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)