RYTEC Turbo-Seal User manual

R Y T E C
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Turbo-Seal
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Installation Manual
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P.O.Box403,OneCedarParkway,Jackson,WI
53037 
Phone262‐677‐9046 Fax
262‐677‐2058
Rytec website: www.rytecdoors.com Rytec On-line store: www.rytecparts.com,
RytecE‐mail: [e-mail], PartsE‐mail: [e-mail] 
[Revision:January22,2013R0815001,©RytecCorporation2004]

PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MATERIAL, TOOLS, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Floor-Loop Activator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fill-In Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL ARRANGEMENT OF
DOOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . .4
LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COUNTERWEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DOOR SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FACTORY-INSTALLED PHOTO EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FIELD-INSTALLED PHOTO EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 11
OPEN- AND CLOSE-LIMIT DOOR POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . .12
Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT . . . . . . . . . . . . 12
Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . .12
Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . .13
KILL SWITCH CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Kill Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Kill Switch Air Bleed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Kill Switch Sensitivity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RESETTING BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PHOTO EYE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTING PHOTO EYES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

INTRODUCTION
1
INTRODUCTION
The information contained in this manual will allow you
to install your Rytec Turbo-Seal®Door in a manner that
will ensure maximum life and trouble-free operation.
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 Technical Support Department at
800-628-1909. Always refer to the serial number of the
door when calling the representative or Technical Sup-
port. The serial number plate is located inside one of the
side columns.
The wiring connections and schematics in this manual
are for general information purposes only. A wiring
schematic is provided with each individual door, specif-
ically covering the control and electrical components of
that door.
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
4 control panel. (See Figure 1.)
IMPORTANT: When installing multiple doors
of the same model but different
sizes, verify the serial number 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 of 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.
A8500206
Head Assembly (Includes
Left Side Column
Right Side Column
Drive Motor Gearbox Assembly)
Rytec
System 4
Control
Panel

2
INSTALLATION—MATERIAL, TOOLS, AND EQUIPMENT
INSTALLATION
MATERIAL, TOOLS, AND EQUIPMENT
1. Threaded rod (¹₂-in. diameter) and other various
wall anchor hardware and material. Concrete
anchor bolts (¹₂-in. diameter).
(See “ANCHORING METHODS” on page 3.)
2. Assorted shim stock.
3. Double-sided tape (to temporarily hold shims).
4. Carpenter’s or spirit level (4-ft. minimum length).
5. Carpenter’s square.
6. Hammer drill.
7. Masonry drill bit (for ¹₂-in. diameter anchors).
8. Three or four bar clamps (48-in. long).
9. Hammer or mallet, and block of wood.
10. Crowbar or pry bar.
11. Assorted hand tools (pliers, tape measure, etc.).
12. Socket and wrench sets.
13. Water level, line level, or transit.
14. Two ladders (taller than height of door opening).
15. Forklift (see “Forklift Requirements” below).
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. Two installers.
2. An electrician is required for making all electrical
connections. (See “Electrician’s Responsibilities”
on page 2.)
NOTE: All electrical work must be performed in
accordance with local and state building
codes.
3. 100% accessibility to the door opening during the
entire installation process. No traffic should be
allowed to pass through the opening while the door
is being installed.
Forklift Requirements
A forklift supplied by the customer, dealer, or installer is
mandatory for the safe and proper installation of this
door. The forklift should have:
• 2,000-pound lift capacity
• Minimum height ability — door height, plus 12 in.
• Side-shift capability (desired)
Electrician’s Responsibilities
For complete details on the responsibilities of the elec-
trician, refer to the Rytec System 4 Drive & Control
Installation & Owner’s Manual.
Floor-Loop Activator Requirements
If a floor-loop activator was ordered and shipped with
your Rytec door, the following additional items will be
required to install the activator.
NOTE: For complete floor-loop installation instruc-
tions, refer to the manual that was shipped
with the activator.
1. Concrete saw (with water cooling attachment).
2. Water supply and garden hose.
3. Wet/dry shop vacuum.
4. 200–500 feet of 16-gauge, 19-strand, type XLPE,
copper, crosslink polyethylene jacket wire (or equiv-
alent). The size of the floor loop will determine the
length of wire required.
5. Bondo P606 Flexible Embedding Sealer (or equiva-
lent) — required to fill saw cuts in floor after the acti-
vator is installed. For cold temperature applications,
Bondo P610 Speed Set must be added to the P606
to ensure the sealer cures properly.
Fill-In Material Requirements
Some applications may require the use of a door pullout
(extension) to gain clearance of an existing obstruction
between the door and the door opening. The following
materials can be used to fill the space or gap between
the door and the door opening.
1. 16-gauge hot-rolled sheet steel.
2. 2-in. x 2-in. x ³₁₆-in. angle iron.

3
INSTALLATION—GENERAL ARRANGEMENT OF DOOR COMPONENTS
GENERAL ARRANGEMENT OF
DOOR COMPONENTS
Figure 2 shows the location of the major components of
the door and the general placement of the associated
sub-assemblies for a typical installation.
This illustration is provided to you for informational pur-
poses only. It should not be relied upon solely during the
installation of your door and its sub-assemblies.
Figure 2
NOTE: Figure 2 shows the front side of the door.
Left and right are determined when view-
ing the front side of the door.
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 are the responsibility of
the door owner. If you have any questions, call your
Rytec representative or the Rytec Technical Support
Department at 800-628-1909.
NOTE: Use ¹₂-in. diameter threaded through bolts
or ¹₂-in. diameter threaded rods to anchor
the door to all wall applications. Use ¹₂-in.
diameter concrete anchor bolts to anchor
the door to a concrete floor.
If expansion anchors are used, a quarterly
inspection should be implemented for safe
and secure door operation.
Concrete, Block, or Brick Walls
Figure 3
Wood, Block, Brick, or Insulated Walls
Figure 4
A8500206
Fused
Disconnect
Control
Bottom Bar
Assembly
Head Assembly (Includes
Left Side Column
(Includes Serial Number
Plate, Counterweight, Front
Right Side Column
(Includes Counterweight,
Front and Rear Photo
Drive Motor Gearbox Assembly,
Fabric Roll, and Optional Hood)
and Rear Photo Eyes)
Panel
Eyes)
A0500005
Side
Expansion
Concrete Wall
Column
Anchor
A0500037
Side
Through Bolt
or Threaded Rod
Crush Plate
(¹₂-in. Thick,
6-in. x 8-in.
Steel)
Wood
Column
Wall

4
INSTALLATION—UNCRATING
Insulated Wall
Figure 5
Insulated Wall
Figure 6
UNCRATING
Your Rytec door has been crated to allow for minimal
handling of assemblies during the installation process.
NOTE: Remove parts and sub-assemblies from
the shipping crate in the order directed
throughout this manual.
1. Remove the top of the crate. (See Figure 7.)
2. Remove the front of the crate.
Figure 7
LOCATING CENTERLINE OF DOOR OPENING
NOTE: Accurate measurements are critical for the
proper installation and operation of your
Rytec door. Verify all measurements.
1. Measure the width of the door opening.
2. Divide the measurement in half to locate the center-
line. Then mark the centerline along the floor.
(See Figure 8.)
Figure 8
A0500039
Insulated Wall
Through Bolt
or Threaded Rod
Side
Column
Aluminum-Clad Lumber
(Front and Back Side — Full Length)
A0500038
Through Bolt
or Threaded Rod
Insulated
Aluminum-Clad Lumber
(Back Side — Full Length)
Wall
Side
Column
A8500070
Head Assembly
(Located in Rear
Open Crate by
First Removing Top,
of Crate)
Then Removing Front
A0500001
Centerline of
Opening
Overall Width
of Door Opening
Half Width of
Door Opening

5
INSTALLATION—LOCATING SIDE COLUMNS
LOCATING SIDE COLUMNS
1. Locate the layout drawing of the door. It should be
attached to the small parts carton packed inside the
shipping crate. This drawing identifies the production
width of your door. Verify the dimension provided by
measuring the width (length) of the head assembly.
2. Using the centerline as a reference point, lay out and
mark half of the door’s production width along the
floor. (See Figure 9.)
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 Technical Support
Department at 800-628-1909.
Figure 9
3. With a carpenter’s square placed against the wall,
mark both sides of the door along the floor. Extend
the line along each edge.
4. Check the floor for level across the door opening.
The floor must be level within 0.12 in. from side to
side. If one side of the opening is higher than the
other, a shim under the side column will be required.
Figure 10 and Figure 11 show two methods that
can be used to ensure level side columns.
NOTE: Contact the Rytec Technical Support
Department if the floor is more than 1 in.
out of level.
Figure 10
Figure 11
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)
A0500004
This Dimension
Must Be Equal
on Both Sides
of Door Opening
Water Level
Shim Plate
(If Required)

6
INSTALLATION—SIDE COLUMNS
SIDE COLUMNS
1. Remove the right side column from the shipping
crate. (See Figure 12.)
2. Remove the cover from the side column by remov-
ing the screws that hold the cover in place. Save all
hardware for later use.
Figure 12
3. Stand the right side column on the floor. Place it
against the wall, just outside the line indicating the
production width of the door. (See Figure 13.)
IMPORTANT: It is critical that the side columns
are mounted square and plumb
with the wall, and level across
the door opening. Using a 4-foot
level and carpenter’s square will
help ensure the columns are cor-
rectly set. Place shims where
necessary.
In addition, the use of bar clamps
will allow you to temporarily
secure the columns to the wall,
while allowing you to make slight
adjustments during the installa-
tion process.
Before drilling any holes, ensure there are
no electrical wires, water pipes, or gas lines,
etc., buried in the floor or hidden in the wall.
4. Once the side column is set plumb and square,
anchor it to the wall and floor. (See Figure 13.) Pre-
drilled anchor holes have been provided in the side
column. DO NOT securely tighten the anchors at
this time — they will be tightened later on, after the
head assembly is installed.
NOTE: Use ¹₂-in. expansion shell or stud-type
anchors for concrete walls. Use through
bolts or threaded rods for brick walls and
other applications where expansion
anchors are not appropriate.
If a stud-type anchor is used for the bottom
anchor, the anchor must not extend more
that 1¹₂ in. above the base plate of the side
column.
Figure 13
5. Mount the left side column to the wall and floor fol-
lowing the above procedure that was used for
installing the right side column.
6. With both columns set and snugly bolted in place,
check the overall squareness of each column.
Compare the diagonal measurements and the
upper and lower horizontal measurements across
the columns. The columns are square and parallel
when the diagonal measurements are equal and
the horizontal measurements are equal.
If either column requires a slight repositioning
(when the difference of either comparison is
greater than ¹₄ in.), use a block of wood and a mal-
let to nudge the column into position.
A8500071
Remove Wood
Forks
Support
Remove Wood
Support
A8500114
Carpenter’s
Right Side
Anchor Hole
Production Width Line
Column
Level
Anchor Holes

7
INSTALLATION—HEAD ASSEMBLY
HEAD ASSEMBLY
1. Remove the control panel, counterweights, and any
other items from the shipping crate that might block
the head assembly during its removal.
2. Remove the head assembly from the crate.
(See Figure 14.)
NOTE: If the head assembly contains a hood,
remove the side cover from both ends of
the head. Save all hardware for later use.
(See Figure 14.)
Figure 14
Secure the head assembly to the forklift
with C-clamps prior to lifting it to the top of
the side columns.
3. Clamp the head assembly to the forklift before lifting
it into position. (See Figure 15.)
Figure 15
4. With the head assembly safely secured to the fork-
lift, place it on top of the side columns. Align the
mounting holes in each side column with the holes
in the head assembly.
5. At each end of the bottom edge of the door panel is
a plastic breakaway tab. Guide each tab into the
channel running along the edge of the adjoining
side column.
6. Attach each side column to the head assembly
using three ¹₂-12 x 1³₄-in. serrated hex head cap
screws and nuts. The screws and nuts are located
in the small parts carton. (See Figure 16.)
Figure 16
A8500066
Standard Head Assembly
Hooded Head Assembly
A8500065
Head
Forks C-Clamps
Assembly
A8500085
Serrated-Flange
Hex Head Screws
and Nuts
Head
Assembly

8
INSTALLATION—COUNTERWEIGHTS
7. After the head assembly is secured to both side col-
umns, securely tighten all floor and wall anchors.
(See Figure 17 and Figure 18.)
Figure 17
Figure 18
8. Unclamp the head assembly from the forklift and
then remove the forklift.
9. Remove the bar clamps that were used to secure
the side columns to the wall.
COUNTERWEIGHTS
A counterweight can weigh in excess of
100 pounds. Make sure that safe handling
procedures are followed and that each
counterweight is securely supported dur-
ing its installation. If not handled properly,
a counterweight can damage door compo-
nents and cause serious personal injury.
1. Place a counterweight on a 2 in. block in front of
each side column with the guide on the weight fac-
ing the outside edge of the side column.
(See Figure 19.)
Figure 19
NOTE: To install the counterweight, attach the
counterweight strap.
2. With the straps hanging straight, attach them to the
counterweights using two ¹₂-13 x 1-in. serrated-
flange hex screws and clamp bars provided in the
small parts carton. Route the straps through the
clamp bars as shown in Figure 20.
Figure 20
3. Twist the counterweight and slide the guide behind
the lip on the front of the side column. Then slide the
counterweight against the side column until the
guide fits behind the conduit guide.
A8500083
Floor
Anchor
A8500084
Wall
Anchors
A8500190
2 in.
Counterweight
A8500116
Serrated-Flange
Hex Screws
Clamp
Counterweight
Strap
Bars
Counterweight

9
INSTALLATION—DOOR SEALING
4. Securely block each counterweight 16 to 20 in.
above the bottom of the side column.
(See Figure 21.)
Figure 21
5. Remove the shipping tape from around each coun-
terweight strap.
NOTE: Door must be in the fully open position.
6. Route each strap over its associated idler pulley as
shown in Figure 22.
Figure 22
7. Tighten the clamp bars to secure each strap. Then
carefully remove the support block out from under
each counterweight to allow the weights to hang
free. If necessary, readjust the straps.
IMPORTANT: The 16 to 20 in. mounting height
for each counterweight, as indi-
cated in Figure 21, is adequate
for most Turbo-Seal doors. How-
ever, for extra-wide or -short
doors, the counterweights may
have to be adjusted closer to the
bottom of the side column.
To check the position of each
counterweight, first release the
motor brake by pulling on the
brake release cable. Then manu-
ally move the door to its fully
closed position. The clearance
between the top of each counter-
weight and the top of its associ-
ated side column must be at
least 2 in.
If an adjustment is necessary,
move the door to the fully open
position. After placing a support
block under the counterweight,
readjust the strap, as required,
until the 2-in. clearance is
achieved.
8. After all adjustments are complete, cut off any
excess strap to within 6 in. of the upper clamp bar.
Tape the loose end of each strap to the main length
of strap.
9. Attach the side column covers using the saved
hardware.
DOOR SEALING
Caulk the side columns and head assembly where they
meet the wall. Use an industrial or construction grade
caulk.
A8500092
16 to 20 in.
A8500115
Counterweight
Idler
Counterweight
Counterweight
Pulley
Strap Spool
Strap

10
INSTALLATION—PHOTO EYES
PHOTO EYES
The Turbo-Seal door is shipped with two sets of photo
eyes for monitoring the front and back sides of the door.
The photo eyes that monitor the back side of the door
were installed at the factory, inside the left and right side
columns. To complete their installation, you will need to
route the control wire for the photo eyes. Later, the
photo eyes to monitor the front side of the door will be
installed.
FACTORY-INSTALLED PHOTO EYE
To complete the installation of the factory-installed
photo eye located inside the left side column, route the
wire cable leading from the photo eye up through the
conduit located in the rear corner of the side column.
(See Figure 23.)
Continue routing this cable through the hole in the top of
the column, then over to the junction box located near
the front of the head assembly.
Figure 23
FIELD-INSTALLED PHOTO EYE
1. Remove the photo eye emitter and receiver module
assemblies, cord grips, and four stainless steel
¹₄-20 hex nuts from the small parts carton.
NOTE: The emitter can be identified by the single
green light located along the barrel of the
photo eye. The receiver has two lights:
one is green and the other is yellow.
(See Figure 24.)
Figure 24
Figure 25
2. Install the photo eye emitter module assembly on
the threaded studs located on the front of the left
side column. Face the photo eye with its lens point-
ing toward the center of the door. Use two stainless
steel ¹₄-20 hex nuts to secure the photo eye module
assemblies to the studs. (See Figure 26.)
A8500093
Hole
Wire Conduit
A2500258
Transmitter
Module
Power Light
(Green)
Designation
A2500259
Receiver
Module
Alignment Light
(Yellow)
Designation

11
INSTALLATION—CONTROL PANEL AND ELECTRICAL CONNECTIONS
Figure 26
3. Install the cord grip in the hole that is just below the
threaded studs.
4. Route the photo eye wire cable through the cord
grip. Pull out the majority of slack between the photo
eye and cord grip (do not pull the cable too tight).
Tighten the cord grip to secure the cable.
(See Figure 27.)
Figure 27
5. Run the wire cable from the back of the cord grip up
through the conduit located at the rear corner of the
side column — taking the same path as the wire
cable on the factory-installed eye. Pass the cable
through the hole in the top of the side column, then
over to the junction box.
6. Install the photo eye receiver module assembly on
the threaded studs located on the right side column.
Use two stainless steel ¹₄-20 hex nuts to secure the
photo eye to the threaded studs.
7. Feed the photo eye cable through the cord grip. Pull
out the majority of slack between the photo eye and
cord grip (do not pull the cable too tight). Tighten the
cord grip to secure the cable.
8. Run the wire cable from the back of the cord grip up
through the conduit located at the rear corner of the
side column — taking the same path as the wire
cable on the factory-installed eye. Pass the cable
through the hole in the top of the side column, then
over to the junction box.
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec Sys-
tem 4 Drive & Control Installation & Owner’s Manual for
information on control panel installation, electrical con-
nections, door limit settings, and initial door startup pro-
cedure.
NOTE: All wiring from the fused disconnect to the
control box and from the control box to the
motor mount side column, as well as con-
duit running from the control box to the
floor, if a floor loop is used, is provided by
the door owner/installer or the electrician.
All wiring and conduit must meet all local
and state codes. Wires provided with the
door are labeled with terminal or contact
numbers.
A8500210
Stainless Steel
Photo Eye
Threaded
Assembly
Predrilled
Hole for
Cord Grip
Studs
Face Lens Toward
Center of Door
Hex Nuts
A8500209
Photo Eye
Cord
Wire Cable
Grip

12
INSTALLATION—OPEN- AND CLOSE-LIMIT DOOR POSITIONS
OPEN- AND CLOSE-LIMIT DOOR POSITIONS
See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The close and open limit
door positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that the
door travel allows the yellow vinyl loop on the bottom bar
to gently seal against the floor. (See Figure 28.)
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 28
Open-Limit Position
The open-limit switch should be adjusted so that the
door travel allows the top of the plastic breakaway tab
on the end of the bottom bar assembly to stop approxi-
mately 1¹₂ to 2 in. from the bottom of the guide block on
each side column. (See Figure 29.)
Figure 29
REVERSING EDGE SWITCH INSPECTION AND
ADJUSTMENT
Do not stand under the door panel when
testing the reversing edge. If the reversing
edge switch is not working properly, the
panel could strike personnel and cause
injury.
To check the reversing edge switch, run the door
through the down cycle. As the door is lowered, tap the
bottom of the reversing edge. If the switch is working
properly, the door will immediately reverse direction and
run to the open position. Push the control panel push-
button to close the door after the check is completed.
If the door does not reverse direction, check the air
bleed and sensitivity of the reversing edge switch.
Reversing Edge Switch Air Bleed Check
The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
1. The reversing edge switch is located inside the bot-
tom bar assembly, on the end opposite the drive
motor. To inspect and adjust the switch, remove the
access cover from the face of the bottom bar
assembly. (See Figure 30.)
A7500195
Ye l l o w
Fabric Panel
Rubber
¹₂ to 1 in.
Reversing
Vinyl Loop
Edge
A8500214
1¹₂ to 2 in.

13
INSTALLATION—REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT
Figure 30
2. Make sure the clear PVC hose is in tight contact
with the air input post so that air leakage cannot
occur and that vibration will not cause the hose to
fall off. Also make sure the hose is not kinked.
(See Figure 31.)
Figure 31
3. The air bleed has been set at the factory and should
not require adjustment. If adjustment is necessary,
turn the air bleed adjustment screws located on the
front and back of the switch fully clockwise — but do
not overtighten. Then turn each screw back (coun-
terclockwise) one full turn.
Reversing Edge Switch Sensitivity Adjustment
The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
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 32.)
Figure 32
2. Turn the sensitivity adjustment screw, located on
the face of the switch, clockwise or counterclock-
wise until continuity is achieved. Then adjust the
screw three-quarter turn counterclockwise. Adjust-
ing the screw counterclockwise decreases sensitiv-
ity, clockwise increases sensitivity. (See Figure 32.)
3. Reattach the wires and resistor, then replace the
access cover.
NOTE: If the reversing edge is too sensitive, the
door may reverse direction during the clos-
ing cycle without coming in contact with an
object. If this occurs, readjust the revers-
ing edge switch.
A8500208
Access Cover
Bottom Bar
Assembly
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

14
INSTALLATION—KILL SWITCH CHECK AND ADJUSTMENT
KILL SWITCH CHECK AND ADJUSTMENT
A kill switch has been mounted in the bottom bar
assembly. The purpose of this switch is to prevent the
door from being operated if the breakaway bottom bar
becomes separated from either side column.
Kill Switch Check
Take precautions to prevent the door from
being operated when performing the fol-
lowing procedure.
1. Move the door to approximately head or chest
height and then stop the door.
NOTE: When a kill switch is activated, it should
not be possible to restart the door until the
door is reassembled and the control panel
is reset.
2. Push the breakaway bottom bar out of the side col-
umn. Door should not operate until control panel is
reset. (See Figure 33 and Figure 34.)
If the kill switch did not operate properly: Adjust
the kill switch and then recheck it. (See "Kill Switch
Air Bleed Adjustment" below.)
If the kill switch operated properly: Reinstall the
bottom bar into the side column. (See “RESET-
TING BOTTOM BAR” on page 15.)
Figure 33
Figure 34
Kill Switch Air Bleed Adjustment
1. The kill switch is mounted in the bottom bar assembly,
on the end below the door motor. To access the
switch, first remove the access cover.
(See Figure 35.)
Figure 35
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 36.)
3. The air bleed has been set at the factory and should
not require adjustment. If adjustment is necessary,
turn the air bleed adjustment screws located on the
front and back of the switch fully clockwise — but do
not overtighten. Then turn each screw back (coun-
terclockwise) one full turn. (See Figure 36.)
A7500050
Bottom Bar
Plastic Tabs Out
of Side Column
Air Switch
Bladder
Assembly
A8500212
Breakaway Tab
Bottom Bar
Assembly
A8500212
Bottom Bar
Access Cover
Assembly

15
INSTALLATION—RESETTING BOTTOM BAR
Figure 36
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 37.)
Figure 37
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.
Adjusting the screw clockwise decreases sensitiv-
ity, counterclockwise increases sensitivity.
(See Figure 37.)
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.
RESETTING BOTTOM BAR
The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
1. Turn off power to the door.
NOTE: If necessary, the door can be manually
raised or lowered to a comfortable height
to make repairs convenient.
2. If necessary, disengage the motor brake and raise
(or lower) the door to a comfortable working height.
3. Position the breakaway tabs on one end of the bot-
tom bar assembly in the side column channel. Lift
the other side of the bottom bar and position the
breakaway tabs in the side column channel.
(See Figure 38.)
Figure 38
A7500202
PVC Hose Must
Be Tight on
Air Input Post
Kill Switch
Air Bleed
Adjustment
Screw (One
on Each Side
of Switch)
A7500202
Upper Air
Input Post
Sensitivity
Remove Wires
to Test and
Adjust Switch
Adjustment
Screw
A8500077
Breakaway
Ta b s
Side Column
Channel

16
INSTALLATION—PHOTO EYE TEST AND ADJUSTMENT
4. Check to make sure the fabric is tucked inside each
channel. (See Figure 39.)
Figure 39
5. Turn power ON.
NOTE: When a kill switch is activated, it should
not be possible to restart the door until the
door is reassembled and the control panel
is reset.
6. Cycle the door and check door operation.
PHOTO EYE TEST AND ADJUSTMENT
The door is equipped with two sets of photo eyes that
monitor the front and back sides of the door. Each set of
eyes consists of an emitter module and a receiver mod-
ule.
To prevent one set of photo eyes from interfering with
the other set of eyes, the emitters and receivers are
mounted diagonally across from each other — the side
columns each have an emitter module and a receiver
module, from each set of eyes. (See Figure 40.)
Figure 40
1. Verify that the photo eye emitter mounted on the
front side of the door is aligned with the receiver on
the opposite side of the door opening. The yellow
light on the photo eye receiver will light when the
emitter and receiver are properly aligned.
(See Figure 41.)
Figure 41
2. If an alignment is necessary, first verify that the
mounting brackets supporting the photo eye emitter
and receiver are perpendicular to the side column
and that the emitter and receiver are aligned.
If the photo eye emitter and receiver are not
aligned, bend the mounting brackets as needed.
3. Verify that the factory-installed photo eyes on the
back side of the door are aligned as described.
Make any necessary adjustments until the photo
eye emitter and receiver are aligned.
4. After all adjustments are made and both sets of
photo eyes are properly aligned, clean the lens of
each photo eye using window cleaner and a soft,
clean cloth.
A8500078
Side Column
Channel
Tu c k Fa b r i c
Into Each
Channel
A7700046
A8600216
Direct Photo
Eye for
Horizontal Beam
Yellow Light Indicates
Photo Eye Emitter and Receiver
Are Properly Aligned