.
2. Orient the Junction Box assembly as shown.
Mount the J-Box assembly with appropriate
fasteners/anchors for the wall construction. Allow
ample room for access to the J-Box, Bearings,
Motor & the head assembly. (See Figure 23)
Figure 23
WIRELESS ANTENNA
NOTE: the wireless antenna is an optional feature of the
Sure-Seal, and may not be included in this
installation of the door. Check the crate to verify.
IMPORTANT: The antenna is a fragile and highly
sensitive instrument. Extreme
care
should be used in handling this piece
of equipment.
1. Remove antenna from small parts carton.
2. Carefully remove packing material from antenna.
Inspect for damage.
NOTE: Do not install antenna if it is found to be damaged.
Call your local Rytec representative or the Technical
Support Department at 800-628-1909 for a
replacement.
J-Box
Assembly
Head
Assembly-
Drive Side
Motor Assy not
shown for clarity
Mounting
Holes
Foam
Insulation
Right side shown
Side
Column
Floor
Mounting
Plate
Production
Width Line
(Wall Edge)
INSTALLATION-ENCODER
10
3. Locate and identify the insert nuts for mounting
the antenna bracket assembly. They are on the
lower inside of the front spreader on the drive
side. (See Figure 24)
Figure 24
4. Install the antenna bracket assembly to the front
spreader with (2) 10-24NC x ¾” long hex flanged
slotted machine screws. Fastener hardware is
located in the small parts carton. (See Figure 24)
5. Route the antenna wire along the front spreader
to the motor encoder and connect it as
documented in that section. (See Figure 24)
NOTE: To secure antenna cable, use plastic ties as
required.
ENCODER
1. Install the Feig encoder hub shaft end to the end
of the encoder coupling shaft and tighten set
screw plate. The Feig encoder hub can be found
in the small parts carton.
NOTE: The large flat washer, split lock washer, and
encoder coupling shaft are factory installed on
the gearbox. Use a mild thread locker on the
set screw.
2. Install encoder mounting plate with encoder
using two/(2) M10-1.5 x 20 mm hex head cap
screws.
3. Connect the encoder cable to the encoder.
4. Install plastic zip tie into the threaded hole in
encoder mounting plate and secure the encoder
cable. (See Figure 25)
All hardware is located in the small parts carton.
Figure 25
Hex Head
Screw
Encoder
Encoder
Mounting
Plate
Feig
Encoder
Hub Shaft
Split Lock
Washer
Encoder
Coupling
Shaft
Washer
To/From Wireless
Antenna
A9800016b
Zip
Tie
INSERT NUT
FASTENERS
HEX SLOTTED
FLANGED
SCREWS
ANTENNA
BRACKET
ASSEMBLY
Phil Pan
Head
Screw
Motor/Gearbox
Assembly
ABM
Motor/Gearbox
Assembly
INSTALLATION-DOOR SEALING
11
DOOR SEALING
Foam insulation is built into the side column. The
insulation is a technical and important item in the
proper operation of the Sure-Seal door. From the
moment the door is uncrated until the door is
installed, strict care should be taken not to damage
the insulation on the back side of the side column.
(See Figure 26)
In addition to the insulation, a thermal break foam
core is constructed into the components of the door
assembly. This gives the door an extra barrier to
combat against temperature differential. (See Figure
26 & Figure 27)
For a tight and air-proof seal, a bead of caulk should
be applied at the inside perimeter of the door
assembly. Use a construction grade of caulk to seal
the door.
IMPORTANT: Use caulk as directed per the
manufacturer’s instructions.
Improper wall preparation may
result in poor adhesion. The door
may not be altered in any form to
apply caulk.
Figure 26
Figure 27
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec
System 4 Drive & Control Installation, Door’s Electrical
Schematic, & Owner’s Manual for information on
control panel installation, electrical connections, door
limit settings, and initial door start-up procedure.
Locate the electrical schematics in the red
documents envelope in the small parts box and wire
the door according to these specifications.
Wall
Foam
Insulation
INSTALLATION-DOOR OPEN & CLOSE LIMIT POSITIONS
12
DOOR OPEN & 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 close- and open-
limit door positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that
the door travel allows the edge seal on the bottom
bar to gently seal against the floor. (See Figure 28)
Damage to the bottom bar parts can occur
if the door seal is allowed to seal too
tightly against the floor. If there is an
optional reversing edge, it should NOT
contact the floor.
Figure 28
Open-Limit Position
When the door is knocked out of position, the System
4 Drive & Control takes over and will raise the tabs
high enough to be reinserted into the side columns.
The open-limit position should be set so that the
middle of the bottom bar is located at the bottom
edge of the 45-degree slope on the front yellow
channel guides of each side column. (See Figure 29)
Figure 29
REVERSING EDGE SWITCH INSPECTION
AND ADJUSTMENT
NOTE: the reversing edge is an optional feature of the
Sure-Seal, and may not be included in this
installation of the door. Check the door to verify.
Do not stand under the door panel
when testing the reversing edge. If the
reversing edge switch is not working
properly, the panel could strike
personnel and cause injury.
To check the reversing edge switch, run the door through
the down cycle. As the door is lowered, tap the bottom of
the reversing edge. The door should immediately reverse
direction and open. The door is set up from the factory for 3
impacts of the reversing edge after which it will remain
open. If the reversing edge is tripped 3 times consecutively
the door will remain open and code F:361 will appear on the
display. Push and hold the RESET button 3 to 5 seconds
and the control will reset. Push the down arrow to close the
door.
If the door does not reverse direction, check the air
bleed and sensitivity of the reversing edge switch.
Reversing Edge Switch Air Bleed Check
The reversing edge switch is located inside the bot- tom bar
assembly, on the same end as the drive motor.
The disconnect must be in the OFF position
and properly locked and tagged before
performing the following procedure.
1. To inspect and adjust the switch, remove the
access cover from the wireless enclosure
assembly on the face of the bottom bar
assembly. (See Figure 29)
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. Also make sure the PVC hose is not
kinked. (See Figure 30)
Open limit
set position
Yellow Channel guide
Bottom Bar
Optional RY-WI
Access Cover
Bottom Bar
End Tab
Insulated
Foam Panel
Bottom Bar
End Tab
Bottom Bar
Edge Seal
INSTALLATION-RESETTING BOTTOM BAR
13
3. The air bleed has been set at the factory and
should not require adjustment. If adjustment is
necessary, turn the air bleed adjustment screws
located on the front and back of the switch fully
clockwise — but do not overtighten. Then turn
each screw back (counterclockwise) one full turn.
Figure 30
Reversing Edge Switch Sensitivity Adjustment
The disconnect must be in the OFF position
and properly locked and tagged before
performing the following procedure.
1. The reversing edge switch is a normally open contact.
The PVC hose is on the lower air input post. To adjust
the switch, first remove the resistor from the contact
terminals and attach an ohmmeter across the two
terminals. (See Figure 31)
Figure 31
2.
Turn
the
sensitivity adjustment screw clockwise
until
continuity is achieved. Then turn the sensitivity screw
2 full turns counterclockwise for a standard setting.
Some doors may require a further adjustment
counterclockwise. (See Figure 31)
NOTE: Testing the reversing edge is the best way
to determine sensitivity.
3. Reattach the wires and resistor; then replace the
access cover.
NOTE: If the reversing edge is too sensitive, the
door may reverse direction during the
closing cycle without coming in contact with
an object. If this occurs, readjust the
RESETTING BOTTOM BAR
Figure 32
NOTE: The resetting bottom bar is an optional feature of
the Sure-Seal, and may not be included in this
installation of the door. Check the door to verify.
For doors with the fully automated self-resetting
bottom bar, after a strike and a clear sensor path the
door will automatically reset the bottom bar. The
process goes as follows:
1. The foam breakaway tabs have popped out of
the side column’s channel due to impact. (See
Figure 32 and Figure 33)
NOTE: If the door panel was damaged during the impact,
remove the door from service and repair. If you
have any questions, contact your Rytec
representative or call the Rytec Technical Support
Department at 800-628-1909.
Figure 33
Bottom Bar
Assembly
End Tabs out of
Side Column
Resistor
Remove Resistor
to Test and
Adjust Switch
Sensitivity
Adjustment
Screw
Reversing
Edge
Switch
Reversing
Ed
ge Switch
(On Same
Side as Doo
r
Motor)
PVC Hose — Must
Be Tight on Lower
Input Hose
Air Bleed
Adjustment
Screw
Bottom Bar
Assembly
Side Column Channel
Bottom Bar
End Tab
INSTALLATION-PATHWATCH LED™ WARNING LIGHTS
14
Figure 34
2. The door panel will momentarily pause and then
execute the reset procedure.
3. The door panel’s foam breakaway tabs will roll
upward above the side column’s channel. (See
Figure 34)
4. The photo eye senses if the path is clear of any
obstructions.
5. Then the door panel will guide itself into the channel
and resume its normal operation. (See Figure 35)
Figure 35
NOTE: The door function is fully automatic; it will
reset, rise to the open position, and reinsert
the bottom bar according to factory installed
parameters. Cycling the door and checking
for proper door operation is not required
unless prescribed, but an occasional test of
the self-repair system would ensure its
proper operation. Should slight adjustments
of the door be needed, please contact your
Rytec Technical Sup- port at 800-628-1909.
PATHWATCH LED™ WARNING LIGHTS
NOTE: The Pathwach LED™is an optional feature
of the Sure-Seal, and may not be included
in this installation of the door. Check the
door to verify.
The standard setting for the warning lights is 3
seconds prior to the door closing, the lights will flash
yellow and then change to a steady red while closing.
Adjustments to the closing time can be made through
the System 4 Control Panel. Please contact your
Rytec Technical Support department at 800-628-
1909 for assistance. (See Figure 36)
IMPORTANT: Photo eyes are used as a safety
feature and not as a door opener.
Never try to interrupt either set of
photo eyes as the door is closing.
Wait for the door to perform its
normal cycle before entering or
exiting doorway.
NOTE: The Pathwatch LED’s are preinstalled in the
side columns at the factorywith the cables
labeled, coiled, pre-routed to the side
column top, and through the grommet. Be
sure to route cables away from all moving
parts. Use cable ties as required.
Patchwatch LED™ is owned by Rytec High Performance Doors.
Figure 36
Front
1. Find and identify the Pathwatch LED warning
light cables/wires in the side columns, both front
and rear. They should be coiled & labeled at the
top and pre-routed through the side column’s
wire chases.
2. After the side columns and head assembly have
been assembled and mounted to the wall,
confirm the front Pathwatch LED Warning light
cables/wires are routed as shown in Figure 20,
Figure 37, and Figure 38:
Door Panel Has Been
Reset & Is Shown in
Normal Operating Position
Optional RY-WI
Access Cover
Side Column
Channel
Door Panel Has Been
Raised & Is Shown in
Door Reset Position
Optional RY-WI
Access Cover
Side Column Channel
Bottom Bar
End Tab
Bottom Bar
End Tab
Amber and Red
Pathwatch
LED™ Warning
Lights
INSTALLATION-PATHWATCH LED™ WARNING LIGHTS
15
a. Through the wire chase on the inside front of
the side column and down to the bottom. (See
Figure 37)
b. Flat across the side column bottom back to the
rear of the side column. Make sure the cables
counterweight or crush plate. (See Figure 37)
c. Up the side column rear wire chase through
the grommet and inside wire chase slot. (See
Figure 20)
d. Up through the gap between the head
assembly rear spreader and the wall. (See
Figure 38)
3. Secure cables/wires with plastic ties to the rear
spreader of the head assembly.
4. Connect cables/wires to junction box per
schematic.
Figure 37
Rear
1. Find and identify the rear Pathwatch LED
warning light cables/wires in the side columns.
They should be coiled & labeled at the top and
pre-routed through the side column’s wire
chases.
2. After the side columns and head assembly have
been assembled and mounted to the wall,
confirm the rear Pathwatch LED Warning light
cables/wires are routed as shown in Figure 20,
Figure 37, and Figure 38:
a. Up the side column rear wire chase through
the grommet and inside wire chase slot. (See
Figure 20 and Figure 37)
b. Through the gap between the head assembly
rear spreader and the wall and to the junction
box. (See Figure 38)
NOTE: Use the rear spreader of the head assembly
to route the cables/wires to the junction box.
3. Secure cables/wires with plastic ties to the rear
spreader of the head assembly. (See Figure 38)
4. Connect cable to junction box per schematic.
Figure 38
Patchwatch LED™ is owned by Rytec High Performance Doors.
Pathwatch LED &
Photo Eye Cables
PATHWATCH LED & PHOTO EYE
CABLE ROUTING (RH SHOWN)
Photo Eye
Cables
Pathwatch
LED Cables
INSTALLATION-PHOTO EYES
16
PHOTO EYES
NOTE: The photo eyes are an optional feature of the
Sure-Seal, and may not be included in this
installation of the door. Check the door to verify.
The photo eyes are provided as a safety feature. If
the photo eyes are correctly installed, interrupting
either set of eyes as the door is closing will reverse
the direction of the door and hold it in the fully open
position until the interruption is removed.
The transmitter and receiver can be identified in 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 39
) 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 40)
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.
Figure 39
Front
1. The front photo eyes are externally mounted on
the front of the side column. Check that the photo
eye and all connections are secure and there is
nothing damaged.
2. Confirm the front cable/wires are routed as
shown in Figure 20, Figure 37, and Figure 38:
a. From the photo eye back into the side column,
down the front side wire chase of the side
column to the bottom. (See Figure 37)
b. Flat across the bottom of the side column back
to the rear side column. Make sure the cables
are flat on the bottom and don’t interfere w/ the
counterweight or crush plate. (See Figure 37)
Figure 40
c. Up the side column rear wire chase through the
grommet and inside wire chase slot. (See Figure 20)
d. Through the gap between the head assembly
rear spreader and the wall to the rear junction
box. (See Figure 38)
NOTE: Use the rear spreader of the head assembly
to route the cables/wires to the junction box
from the non-motor side.
3. Secure cables/wires with plastic ties to the rear
spreader of the head assembly. (See Figure 38)
4. Connect cables/wires to junction box per
schematic.
Rear
1. The rear photo eyes are internally mounted in
the rear of the side column. Check that the
photo eye and all connections are secure and
there is nothing damaged.
2. Confirm the rear cable/wires are routed as shown
in Figure 20, Figure 37, and Figure 38:
a. Up the side column rear wire chase through the
grommet and inside wire chase slot. (See
Figure 20, and Figure 37)
b. Through the gap between the head assembly
rear spreader and the wall to the rear junction
box. (See Figure 38)
NOTE: Use the rear spreader of the head assembly
to route the cables/wires to the junction box
from the non-motor side.
3. Secure cable with plastic ties to the rear spreader
of the head assembly. (See Figure 38)
4. Connect cable/wires to junction box per
schematic.
Transmitter
Module
Designation
Power
Light
(Green)
Receiver
Module
Designation
Alignment
Light
(Green)
Yellow
back
Red
back
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