RYTEC Pharma-Roll User manual

Pharma-Roll®
Installation Manual
[Revision: January 15, 2009, 0715009, ©Rytec Corporation 2007]

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 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SIDE COLUMN MOTOR SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPREADER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Door without Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Door with Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALL ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
PHOTO EYE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL WIRING ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coil Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . .13

OPEN AND CLOSE DOOR LIMIT POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Close Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Open Limit Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . .14
Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . .14
Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 14
PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 15
Kill Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Kill Switch Air Bleed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Kill Switch Sensitivity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
PHOTO EYE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Photo Eye Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Photo Eye Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
RESETTING BOTTOM BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
INSTALL HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1
INTRODUCTION—DOOR SERIAL NUMBER(S)
INTRODUCTION
The information contained in this manual will allow you
to install your Rytec Pharma-Roll®Door in a manner
that will ensure maximum life and trouble-free opera-
tion.
Any unauthorized changes in procedure, or failure to fol-
low the steps as outlined in this manual, will automati-
cally 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 oper-
ation 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 represen-
tative or call the Rytec Customer Support Department
at 800-628-1909. Always refer to the serial number of
the door when calling the representative or Customer
Support. The serial number plate is located inside one
of the side columns.
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)
Yo u r DOOR SERIAL NUMBER information can be
found in three universal locations. These are at the
inside of either side column (approximately eye level),
on the drive motor, and on the inside door of the System
3 control panel. (See Figure 1.)
IMPORTANT: When installing multiple doors
of the same model but in differ-
ent sizes, verify the serial num-
ber in the control panel with the
one in the side column.
Figure 1
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader to potentially hazardous situa-
tions, or situations where additional information to suc-
cessfully perform the procedure is presented:
WARNING is used to indicate the potential
for personal injury, if the procedure is not
performed as described.
CAUTION is used to indicate the potential
for damage to the product or property
damage, if the procedure is not followed
as described.
IMPORTANT: IMPORTANT is used to relay
information CRITICAL to the
successful completion of the
procedure.
NOTE: NOTE is used to provide additional infor-
mation to aid in the performance of the
procedure or operation of the door, but not
necessarily safety related.
A7500253
Drive Motor/Gearbox
Left Side Column
Right Side
Column
Rytec
System 3
Control
Panel

2
INSTALLATION—TOOLS AND EQUIPMENT REQUIRED
INSTALLATION
TOOLS AND EQUIPMENT REQUIRED
1. Socket and wrench set
2. ½-in. diameter concrete anchor bolts (See
“ANCHORING METHODS” on page 3.)
3. ½-in. diameter threaded rod (See “ANCHORING
METHODS” on page 3.)
4. Two ladders (taller than the door opening height)
5. Forklift
6. Carpenter’s level (4-ft.-long minimum)
7. Carpenter’s square
8. Hammer drill
9. ½-inch diameter masonry drill bit
10. Three or four, 1-ft.-long bar clamps
11. Hammer and mallets
12. Crowbar or prybar
13. Assorted hand tools (pliers, tape measure, etc.)
14. Assorted shim stock
15. Water level, line level, or transit
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 equiv-
alent). The length of wire is determined by the size
of the loop.
4. Bondo P606 flexible embedding sealer (or equiva-
lent) — required to fill grooves in floor. For cold tem-
perature 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 instruc-
tions, 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.
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.
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 fused disconnect
should be installed prior to the start of the door
installation. (See Figure 2 for layout.)
ELECTRICIAN’S RESPONSIBLITIES
For complete details on the responsibilities of the elec-
trician, refer to the Rytec System 3 Drive & Control
Installation & Owner’s Manual.
GENERAL ARRANGEMENT OF DOOR PARTS
Figure 2 shows the location of the major components of
your door. This illustration should be used as reference
only and should not be used as part of the installation
instructions.
Figure 2
NOTE: The above illustration shows the front side
of the door. Left and right are determined
when viewing the front side of the door.
A7500253
Fused Left Side Column
Fabric Roll
Right Side
Column
Bottom Bar
Photo Eye ‚
Front and Rear
Disconnect
Drive Motor/Gearbox
Rytec
System 3
Control
Panel
Photo Eye ‚
Front and Rear

3
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 3 through Figure 6 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 Customer Support Depart-
ment 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 or wall.
If expansion anchors are used, a quarterly
inspection should be implemented for safe
and secure door operation.
Concrete, Block, or Brick Walls
Figure 3
Wood, Block, Brick, or Insulated Walls
Figure 4
Insulated Wall
Figure 5
Insulated Wall
Figure 6
A0500005
Side
Expansion
Concrete Wall
Column
Anchor
A0500037
Side
Through Bolt
or Threaded Rod
Crush Plate
Wood
Column
Wall
A0500039
Insulated Wall
Aluminum-Clad Lumber
(Back Side — Full Length)
Through Bolt
or Threaded Rod
Side
Column
A0500038
Through Bolt
or Threaded Rod
Insulated
Aluminum-Clad Lumber
(Back Side — Full Length)
Wall
Side
Column

4
INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING
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 center-
line. Then mark the centerline along the floor.
(See Figure 7.)
Figure 7
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 produc-
tion 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 8.)
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 repre-
sentative or Rytec Customer Support
Department at 800-628-1909.
Figure 8
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 9 and Figure 10 show two methods that can
be used to ensure level side columns.
NOTE: Contact the Rytec Customer Support
Department if the floor is more than 1 in.
out of level.
Figure 9
A0500001
Centerline of
Opening
Overall Width
of Door Opening
Half Width of
Door Opening
A0500002
Half of Door Centerline of
Opening
Production
Extend and Mark
Edges of Door Along Floor
Width
A0500003
Line Level
This Dimension Must Be
Equal on Both Sides of
Door Opening
Shim Plate
(If Required)

5
INSTALLATION—SIDE COLUMNS
Figure 10
SIDE COLUMNS
NOTE: DO NOT change the location of the drive
motor without first contacting your Rytec
representative or the Rytec Customer
Support Department at 800-628-1909.
1. Remove the drive motor side column from the ship-
ping crate. The drive motor side column is identified
by the seal edge that faces inward during installa-
tion for a left-hand-side motor mounting.
(See Figure 11.)
Figure 11
2. Stand the drive motor side column on the floor and
tight against the wall to determine which side of the
door to place the side column.
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 12.)
Figure 12
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 rec-
ommended 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 mate-
rial is the responsibility of the door owner.
A0500004
This Dimension
Must Be Equal
on Both Sides
of Door Opening
Water Level Shim Plate
(If Required)
A3000090
Seal Edge
Motor Mount
Side Column
Top
Bottom
A3000091
Anchor Holes
(Two Anchors
Required)
Production Width Line
(Side Column Must Be
Located on Outside
Edge of Line)
Seal
Anchor Holes
(Three Anchors
Required)
Left Side Column
Top
Bottom

6
INSTALLATION—SIDE COLUMN MOTOR SUPPORT
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 12.) DO NOT tighten the anchor hardware at
this time.
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 expan-
sion 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.
SIDE COLUMN MOTOR SUPPORT
On doors greater than 14 feet tall (or wide),
a side column motor support will be sup-
plied with the small parts box as seen in
Figure 13. Failure to install this part prop-
erly may result in equipment failure and/or
personal injury.
Figure 13
IMPORTANT: For doors that are oversized
beyond 14 ft. in height (or width)
should have a side column
motor support included in the
small parts box.
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 1¹₄-in.
serrated-flange hex screws and nuts. The brackets
and mounting hardware were shipped in the small
parts carton. (See Figure 14.)
Figure 14
2. Attach the spreader assembly to the inside face of
each side column using two ³₈-16 x 1¹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.)
A7600056
A8500004
Serrated-Flange
Hex Screw (Two
L-Shaped Support
Bracket (Mounted to
Top of Header
Spreader
Extrusion
Serrated-Flange Hex
Nut (Two on Each End)
on Each End)
Extrusion)

7
INSTALLATION—SPREADER ASSEMBLY
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 col-
umns to the wall.
5. Remove any bar clamps that may have been used
to temporarily hold the side columns 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 Customer
Support Department at 800-628-1909.
1. Identify the drive motor side column by the wire
access holes along its outside edge. This is impor-
tant 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
1¹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 6³₄ in. from
the end of the bracket, nearest to
the outside face of the side col-
umn. (See Figure 16.)
Figure 16
3. Attach the spreader assembly to the U-brackets
using two ³₈-16 x 1¹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.)
Figure 17
A8500005
L-Bracket
(Fits Behind
Inside Face of
Serrated-Flange
Hex Screw (Two
on Each End)
Inside Face of
Serrated-Flange
Hex Nut (Two
on Each End)
Side Column)
Side Column
A8500152
6³₄ in.
Serrated-Flange
Hex Nut (Two
Each Side)
Large
Large U-Bracket
(Drive Motor
Serrated-Flange
Hex Screw (Two
Each Side)
Small
U-Bracket
U-Bracket
Side Column)
A8500153
Header
Serrated-Flange
Hex Screw (Two
Each Side)
Serrated-Flange
Hex Nut
(Two per Side)
Support
Bracket
Extrusion
Left Side Column

8
INSTALLATION—HEAD ASSEMBLY
4. Check that the side columns are plumb and square
with the floor and wall.
5. Tighten all anchor hardware securing both side col-
umns to the wall.
6. Remove any bar clamps that may have been used
to temporarily hold the side columns to the wall.
HEAD ASSEMBLY
1. Before removing the head/fabric roll assembly from
the shipping crate, locate four ¹₂-13 x 1¹₄-in. ser-
rated-flange hex screws, four ¹₂-13 serrated-flange
nuts, and the flange bearing assembly in the small
parts carton.
NOTE: The ¹₂-13 x 6-in. hex screws that were
installed earlier will be used to attach the
head assembly to the side columns.
Also, some oversized doors require a
steel spacer between both side columns
and the head assembly. If your door is
oversized, locate two 9-in. x 1³₄-in. steel
spacers shipped in the small parts carton.
(The spacers are further identified by a
hole at each end.)
2. Remove the head/fabric roll assembly from the
shipping crate.
Before the head/fabric roll assembly is
lifted into place, make sure both side col-
umns are secured to the building wall.
Also, the head/fabric roll assembly must
be secured to the forklift before lifting it in
place. Failure to properly secure the side
columns or the head/fabric assembly can
result in serious personal injury and prop-
erty damage. DO NOT remove the forklift
from under the head/fabric roll assembly
until it is secured to both side columns.
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: Install the head/fabric roll
assembly with the bottom bar/
fabric roll coming off 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.)
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 col-
umn using two ¹₂-13 x 1¹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. (See Figure 18.)
Figure 18
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.)
A7500247
Serrated-Flange
Hex Screws and Nuts
IMPORTANT: Install Spacer between
Motor Mounting Bracket and Side
Column (If Spacer Is Supplied)
Motor Mounting
Bracket
Side Column

9
INSTALLATION—HEAD ASSEMBLY
Figure 19
7. Bolt the flange bearing assembly to the side column
using two ¹₂-13 x 1¹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 adjust-
ing 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 col-
umns. Then tighten the set screw to lock the flange
bearing to the drum shaft. (See Figure 20 and
Figure 21.)
Figure 20
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 col-
umns (See Figure 21.) and hardware asso-
ciated with side column motor support
(See Figure 22.).
Figure 21
A8500009
Serrated-Flange
Hex Screw Serrated-Flange
Hex Nut (Two
Flange Bearing
Head/Fabric
Assembly
(Two Required)
IMPORTANT: Install Spacer between Flange
Bearing Assembly and Side Column
(If Spacer Is Supplied)
Required)
Roll Assembly
A8500017
Level
Tighten Flange Adjust Bracket
Up or Down
as Required
Tighten Hex
Bearing Set Screw
Screws
A7500301
Tighten Each
Set of Nuts
on 6-in.
Screws
Side
Column
Mounting
Bracket

10
INSTALLATION—BOTTOM BAR
Figure 22
DO NOT remove the shipping bands hold-
ing the fabric material to the drum roll
assembly at this time.
9. Do not remove the shipping bands securing the fab-
ric material to the drum roll. Only remove the fasten-
ers securing the drum assembly to the forklift. Then
lower and move the forklift out of the way.
BOTTOM BAR
1. Check the brake release lever located on the motor/
brake assembly. The brake must be in the engaged
position. (See Figure 23.)
Figure 23
NOTE: When released, the motor brake will de-
fault to the engaged position.
2. Cut and remove the shipping bands holding the fab-
ric to the roll.
3. Insert the plastic tabs on the bottom bar into the slot
of each side column. (See Figure 24.)
Figure 24
A7600059
Mounting
Bracket
Side
Column
Tighten Nuts
on 6-in. Screws
A7500225
Manual
Brake Release
Stub Shaft Crank Mounting
Location
A7500196
Plastic Tabs on
Bottom Bar Fit
into the Slot in
the Side Column

11
INSTALLATION—INSTALL ENCODER
INSTALL ENCODER
1. Install the encoder coupling shaft to the end of the
motor drive shaft using a ¹/₂-13 x 1-in. hex head cap
screw, Eurodrive washer, and a split lock washer.
2. Install the FEIG encoder hub shaft end to the end of
the encoder coupling shaft and tighten set screw.
NOTE: Use a low strength thread locker on set
screw.
3. Install encoder mounting plate with encoder using
four M8 x 1¹₄ x 18 mm socket head cap screws.
4. Connect encoder cable to encoder.
5. Install plastic zip tie into socket head screw and
secure the encoder cable. (See Figure 25.)
NOTE: The zip tie that is used in the securing of
the encoder cable is of special design. The
ribbed end inserts into the valley of the
socket head cap screw.
All hardware is located in the small parts
carton.
Figure 25
Caulking
Caulk between the side columns, the head extrusion,
and the wall.
PHOTO EYE INSTALLATION
The disconnect must be in the “OFF” posi-
tion and properly locked and tagged before
performing the following procedure.
NOTE: The door is shipped with two sets of photo
eyes. One set monitors the back side of
the door. The other set monitors the front
side of the door. Each set consists of an
emitter module and a receiver module.
The photo eyes are provided as a safety
feature. With the photo eyes correctly
installed, interrupting either set of eyes as
the door is closing will reverse the direc-
tion of the door and hold it in the fully open
position until the interruption is removed.
Figure 26
NOTE: Locate the photo eyes on the wall adjacent
to the sides of the door. Each eye must be
installed 12–36 in. above the floor and as
close to the door as possible. They must
also be mounted directly across from each
other.(See Figure 27)
The photo eyes, their required wire
cables, and mounting brackets were
shipped in the small parts carton. You
must provide the hardware to install the
brackets on your particular wall. The photo
eyes provided MUST all be properly
installed. (See Figure 27.)
A7500341
Socket Head
Cap Screw
Encoder
Encoder
Coupling
Shaft
Encoder
Mounting
Plate
Zip Tie
Feig
Encoder
Hub Shaft
A7500253
Photo Eye
(Front and Rear
Sides of Door)
Photo Eye
(Front and Rear
Sides of Door)

12
INSTALLATION—ELECTRICAL WIRING ROUTING
Figure 27
IMPORTANT: To prevent the eyes on the front
side of the door from interfering
with the eyes on the back of the
door, the emitter modules must
be installed diagonally from
each other. The same is true for
the receiver modules.
1. After the mounting brackets are in place, install the
emitter module in the left bracket and the receiver
module in the right bracket.
NOTE: The receiver module can be identified by
the two small lights, one yellow and one
green. The emitter module has only a
green light. The yellow alignment light will
be lit when the photo eyes are aligned.
(See Figure 28)
Figure 28
Position the large, plastic nuts found on
the end of each photo eye so that the lens
on either eye does not protrude too far
past the edge of the mounting bracket. If a
lens sticks out too far, that photo eye will
be susceptible to damage.
2. Thread the connector found on the terminated end
of each wire cable onto the end of the photo eyes.
NOTE: Be sure the path through which the wire
cables are routed hides and protects them
from damage. If necessary, run conduit to
each mounting bracket to protect the
cables.
3. Route the wire cables from the photo eyes to the
control panel in a manner conforming to all applica-
ble codes and regulations. Shielded cable is recom-
mended for all photo eye wires.
4. Connect the photo eyes to the control panel as
shown on the schematic that was shipped with the
door.
5. After all work is complete, clean the lens of each
photo eye using window cleaner and a soft, clean
cloth.
ELECTRICAL WIRING ROUTING
1. Locate the Rytec control box and fused disconnect.
(See Figure 29.)
Figure 29
Anchor
Locate
Hardware
A750119
Photo Eyes
12–36-in. O
Floor
Mount Bracket
Adjacent to Side
Column
Left Side of Door — Right Side Is a Mirror Image
A6500173
Power Light
(Green)
Alignment Light
(Yellow)
Emitter Module
NOTE: Photo eyes are joined for photo purposes.
Receiver
Module
A7500253
Fused Disconnect
(Supplied by Door
Owner)
Conduit to Floor Loop
(If Required) Supplied
by Door Owner
4 ft.
Rytec
System 3
Control
Panel

13
INSTALLATION—CONTROL PANEL AND ELECTRICAL CONNECTIONS
The fused disconnect must be in the OFF
position and the fuses removed before
wiring of the control box begins.
2. Run wires from the encoder and motor to the control
box using approved conduit.
Coil Cord Installation
DO NOT twist the cord during installation.
Twisting the coil cord will cause it to tangle
or fail, leading to serious problems.
Ensure that the coil cord does not have
any excessive slack when installation is
complete. It should not touch the floor.
1. Manually open the door. Allow the cord to hang
down to remove any twists in the cord.
2. Route the coil cord to a junction box near the side
column and through the hole in the junction box.
3. Place cord grip nut over the end of the coil cord. The
nut was shipped in the small parts carton.
4. Tighten the nut to attach the cord grip to the junction
box.
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec Sys-
tem 3 Drive & Control Installation & Owner’s Manual for
information on control panel installation, electrical con-
nections, door limit settings, and initial door start-up pro-
cedure.
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 termi-
nal or contact numbers.
OPEN AND CLOSE DOOR LIMIT POSITIONS
See the Rytec System 3 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The open and close limit
door 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 30.)
DO NOT allow the rubber reversing edge, enclosed in
the yellow vinyl loop, to come in contact with the floor.
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.
Figure 30
Open Limit Position
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 31.)
Figure 31
Yellow Vinyl Loop
Fabric Panel
Rubber
¹₂‚Äì1 i
Reversing Edge
A7500195
A7500196
Bottom of Yellow
Vinyl Loop Even
with Bend in
Side Column

14
INSTALLATION—PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT
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.
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 32.)
Figure 32
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 33.)
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 back counter-
clockwise one full turn. (See Figure 33.)
Figure 33
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 34.)
2. Turn the adjustment screw, located on the face of
the switch, clockwise or counterclockwise until con-
tinuity is achieved. Then turn the screw 3/4 turn
counterclockwise. Ohmmeter should no longer
show continuity. Turning the screw counterclock-
wise decreases sensitivity. Turning the screw clock-
wise increases sensitivity. (See Figure 34.)
Figure 34
3. Attach the resistor and wires and then replace the
access cover on the bottom bar.
NOTE: Replace the resistor and mount to either
the coil cord wires or the reversing edge
switch. The reversing edge connection is
dependent on the resistor being present
on either the coil cord wires or the revers-
ing edge switch.
A7500201
Access Cover
Bottom Bar
Reversing
Edge Switch
(On Side
Opposite
Door Motor)
PVC Hose Must Be Tight
on Lower Input Hose
Air Bleed
Adjustment
Screw
A7500227
Reversing
Edge Switch
to Test and
Adjust Switch
Resistor
and Resistor
Remove Wires
Sensitivity
Adjustment Screw
A7500227

15
INSTALLATION—PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT
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.
PNEUMATIC KILL SWITCH CHECK AND
ADJUSTMENT
A kill switch has been mounted in the bottom bar
assembly to prevent door operation if the breakaway
bottom bar becomes separated from either side column.
Kill Switch Check
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 col-
umn. Door should not operate until control box is
reset. (See Figure 35 and Figure 36.)
If the kill switch did not operate properly: Adjust
the kill switch and then recheck it. (See “Kill Switch
Air Bleed Adjustment” on this page.)
If the kill switch operated properly: Reinstall the
bottom bar into the side column. (See “RESET-
TING BOTTOM BAR ASSEMBLY” on page 16.)
Figure 35
Figure 36
Kill Switch Air Bleed Adjustment
1. The kill switch is mounted in the bottom bar assembly,
on the same side as the door motor. To access the
switch, first remove the access cover. (See Figure 37.)
Figure 37
2. Make sure the clear PVC hose is tight on the air
input post so that air leakage cannot occur and
vibration will not cause the hose to fall off. Also
make sure the hose is not kinked. (See Figure 38.)
Figure 38
3. The air bleed has been set at the factory and should
not require adjustment. To adjust 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 each screw back counter-
clockwise one full turn. (See Figure 38.)
4. To adjust the kill switch sensitivity, see “Kill Switch
Sensitivity Adjustment” on page 16.
A7500050
Bottom Bar
Plastic Tabs Out
of Side Column
Air Switch Bladder
A8500179
Bottom Bar Assembly
Breakaway Tabs
A7500198 Bottom Bar
Access Cover
A7500202
PVC Hose Must
Be Tight on
Air Input Post
Kill Switch (On
Same Side as
Door Motor)
Air Bleed
Adjustment
Screw (One
on Front and
One on Back

16
INSTALLATION—PHOTO EYE INSPECTION
Kill Switch Sensitivity Adjustment
The kill switch assembly is a normally closed contact.
The PVC hose is on the upper air input post.
1. Remove the wires from the contact terminals and
attach an ohmmeter across the two terminals.
(See Figure 39.)
2. To adjust the switch, turn the small adjusting screw,
located on the face of the switch, clockwise or coun-
terclockwise until continuity is achieved. Then turn
the screw two turns clockwise for final adjustment.
Ohmmeter should continue to show continuity.
Turning the screw clockwise decreases sensitivity.
Turning the screw counterclockwise increases sen-
sitivity. (See Figure 39.)
Figure 39
3. Reconnect the wires onto the switch. Replace the
access cover on bottom bar.
NOTE: If the kill switch is set too sensitive, it may
cause the door to stop during the opening
or closing cycles. If this occurs, readjust
the kill switch sensitivity setting.
PHOTO EYE INSPECTION
NOTE: The door has two sets of safety photo eyes
used as a safety device to prevent the door
from closing if an object is in the path of the
door panel. The photo eyes are not meant
to be used as door activators. Both sets of
eyes must be working correctly for the door
to operate.
Indicator Lights
With power applied to the control panel, the green light
on each photo eye indicates the eye is powered up.
When the yellow light on the receiver module is also lit,
the emitter and receiver module, from the same set, 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.
Photo Eye Test
Personnel and objects should not be in the
path of the door when the following
inspection is performed. If the photo eyes
are not working properly, the door could
strike the personnel or object in its path.
1. Raise the door to the fully open position.
2. Place an object in the path of the front photo eye
beam. Then attempt to close the door by pressing
the button on the control panel. The door should not
operate.
3. Remove the object and cycle the door to verify that
the front set of eyes is working properly. If the eyes
are not working properly, see “Photo Eye Trouble-
shooting” below.
4. Repeat the above steps on the rear set of photo
eyes to verify that both sets are working properly.
Photo Eye Troubleshooting
If either green light is not lit, make sure power is turned
on, and that all wiring has continuity and is installed and
connected properly. If the green lights are on, but the
yellow light is off, check the alignment of the emitter and
receiver modules.
RESETTING BOTTOM BAR ASSEMBLY
Turn off power to the door. Make sure
power is locked off and properly tagged.
1. Position the breakaway tabs on one end of the bot-
tom bar assembly in the side column channel. Lift
the other end of the bottom bar and position the
breakaway tabs in the remaining side column chan-
nel. (See Figure 40.)
Figure 40
A7500202
PVC Hose Must
Be Tight on Air
Kill Switch (On
Sensitivity
Adjustment Screw
Same Side as
Door Motor)
Remove Wires
to Test and
Adjust Switch
Input Post
A7500038