RYTEC Plexline PL5000 User manual

R Y T E C
P.O. Box 403, One Cedar Parkway, Jackson, WI 53037
Phone: [phone] Fax: [phone]
Rytec Website: www.rytecdoors.com Rytec On-line store: www.rytecparts.com
Rytec E-mail: [e-mail] Parts E-mail: [e-mail]
[Revision: AA (2017-08-03), R1160103-0, ©Rytec Corporation 2010 ]
Plexline®
Owner’s Manual

PLEXLINE® PL5000 & PL5500 LIMITED WARRANTY
Rytec Corporation (“Seller”), an Illinois corporation with its principal place of business at One Cedar
Parkway, PO Box 403, Jackson, WI 53037, warrants to the original registered end-user commercial
purchaser (“Buyer”) that the Plexline® PL5000 & PL5500 (“Product”) sold to the Buyer will be free of
defects in materials and workmanship (ordinary wear and tear excepted) for the time periods set forth
below:
•Mechanical components for a period of Two (2) Years from the date of shipment of the Productfrom
the Seller's plant (“Shipment”).
•Electrical components for a period of Two (2) Years from Shipment.
•Standard door panels, including Vinyl, for a period of One (1) Year from Shipment.
•Optional door panels, including 2 Ply Rilon and 2 Ply USDA for a period of Three (3) Years from
shipment and screen, windows, for a period of One (1) Year from shipment.
•Brush or vinyl seals,side column wear strips,Vinyl Loop Seal, Vision Panel Sections,Wind rib
guides, wireless mobile unit battery are considered wear items and are not covered under this
Limited Warranty.
•Aftermarket parts, accessories and assemblies for a period of ninety (90) days from the date of
Shipment.
Remedies. Seller’s obligation under this Limited Warranty is limited to repairing or replacing, at Seller’s
option, any part which is determined by Seller to be defective during the applicable warrantyperiod. Such
repair or replacement shall be the Seller’s sole obligation and the Buyer’s exclusive remedy under this Lim-
ited Warranty.
Labor. Except in the case of aftermarket parts, accessories and assemblies, labor is warranted for one
year. This means that Seller will provide warranty service without charge for labor in the first year of the
warrantyperiod. Thereafter, a charge will apply in to any repair or replacement under this Limited Warranty.
In the case of aftermarket parts, accessories and assemblies, Seller will provide replacement parts only.
Claims. Claims under this Limited Warrantymust be made (i) within 30 (thirty) days after discovery and (ii)
prior to expiration of the applicable warranty period. Claims shall be made in writing delivered to the Seller
at the address provided in the first paragraph of this warranty. Buyer must allow Seller and Dealer, or their
agents, a reasonable opportunityto inspect any Product claimed to be defective and shall, at Seller’s
option, either (x) grant Seller and Dealer or their agents access to Buyer’s premises for the purpose of
repairing or replacing the Product or (y) return of the Product to the Seller, f.o.b. Seller’s factory.
Original Buyer. This Limited Warranty is made to the original Buyer of the Product and is not assignable
or transferable. This Limited Warranty shall not be altered or amended except in a written instrument
signed by Buyer and Seller.
Not Warranted. Seller does not warrant against and is not responsible for, and no implied warranty shall
be deemed to cover, damages that result directly or indirectly from: (i) the unauthorized modification or
repair of the Product, (ii) damage due to misuse, neglect, accident, failure to provide necessary mainte-
nance, or normal wear and tear of the Product, (iii) failure to follow Seller’s instructions for installation,
operation or maintenance of the Product, (iv) use of the Product in a manner that is inconsistent with
Seller's guidelines or local building codes, (v) movement, settling, distortion, or collapse of the ground, or
of improvementsto which the Products are affixed, (vi) fire, flood, earthquake,elements of nature or acts of
God, riots, civil disorder, war, or any other cause beyond the reasonable control of Seller, (vii) improper
handling, storage, abuse, or neglect of the Product by Buyer or by any third party.

DISCLAIMERS. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS
AND WARRANTIES, EXPRESS OR IMPLIED, AND THE SELLER EXPRESSLY DISCLAIMS AND
EXCLUDES ANY IMPLIED WARRANTIES OF MERCHANTABILITYOR FITNESS FOR PURPOSE.
SELLER SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONSOR LIABILITIES,WHETHER ARIS-
ING OUT OF BREACH OF CONTRACT,WARRANTY, TORT (INCLUDING NEGLIGENCE AND STRICT
LIABILITY) OR OTHER THEORIES OF LAW, WITH RESPECT TO THE PRODUCTS SOLD OR SER-
VICES RENDERED BY THE SELLER, OR ANY UNDERTAKINGS,ACTS, OR OMISSIONS RELATING
THERETO.
LIMITATION OF LIABILITY. IN NO EVENT WILL SELLER BE RESPONSIBLEFOR, OR LIABLE TO ANY-
ONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL, OR CONSEQUENTIALDAM-
AGES, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Such
excluded damages include,but arenot limited to, personal injury, damage to property,loss of goodwill,loss
of profits, loss of use, cost of cover with any substitute product, interruption of business, or other similar
indirect financial loss.
Product Descriptions. Any description of the Products, whether in writing or made orally by the Seller or
the Seller’s agents, including specifications, samples, models, bulletins, drawings, diagrams, engineering
or similar materials used in connection with the Buyer’s order, are for the sole purpose of identifying the
Product and shall not be construed as an express warranty. Any suggestions by the Seller or the Seller’s
agents regarding the use, application, or suitability of the Product shall not be construed as an express
warranty unless confirmed to be such in writing by the Seller.
Limited Warranty Void. This Limited Warranty shall be void in its entiretyif:
a. The Product is modified in a manner not approved in writing by Seller; or
b. Buyer fails to maintain the Product in accordance with instructions contained in the Owner’s Manual
for the Product.
© Rytec Corporation 12.12.2012

TABLE OF CONTENTS
PAGE
INTRODUCTION.....................................................................................................1
HOW TO USE MANUAL................................................................................................1
DOOR SERIAL NUMBER(S) .........................................................................................1
GENERAL ARRANGEMENT OF DOOR COMPONENTS .............................................1
OPERATION...........................................................................................................2
OPERATING CONTROL SYSTEM................................................................................2
PHOTO EYES................................................................................................................2
BOTTOM BAR ASSEMBLY ..........................................................................................2
Breakaway Capability...............................................................................................2
IMPACT..................................................................................................................2
REPAIR (RETURN TO OPERATING POSITION) ..................................................2
Reversing Edge.........................................................................................................3
POWER DRIVE SYSTEM ..............................................................................................3
SAMPLE OBJECT LIST ................................................................................................3
MOVE THE DOOR MANUALLY....................................................................................4
Lower Door with Hand Crank...................................................................................4
Raise Door with Hand Crank....................................................................................5
Lower Door with Manual Brake Release..................................................................5
Raise Door with Manual Brake Release ..................................................................6
PLANNED MAINTENANCE ...................................................................................6
RECOMMENDED SCHEDULE......................................................................................6
DAILY INSPECTION......................................................................................................6
Damage Inspection...................................................................................................6
Door Operation .........................................................................................................7
Reversing Edge Inspection ......................................................................................7
Photo Eye Inspection ...............................................................................................7
QUARTERLY INSPECTION ...........................................................................................7
Mounting Hardware Inspection................................................................................7
MOTOR MOUNTING HARDWARE........................................................................7
ENCODER HARDWARE........................................................................................8
SIDE COLUMN HARDWARE.................................................................................8
BEARING BLOCK HARDWARE.............................................................................8
Fabric Inspection......................................................................................................8
Door Limit Inspection ...............................................................................................9
CLOSE LIMIT.........................................................................................................9
OPEN LIMIT...........................................................................................................9
Motor Brake Inspection ..........................................................................................10
Bottom Bar Inspection............................................................................................10

TABLE OF CONTENTS
PAGE
Kill Switch Inspection.............................................................................................10
Lubrication..............................................................................................................10
Weather Seal Inspection.........................................................................................11
HEADER ASSEMBLY ..........................................................................................11
SIDE COLUMNS..................................................................................................11
Activator/Control Panel Inspection........................................................................11
Electrical Connection Inspection...........................................................................12
ADJUSTMENTS ...................................................................................................12
DOOR OPEN- AND CLOSE-LIMIT POSITIONS ..........................................................12
Close-Limit Position ...............................................................................................12
Open-Limit Position................................................................................................12
PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT .......................................13
Reversing Edge Switch Air Bleed Check ..............................................................13
Reversing Edge Switch Sensitivity Adjustment ...................................................13
PNEUMATIC KILL SWITCH ADJUSTMENT................................................................14
Kill Switch Air Bleed Check ...................................................................................14
Kill Switch Sensitivity Adjustment ........................................................................14
PHOTO EYE ADJUSTMENT .......................................................................................15
MOTOR BRAKE ADJUSTMENT..................................................................................15
REPLACEMENT PROCEDURES.........................................................................16
COUNTERWEIGHT STRAP ........................................................................................16
IDLER PULLEY ...........................................................................................................18
NON-DRIVE BEARING................................................................................................19
MOTOR/GEARBOX .....................................................................................................20
BRUSH AND WEATHER SEAL(S)..............................................................................24
Spreader Assembly ................................................................................................24
Side Column and Cover..........................................................................................25
WEAR STRIP(S) ..........................................................................................................26
Side Column and Cover..........................................................................................26
PARTS LIST..........................................................................................................27
PARTS ORDERING INFORMATION............................................................................27
How to Order Parts.................................................................................................27
Substitute Parts ......................................................................................................27
Return of Parts........................................................................................................27
RYTEC TECHNCIAL KNOWLEDGE CENTER............................................................27
SIDE COLUMN ............................................................................................................28
SIDE COLUMN W/BRAKE & COUNTERWEIGHT.......................................................30

TABLE OF CONTENTS
PAGE
SIDE COLUMN –COUNTERWEIGHT.........................................................................31
REAR SPREADER —BRUSH SEAL..........................................................................32
REAR SPREADER —ANTENNA HARDWARE & ENCODER....................................33
MOTOR ASSEMBLY ...................................................................................................34
DRUM ASSEMBLY......................................................................................................35
BOTTOM BAR ASSEMBLY ........................................................................................36
HOOD ASSEMBLY ......................................................................................................38
PHOTO EYES..............................................................................................................39
COMMON SPARE PARTS ..........................................................................................40

INTRODUCTION-HOW TO USE MANUAL
1
INTRODUCTION
The information contained in this manual will allow
you to operate and maintain your Rytec®Plexline®
Door in a manner which will ensure maximum life
and trouble-free operation.
Any unauthorized changes to these procedures, or
failure to follow the steps as outlined, will
automatically void the warranty. Any changes to the
working parts, assemblies, or specifications as
written, which 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.
DO NOT OPERATE OR PERFORM MAINTENANCE
ON THIS DOOR UNTIL YOU READ AND
UNDERSTAND 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 wiring connections and schematics in this
manual are for general information purposes only. A
wiring schematic is provided with each individual
door specifically covering the control panel and
electrical components of that door. The schematic for
a specific door is shipped inside the cover of the
System 4 control panel.
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader of potentially hazardous
situations, or situations where additional information
to successfully perform the procedure is presented:
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
three (3) universal locations that this information can
be attained. These are on the left & right side column
assembly (at approximately eye level), on the drive
motor assembly, and inside the door of the System 4
Control panel. (See Figure 1)
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, drive assembly, etc.).
Failure to do this will void the
manufacturer’s warranty and may lead to
catastrophic failure and/or personal injury!
Mark any items not previously marked.
NOTE:The following illustration shows the front
side of the door. Left and right sides are
determined when viewing the front side of
the door.
Figure 1
GENERAL ARRANGEMENT OF DOOR
COMPONENTS
Figure 1 shows the location of the major components
of your Plexline door. This illustration also shows the
general placement of the associated control sub-
assemblies for a typical installation.
Motor-Gear
Drive
Fused
Disconnect
(By Others)
System 4
Control
Panel
Side
Columns
Door Panel
Assembly
Bottom Bar
Assembly
LH Front
Photo Eye
Assembly
RH Front
Photo Eye
Assembly
Hood with
Fabric Roll
RH Power
Drive
System

OPERATION-OPERATING CONTROL SYSTEM
2
The illustration is provided to you for informational
purposes only. It should not be relied upon solely for
the operation and maintenance of your door and its
sub-assemblies.
OPERATION
OPERATING CONTROL SYSTEM
The Plexline door is equipped with the Rytec System
4Drive & Control, a solid-state, microprocessor-
based control system designed exclusively to
operate Rytec high-performance doors. It provides
connections for multiple activators, close-delay
timers, and status indicators. All command functions
to operate the drive and control system are software
controlled. For information on control panel
operation, see the Rytec System 4 Drive & Control
Installation & Owner’s Manual. (See Figure 2)
Figure 2
PHOTO EYES
Your Plexline is equipped with four photo eyes, one
mounted in each side column and the other set field
installed in the front of the door. The purpose of
these photo eyes is to hold the door open or, if the
door is closing, reverse the door to the open position
if a vehicle, person, or any object is in the path of the
photo eye beam.
The photo eye is not active when the door is closed.
After the obstruction breaking the photo eye beam is
removed:
Thedoor willremainopenifit wasoriginally
opened by a non-automatic activator until it is
closed by a non-automatic activator.
The door will close automatically if it was
originally opened with an automatic activator.
BOTTOM BAR ASSEMBLY
The bottom bar assembly provides two functions:
breakaway capability and reversing edge.
Breakaway Capability
IMPACT
Plastic tabs mounted at each end of the bottom bar
pro- vide adequate strength to keep the assembly in
contact with the side columns during normal
operation. The tabs, however, are flexible enough to
allow the bottom bar to separate from either or both
of the side columns if the bottom bar is struck by a
vehicle or load passing through the door. A kill switch
assembly made up of air bladders and a pressure
switch mounted in the bottom bar will turn off
electrical power to the door if the bottom bar is
separated from the side column. This feature pre-
vents the bottom bar from being bent or damaged if
struck by a vehicle or load.
Figure 3
REPAIR (RETURN TO OPERATING POSITION)
IMPORTANT: If the bottom bar or door panel
assembly has been damaged,
remove door from service.
1. Position the plastic tabs of the bottom bar in front
of the side column. (See Figure 3) 4
Figure 4
2. Press and hold the up arrow on the control panel
until the door is in the fully open position. (See
Figure 4)
System 4
Control
Panel
Fused
Disconnect
Bottom Bar Assembly
Bottom
Bar Tabs
Side Column
Assembly
Bottom Bar Assembly
Bottom Bar
Tabs in Front of
Side Column
Side Column
Assembly
A9800030
A9800030
RESET Button

OPERATION-POWER DRIVE SYSTEM
3
Figure 5
3. Press the down arrow and the door will close in
automatic mode and be ready for service.
NOTE:It should not be possible to restart the door
until the door has been reassembled and
the control system reset. Check to make
sure that the fabric is inside each channel.
4. Perform operations check of the door.
Reversing Edge
The door is equipped with a pneumatic reversing
edge mountedat the bottomof the bottom bar
assembly. If an object is left in the path of the door
panel as it closes, the pressure-sensitive edge will
sense the contact with the object and automatically
reverse the door to the open position, thus preventing
damage to the bottom bar. (See Figure 6)
Figure 6
POWER DRIVE SYSTEM
The Plexline power drive system consists of an
electric motor/brake assembly, reduction gear
assembly, and encoder. The standard Plexline is
equipped with a variable-speed motor. The control
system will vary the door speed depending on door
position. The power drive system can be mounted on
either the right or left end of the fabric roll.
The power drive system incorporates an electric
brake usedto stopthe door travel whenelectrical
powertothe door is shut off. A manual brake release
is provided for manualopening or closing of the door
if a power failure occurs, or when routine
maintenance needs to be per- formedwith thepower
disconnected. A hand crank(provided with your door)
is used to manually open or close the door. (See
Figure 7)
An encoder, mounted on the end of the fabric drum
shaft, generates electrical signals as the door panel
moves.Thesesignals areusedby thecontrolsystem
to monitor the position of the door. (See Figure 7)
Figure 7
SAMPLE OBJECT LIST
Included with every door shipped is an Object List as
shown in Figure 8 which is a sample version. This list
contains key information specific to the door such as
the model, serial number, door Production Size
specifications, etc. Locate this document (it will be
with the small parts for the door) as you will need
information on it which will be key for proper
installation, operation, and maintenance. Keep this
document along with the manuals in a safe place for
future reference.
Reversing
Edge
Bottom Bar
Assembly
A9800031
Bottom Bar Assembly
Bottom Bar
Tabs in Front of
Side Column
Side Column
Assembly
A9800032
Bottom Bar
End Tabs
Motor
Gear Drive
Assembly
Motor
Hand
Crank
Motor
Brake
Assembly
Door Panel
Drum
Assembly
A9800033

OPERATION-MOVE THE DOOR MANUALLY
4
Figure 8
MOVE THE DOOR MANUALLY
IMPORTANT: The following instructions may
also be used in case of a power
outage. When the power is
restored and the disconnect is not
in the off position, the door will
close and possibly cause damage,
personal injury, or even death.
The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
DO NOT stand under the door panel when
moving the door.
Lower Door with Hand Crank
If the Plexline has a counterweight, the
door panel will be upward biased. If the
power is removed and the brake is fully
released, the door will travel very quickly to
the open position and the bottom bar may
become pinched or stuck in the head
assembly. Releasing the brake partially will
allow the door to open smoothly. Failure to
restrict motor movement using the brake
can result in the panel free-wheeling to an
open position, which can result in damage
to the bottom bar, fabric door panel, or
personnel.
1. Turn off power to the door.
2. Place the crank handle on the shaft at the bottom
of the motor.
NOTE:On a door that has a counterweight
installed, this will have an upward biased
door panel. Hold the hand crank firmly
while disengagingthe brake to preventthe
door from moving.

OPERATION-MOVE THE DOOR MANUALLY
5
Figure 9
3. Pull down and hold the manual brake release to
disengage the brake. Using the crank, hand turn
the motor shaft to lower the door to a desired
height. (See Figure 9)
4. Let go of the manual brake release to engage the
brake and lock the door in place.
5. Remove crank.
Remove the crank handle before applying
power to the door. Failure to remove the
crank handle could result in personal injury
or property damage.
Raise Door with Hand Crank
If the Plexline has a counterweight, the door
panel will be upward biased. If the power is
removed and the brake is fully released, the
door will travel very quickly to the open
position and the bottom bar may become
pinched or stuck in the head assembly.
Releasing the brake partially will allow the
door to open smoothly. Failure to restrict
motor movement using the brake can result
in the panel free-wheeling to an open
position, which can result in damage to the
bottom bar, fabric door panel, or personnel.
1. Turn off power to the door.
2. Place the crank handle on the shaft at the bottom
of the motor.
NOTE:On a door that has a counterweight
installed, this will have an upward biased
door panel. Hold the hand crank firmly
while disengaging the brake to prevent the
door from moving.
3. Pull down and hold the manual brake release to
disengage the brake. Using the crank, hand turn
the motor shaft to raise the door to the desired
height. (See Figure 9)
4. Let go of the manual brake release to fully
engage the brake.
Remove the crank handle before applying
power to the door. Failure to remove the
crank handle could result in personal injury
or property damage.
5. Remove crank.
Lower Door with Manual Brake Release
If the Plexline has a counterweight, the door
panel will be upward biased. If the power is
removed and the brake is fully released, the
door will travel very quickly to the open
position and the bottom bar may become
pinched or stuck in the head assembly.
Releasing the brake partially will allow the
door to open smoothly. Failure to restrict
motor movement using the brake can result
in the panel free-wheeling to an open
position, which can result in damage to the
bottom bar, fabric door panel, or personnel.
1. Place the crank handle on the shaft at the bottom
of the motor.
NOTE:On a door that has a counterweight
installed, this will have an upward biased
door panel. Hold the hand crank firmly
while disengaging the brake to prevent the
door from moving.
2. Pull down and hold the manual brake release to
disengage the brake. Using the crank, by hand
turn the motor shaft to lower the door to the
desired height. (See Figure 10)
Motor Hand
Brake Release
Motor Hand
Crank
Mounting
Location
A9800034

PLANNED MAINTENANCE-RECOMMENDED SCHEDULE
6
Figure 10
3. Let go of the manual brake release to engage the
brake and lock the door in place.
Remove the crank handle before applying
power to the door. Failure to remove the
crank handle could result in personal injury
or property damage.
4. Remove crank.
Raise Door with Manual Brake Release
If the Plexline has a counterweight, the door
panel will be upward biased. If the power is
removed and the brake is fully released, the
door will travel very quickly to the open
position and the bottom bar may become
pinched or stuck in the head assembly.
Releasing the brake partially will allow the
door to open smoothly. Failure to restrict
motor movement using the brake can result
in the panel free-wheeling to an open
position, which can result in damage to the
bottom bar, fabric door panel, or personnel.
1. Turn off power to the door.
2. Gently pull down and hold the manual brake
release to disengage the brake.
3. Allow the door to openly smoothly to the desired
height.
4. Let go of the manual brake release to fully
engage the brake.
PLANNED MAINTENANCE
RECOMMENDED SCHEDULE
DAILY INSPECTION
Damage Inspection
Inspect the door to see that components have not
been damaged. Example: bent bottom bar, tear in
fabric panel, damage to side column(s), etc. (See
Figure 11)
Figure 11
Daily
Quarterly
Damage Inspection
Door Operation
Reversing Edge Inspection
Photo Eye Inspection
Mounting Hardware Inspection
Fabric Inspection
Door Limit Inspection
Motor Brake Inspection
Bottom Bar Inspection
Kill Switch Inspection
Lubrication
Weather Seal Inspection
Activator/Control Panel Inspection
Electrical Connection Inspection
Wall Anchor Inspection
Motor Hand
Brake Release
Motor Hand
Crank
Mounting
Location
A9800034
Hood with
Fabric Roll
A9800058
Right Side
Column
Fused
Disconnect
(By Others)
System 4
Control
Panel
Bottom Bar
Assembly
LH Front
Photo Eye
Assembly
RH Front
Photo Eye
Assembly
Left Side
Column

7
PLANNED MAINTENANCE—DAILY INSPECTION
Door Operation
Run the door through four or five complete cycles to
ensure that the door is operating smoothly and effi-
ciently and that binding or unusual noises do not
exist. DO NOT continue to operate the door if it is
not running properly, as this could cause additional
damage.
Reversing Edge Inspection
DO NOT stand under the door panel when
performing the following inspection. If the
reversing edge is not working properly, the
bottom bar could strike the person per-
forming the inspection. DO NOT use the
door if the reversing edge does not operate
properly. If the door does not reverse prop-
erly, see “PNEUMATIC REVERSING EDGE
SWITCH ADJUSTMENT” on page 13.
While the door is running through the down cycle, tap
the bottom of the reversing edge. If the reversing
edge is operating properly, the door should
immediately reverse and run to the fully open
position. Press the control panel down key to close
the door after the inspection is complete. If the
reversing edge does not work properly, see
“PNEUMATIC REVERSING EDGE SWITCH
ADJUSTMENT” on page 13 for adjustment
procedure.
Photo Eye Inspection
NOTE: Two sets of photo eyes have been pro-
vided with the Plexline door. These
photo eyes act as a safety device to
prevent the door from closing if an
object is within the photo eye beam. The
photo eyes are not meant to be used as
door activators.
1. Raise the door to the fully open position by
pressing the up key on the front of the control
panel.
2. Place an object in front of the photo eye in a
position where it will break the photo eye beam.
3. Press the down key on the front of the control
panel. The door should not operate.
Personnel being used for this inspection
should not be in the path of the door panel
when this check is made. If the photo eyes
are not working properly, the door panel will
lower, striking personnel or any objects in
its path. DO NOT use the door if the photo
eyes do not operate properly.
4. If a photo eye does not operate properly, the
photo eye lens may be dirty. Clean as required
using window cleaner and a clean, soft cloth. If
cleaning does not solve the problem, see
“PHOTO EYE ADJUSTMENT” on page 15 for
adjustment procedures.
QUARTERLY INSPECTION
Mounting Hardware Inspection
Check all mounting hardware to ensure all nuts,
bolts, and set screws are tight. Example: motor
mounting hard- ware, anchor or through wall bolts,
bearing block, mounting hardware, etc. (See Figure
12 - Figure 16)
MOTOR MOUNTING HARDWARE
Motor Mounting
Bracket- to-Side
Column Hardware
(Four Places)
A9800038
Figure 12
1. Tighten four bracket-to-gearboxscrews to15–20
foot-pounds.
2. Tighten thetwo bracket-to-side column socket
head cap screws, if loose.

PLANNED MAINTENANCE-QUARTERLY INSPECTION
8
ENCODER HARDWARE
Figure 13
SIDE COLUMN HARDWARE
Figure 14
Figure 15
BEARING BLOCK HARDWARE
Figure 16
Fabric Inspection
1. Check fabric panels for tears. Replace if required.
2. Checkall panels to ensure theyaretightly
enclosed in the wind ribs and pins are in place in
wind ribs. (See Figure 17)
A7500314
Mounting
Hardware
Mounting
Hardware
Power Drive
System
A9800041
Top
Anchors
A9800039, A9800040
Middle
Anchors
Lower
Anchors
Photo
Eye
A9800015
Check All
Hardware
Side
Columns

9
PLANNED MAINTENANCE—QUARTERLY INSPECTION
Fabric Panel
Pins in Place
(Both Ends)
Rubber
Reversing
Edge
Panels Tightly
Enclosed in
Vinyl Loop
½ to 1 in.
Wind Rib A7500195
A9800042
Figure 17
Figure 18
2. If thereversing edge does not sealproperlyagainst
the floor, see the Rytec System 4 Drive & Control
Installation & Owner’sManualforadjustment
procedure.
3. Check the vision panel for clarity. Clean or replace
the panel as required.
IMPORTANT: Use any good brand of window
cleaner and a clean, soft cloth to
clean vision panel. DO NOT use an
abrasive cleaner or a petroleum-
basedsolvent.
OPEN LIMIT
1. With the door in the open position, check the location
of the plastic tabs and yellow vinyl loop on the bottom
bar. It shouldbe in the position shown in Figure 19.
4. Check lower panel to ensure that it is fastened to
the plastic tab at each end of the bottom bar.
Tighten or replace hardware, if required. If fabric is
torn and cannot be re-bolted to the plastic tab,
replace panel.
5. Run the door through two or three cycles. Check
that the panels are tracking properly in the side
columns.
Door Limit Inspection
CLOSE LIMIT
1. With the door in the closed position, check the
yellow vinyl loop on the bottom bar. It should be in
the position shown in Figure 18.
Side Column
Plastic Tabs
Damage to the rubber reversing edge or
other bottom bar parts can occur if the
door is allowed to seal too tightly against
the floor. (See Figure 18)
A9800031
Figure 19
Vinyl Loop

10
PLANNED MAINTENANCE—QUARTERLY INSPECTION
2. If thepaneldoesnotstopin theproperlocation,see
the Rytec System 4 Drive & Control Installation &
Owner’s Manual for adjustment procedure.
Motor Brake Inspection
The motor brake assembly is designed to stop the door
panel travel at the locations indicated in the limit inspec
tion section. If the limits are set properly and the door
drifts past the set limits, adjust the brake. (See
“MOTOR BRAKE ADJUSTMENT” on page 15 for
procedures.)
Bottom Bar Inspection
1. Inspect the roll pins securing the bottom bar to the
fabric. It is critical that hardware is tight to prevent
shifting of the fabric in the bottom bar.
(See Figure 20 )
Screws Securing
To check the kill switch assembly, proceed as follows:
Take precautions to prevent the door from
being opened or closed while performing
the following procedure.
1. Lower the door to approximatelyhead 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 one of the
side columns. (See Figure 21)
If the kill switch operated properly: Reinstall the
bottom bar into the side column and repeat the pro-
cedure on the remaining column. (See “BOTTOM
BAR ASSEMBLY” on page 2)
Roll Pins Securing
Bottom Bar to
Fabric Panel
Wireless Assembly
Inside Bottom Bar
If the kill switch did not operate properly:Check
the switch for damage. Replace if required. Check
all switch wiring. Correct if required. Adjust if
required. (See “PNEUMATIC KILL SWITCH
ADJUSTMENT” on page 14.) Retest kill switch.
Hardware Securing
Plastic Tabs to
Bottom Bar
Vinyl Loop and
Reversing Edge
A9800032
Figure 20
Plastic Tabs
2. Check hardware used to secure the breakaway
assembly to the bottom bar on both sides. Tighten as
required.
3. Check the reversing edge to see that it is tightly
A9800030
Side
Column
Figure 21
secured in the bottom bar.
4. Inspectthe vinyl loop of the reversingedge for abra-
sion or tearing. Replace if required. Make sure screw
securing vinyl loop is in place and tight.
Kill Switch Inspection
A kill switch assembly has been installed in the break-
away bottom bar. The purpose of this assembly is to
prevent the door from being operated if the breakaway
bar becomes separated from either side column.
Lubrication
1. Flanged Bearing: The fabric roll is supported by a
flanged bearing located on the roll shaft end opposite
the motor/brake assembly.Theflangedbearing is
equipped with a grease fitting. Recommended
lubrication is a lithium-basedgrease conforming to
NLGI Grade 2 standards. It should be medium vis-
cosity, low torque, with an operating temperature range
of –30°F to +200°F. (See Figure 22)

PLANNED MAINTENANCE-QUARTERLY INSPECTION
11
Figure 22
2. Motor Gearbox Assembly: The motor gearbox is
filled with synthetic oil, which does not need to be
changed but should be checked regularly for
proper oil level. The level can be checked at the
plug located on the lower section of the gearbox.
Recommended oil for refill is as follows:
Mobil®1 SHC 630 Synthetic Gear Oil (Mobilgear
630)
Fill the gearbox by removing the breather at the
top of the gearbox and add oil through exposed
hole. Add oil until it starts draining from the check
plug hole. (See Figure 23)
Figure 23
1Mobil is a registered trademark of Exxon Mobil
Corporation.
Weather Seal Inspection
HEADER ASSEMBLY
Inspect the header weather seal for wear or damage.
(See Figure 24) Replace if necessary. (See “BRUSH
and WEATHER SEAL(S)” on page 24)
Figure 24
SIDE COLUMNS
Inspect the side column weather seal for wear or
damage (See Figure 25) Replace if necessary. (See
“BRUSH and WEATHER SEAL(S)” on page 24)
Figure 25
Activator/Control Panel Inspection
1. Inspect all warning/safetylabels. All warning labels
should be intact and clearly readable. Replace
labels as needed.
Grease
Fitting
Flanged
Bearing
Assembly
A9800015
A9800043
Remove Plug to
Check Oil Level
Remove Breather
and Add Oil
Weather
Seal
A9800045
A9800034

12
ADJUSTMENTS—DOOR OPEN- AND CLOSE-LIMIT POSITIONS
2. Operate the door five or six complete cycles with
each activator that has been installed on the door.
Check the control panel for proper operation. If
adjustment or repair is required, see the activator
instructions or Rytec System 4 Drive & Control
Installation & Owner’s Manual.
Typical activators may be floor loops, pull cords,
push buttons, motion detectors, radio controls,
photo eyes, etc. The opening is controlled by the
activator, and closing may be controlledby the acti-
vator or a timer in the control panel.
Electrical Connection Inspection
Fabric Panel
Rubber
Reversing
Edge
Vinyl Loop
A7500195
Open-Limit Position
Figure 26
½ to 1 in.
The disconnect must be in the OFF posi
tion and properly locked and tagged before
performing the following procedure.
The open-limit position should be adjusted so that the
doortravelallowsthebottombar assembly tostopatthe
position shown in Figure 27.
1. Inspect electrical connections to the power drive
assembly and encoder assembly.
2. Inspect connections of wires in the side column.
3. Inspect control panel wiring. See Rytec System 4
Drive & Control Installation & Owner’s Manual for
control panel inspection procedure.
ADJUSTMENTS
DOOR OPEN- AND CLOSE-LIMIT POSITIONS
See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedurefor adjusting
the openand closedoorlimits.Theopen-andclose-limit
door positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that the
doortravel allows thevinyl looponthebottombar to
gently seal against the floor. (See Figure 26)
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 is allowed to seal too tightly against
the floor.
A9800031
Plastic
Tabs
3
in.
Bottom Bar
Assembly
Figure 27