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