Rite-Hite TRAKLINE 8910 Roll Door, TRAKLINE 8920 Fold Door Owners Manual
Below you will find brief information for Roll Door TRAKLINE 8910, Fold Door TRAKLINE 8920. The TRAKLINE roll or fold door is designed to be a fast, smooth opening, low maintenance door that provides superior environmental separation while reducing passage time and temperature loss. The door has a universal controller, interior sideframe controls, exterior/interior folding door, V-Flex curtain release system and heavy-duty industrial materials for high cycles and minimal wear. This manual is a complete guide to installation, operation and servicing of the door.
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TRAKLINE™
ROLL DOOR - MODEL 8910
FOLD DOOR - MODEL 8920
This Manual Covers Doors Shipped After 2-20-06.
PRINTED IN U.S.A.
EMAIL: [email protected]
PUBLICATION NO. 891020G
JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
PRODUCT INTRODUCTION
TABLE OF CONTENTS
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .3
SIDEFRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4
ROLLER TUBE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .5
DRIVE SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . .7
HEADER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
V-FLEX STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .9
COUNTER BALANCE / THRU-WALL BRAKE RELEASE . . .13
ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .14
PHOTOEYE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .16
LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .18
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . .19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ELECTRICAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . .23
ARCHITECTURAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . .27
NOTICE TO USER
Our mission is to “Improve Industrial Safety, Security and
Productivity Worldwide Through Quality and Innovation.”
Thank you for purchasing the TRAKLINE™ ROLL or FOLD door from
RITE-HITE DOORS, INC. The TRAKLINE door is designed to be a fast, smooth opening, low maintenance door that provides superior environmental separation while reducing passage time and temperature loss.
This manual should be thoroughly read and understood before beginning the installation, operation or servicing of this door.
Refer to Partslist Manual for Exploded Views and Part Numbers.
This owners manual MUST be stored near the door.
RITE-HITE DOORS, INC. reserves the right to modify the electrical and architectural drawings in this manual as well as the actual parts used on this product are subject to manufacturing changes and may be different than shown in this manual. Due to unique circumstances with varying requirements, separate prints may be included with the unit.
The information contained in this manual will allow you to operate and maintain the door in a manner which will insure maximum life and trouble free operation. The serial # for your door is on a label located on the side of the control box and sideframe.
This manual should be thoroughly read and understood before beginning the installation, operation or servicing of this door.
Complete Final Checklist prior to leaving site.
Refer to partslist manual for exploded views and part numbers.
Your local RITE-HITE DOORS, INC. Representative provides the
Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. If any procedures for the installation, operation or maintenance of the TRAKLINE door have been left out of this manual or are not complete, contact RITE-HITE DOORS, INC. Technical
Support at 1-563-589-2722.
RITE-HITE DOORS, INC. are covered by one or more of the following
U.S. patents, including patents applied for, pending, or issued:
5,025,846, 5,143,137, 5,203,175, 5,329,781, 5,353,859, 5,392,836,
5,450,890, 5,542,463, 5,579,820, 5,601,134, 5,638,883, 5,655,591,
5,730,197, 5,743,317, 5,794,678, 5,887,385, 5,915,448, 5,944,086,
5,957,187, 6,042,158, 6,089,305, 6,098,695, 6,145,571, 6,148,897,
6,192,960, 6,321,822, 6,325,195, 6,330,763, 6,352,097, 6,360,487,
6,574,832, 6,598,648, 6,612,357, 6,615,898, 6,659,158
FEATURES
- i-COMM™ Universal Controller
- Interior Rolling Door with Standard Sideframe Controls
- Exterior/Interior Folding Door.
- V-Flex™ Curtain Release System.
- Fast smooth opening with a maximum speed of up to 40 in/sec.
- Motor options of 3 Phase 60 Hertz-208V, 230V, 460V, 575V
- Motor option with 3Ø 50 Hertz 400V may have slower speeds
- One or Two directional curtain breakaway.
- High Wind package.
- Heavy-duty industrial materials for high cycles and minimal wear.
TOOLS AND MATERIAL REQUIRED
Straps For Lifting Roller Tube and Header (optional)
Forklift With High Boom
Scissors Lift or 20’ Extension Ladder
8’ or 10’Step Ladder
Tube of Anti-Seize or Grease Lubricant
Set of Allen Wrenches (1/8”, 5/32”)
Caulk Gun and Tubes
1 1/4” & 1 1/2” Open End Wrench
1/2” & 9/16” Open End Wrench or Ratchet Wrench
1/2” & 9/16” Socket
Cordless Drill (3/8” or 1/2”) w/Phillips Bit
18” Long Drill Bits For Thru-Bolting
Straight Screwdriver (small 1/8” blade)
Phillips Screwdriver
Hammer
Hammer Drill
3/8” or 1/2” Masonry Bits
Hole Saw
5/16” Driver Bit For Drill
Tape Measure 25’ Minimum
Wire Strippers and Side Cutters
Retaining Ring Pliers
3/16” Punch
Utility Knife
6’ Carpenters Level
Water Level
Multi-Meter
Hardware for mounting the door to the wall, shimming and anchoring to the floor are not provided.
WARRANTY
RITE-HITE DOORS, INC. warrants that it’s TRAKLINE door, including electrical components, will be free from defects in design, materials, and workmanship for 150,000 cycles or for a period of one (1) year from the date of shipment. The panel fabric warranty covers material failure under normal wear conditions; it does not cover labor or damage incurred from abuse, misuse or impact. Warranty does not cover wear items such as seals, belts, fuses, and bulbs. All claims for breach of this warranty must be made within thirty (30) days after the defect is or can, with reasonable care, be discovered. To be entitled to the benefits of this warranty, the products must have been properly installed, maintained, operated within their rated capacities, and not otherwise abused. Periodic lubrication and adjustment are the sole responsibility of the owner. This is RITE-HITE DOORS, INC. exclusive warranty.
RITE-HITE DOORS, INC. expressly disclaims all implied warranties of merchantability and fitness. Non-standard RITE-HITE DOORS, INC.
warranties, if any, must be specified by RITE-HITE DOORS, INC. in writing. In the event of any defects covered by this warranty, RITE-
HITE DOORS, INC. will remedy such defects by repairing or replacing any defective equipment or parts, bearing all of the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract negligence or strict liability. Neither
RITE-HITE DOORS, INC., RITE-HITE DOORS, INC. representatives or any other manufacturer whose products are the subject of this transaction, shall in any event be liable for any loss or use of any equipment or incidental or consequential damages of any kind whether for breach of warranty, negligence, or strict liability. The application of a manufacturer's specifications to a particular job is the responsibility of the purchaser.
RITE-HITE DOORS, INC.
8900 N. Arbon Drive
P.O. Box 245020
Milwaukee, Wisconsin 53224-9520
Sales: 414-355-2600
Toll Free: 800-456-0600
Aftermarket: 563-589-2781
Service: 563-589-2722
Service Fax: 563-589-2737
Representatives in All Major Cities www.ritehite.com
2 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
INSTALLATION INSTRUCTIONS
QTY DESCRIPTION
Crate Containing the following
1 Header Front Brace (w/Curtain and/or V-Flex Straps)
1
1
1
Header Rear Brace (w/Curtain and/or V-Flex Straps)
Roller Tube w/Lift Straps or Curtain
Header Front Brace (Roll)
1
1
1 a/r a/r
1
1
1
1
1
Header Rear Brace (Roll)
RH Sideframe
LH Sideframe
Control Box (optional) w/Electrical Prints and O.M.
Drive Assembly w/Cables attached
Control Box Cable (optional)
Photoeye Cables for Thru-Beam (optional)
Drive Shroud
Header Covers & Extrusions
Sideframe Covers & Extrusions
Parts Box Containing the Following
1 Owners Manual
1
1
1
Limit Switch Sprocket Large w/Set Screws (2)
Limit Switch Chain (17” RHD, 18” LHD)
Limit Switch Chain Link
1
2
1
12/14
12/14
1/4” x 3/16” x 4 1/2” Key
Bearing Lock Collar
Retaining Ring
3/8-16 X 1” Bolts for Header Braces
3/8” Nuts for Header Braces
12/14
12/14
1
1
2
3/8” Lock Washers for Header Braces
3/8” Flat Washers for Header Braces
#8 x 1/2” Self Tap/Drill Screw
#10 Int/Ext Lock Washer (Control Box Option)
Stand Clear Warning Labels (Control Box Option)
3 #12-14 x 3/4” Self Tap/Drill Screws
PRELIMINARY INSTRUCTIONS
Here are a few things to verify before getting started:
1.
Make sure you are working at the correct door location and that you have any required work or building permits.
2.
Make sure the electrician is ready to bring the correct electrical power supply to the door and the electrical power can be shut off without interfering with other plant operations.
3.
Barricade the work area on both sides of the opening.
4.
Detour material handling equipment (fork lift trucks, etc.) during the installation of the door.
5.
Verify there is nothing buried in the floor (electrical supply, communication lines, etc.) where the anchor bolts will be installed.
6.
Inspect the installation site to make sure there are no overhead obstructions (sprinkler pipes, HVAC systems, electrical supply lines, etc.) that might interfere with the lifting of the door assembly during installation.
7.
Move the crate as close to the opening as possible.
8.
When unpacking the door components remove the smaller items first, electrical components, parts box, gearmotor, roller tube, header braces/curtain assembly, and the sideframe assemblies last.
9.
Measure the overall width of the door opening near the top and the floor (Dimensions AA and BB), Figure 1.
These measurements should be ± 1/4".
TWO-WAY BREAKAWAY
Must Be Equal to O.D.W.
+1/4”/-0” and Perpendicular to Wall
Wall
AA
CC
Level
Sideframe
Sideframe
LISTING OF MEASUREMENTS AND
MARKINGS REQUIRED
DOOR OPENING
Door width at bottom
Door width at top
Door height left
Door height right
FLOOR LEVEL
Mark left wall where water is level.
Mark right wall where water is level.
DD
Wall
High Side
Water Level
BB
TWO WAY BREAKAWAY
1/2 O.D.W.
ONE-WAY BREAKAWAY
Must Be Equal to O.D.W. Plus 10 3/4”
+1/4”/-0” and Perpendicular to Wall
ONE WAY BREAKAWAY
1/2 O.D.W. plus 5 3/8”
FIGURE 1-SIDEFRAME MARKING
Low Side
“AA” & “BB” Dimension must be the same
DOOR MUST BE:
-Plumb/Perpendicular
-The door must be installed level, even if floor is not level.
Pub. No. 891020G JANUARY 2007 3
TRAKLINE™ ROLL / FOLD Model 8910/20
SIDEFRAME INSTALLATION
10.
Measure the height of the opening at the left and righthand sides (Dimensions CC and DD), Figure 1.
These should be within ±1/2" of the dimensions listed on the
Serial Number label. If the measurements do not agree,
STOP! Contact your RITE-HITE DOORS, INC.
representative.
Compare these measurements to the sizes listed on the
Serial Number label for the door to be installed. Make sure to match the door serial# with the correct serial# on the control box, in case of multiple doors.
PREPARING THE JAMB
1.
When preparing the sideframe locations, make all measurements from the centerline of the door opening.
Measure between the jamb at the top of the opening and at the floor and divide this measurement in half and mark the centerline on the wall and on the floor, Figure 1.
Drop a plumb bob from the mark at the top of the jamb and place a mark on the floor. The dimension should be within 1/8”, if not place a mark half way between these two marks.
11.
Verify that the door jambs are plumb and perpendicular and that the header is level.
ONE-WAY BREAKAWAY:
2.
From this centerline, measure 1/2 O.D.W. plus 5 3/8" and place a mark on the floor on each side. This will offset the location of the V-Flex™ curtain release system, Figure 1.
12.
Make sure that the floor is level using a carpenter’s level or hydro-level (water level). If the floor is not level to within 1/8", shimming of the sideframe assemblies will be required, Figure 1.
TWO-WAY BREAKAWAY:
3.
From this centerline, measure 1/2 O.D.W. and place a mark on the floor on each side, Figure 1.
NOTE: For one directional breakaway the sideframes are mounted at O.D.W. plus 10 3/4”: +1/4” -0”.
For two way-directional breakaway the sideframes are mounted at O.D.W: +1/4” -0”.
4.
Measure across the door opening from sideframe mark to sideframe mark to double check the overall dimension,
Figure 1.
Make sure that the distance between the marks does not vary more than +1/4 / -0".
It is not recommended to weld sideframes in place until door has been tested to ensure proper operation
5.
At each sideframe location measure approximately 24" above the floor and mark. Using a hydro-level determine if the locations marked are level. If not, determine the amount of sideframe shimming required by marking the high side level on the wall, Figure 1.
NOTE: Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 23-26.
Always check parts or control box for prints.
6.
The preferred method of installing the door is to assemble the door on the floor and raise the door as a unit using cargo straps attached to the roller tube. If overhead or side space is limited or the correct tools are not in place, install the door on the wall.
!
C A U T I O N ! ! !
Make sure to barricade the door opening on both sides to prevent unauthorized use until the door has been completely installed.
NOTE: Anchors, wall fasteners and shims are not supplied. Solid plastic or metal shims must fully support the sideframe base plate. Drill or cut through the shims to allow for the proper installation of the anchor bolts.
Roller Tube
Right Hand Sideframe
4
Block Support
Left Hand Sideframe
Place Block Under Guards Here to Balance Sideframes
FIGURE 3
Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
ROLLER TUBE INSTALLATION
NOTE: Handle sideframes with care as control components may be inside.
1.
Determine the drive sideframe by locating the integral control station and photoeyes inside of it, unless the optional control box is selected. Place the sideframes on blocks in front of the opening, with the top of the sideframe toward the opening and the back of the sideframe facing the floor, Figure 3.
An additional block may need to be placed under the guards at the bottom of the sideframe to prevent sideframes from tipping over.
ROLLER TUBE INSTALLATION
NOTE:
The non-drive side must wait until the door has been lifted and both header braces have been installed.
If the door is a right hand drive, the three bolts holding the sideframe anti-rotation bracket in place, will need to be loosened to fasten the rear header brace to the sideframe. Make sure not to rotate bracket around while loosening bolts.
The “L” brackets may also need to be loosened up to get the header braces attached to the sideframe.
FOLD DOOR ONLY NOTE:
2.
MAKE SURE THAT THE BEARING CAM LOCK FACES
OUTWARD, FIGURE 4.
3.
Install the roller tube non-drive shaft (shortest end w/no steps) through the bearing plate on the non-drive sideframe, Figure 4. Roll Door Only: The curtain will roll off the front of the roller tube, away from the wall.
4.
Install the drive shaft through bearing plate on drive sideframe, Figure 4.
NOTE: The bearing plate fasteners are shipped loose so the bearing can be self aligned when the door is installed on the wall. These fasteners MUST BE tightened later.
A exterior/exterior or interior/interior, will have the curtain attached to the front header brace. An exterior/interior mounted door will have the curtain attached to the rear header brace.
The lifting straps on the curtain will always be on the inside of the building.
The front header brace will be attached after the door is installed on the wall for ease of lifting and to prevent damage during lifting.
HEADER BRACE INSTALL
1.
ROLL DOOR - Attach the center brace bracket onto rear header brace, using the two 3/8”x1” hex head bolts with flat, lock washer and nuts, Figure 5.
5.
Remove one lock collar from the parts box and install the locking collar to the drive shaft by turning it clockwise by hand until snug, Figure 4.
NOTE: It may be necessary to hold the roller tube assembly from moving while completing this next procedure.
6.
Using a hammer and punch, drive the collar clockwise using the driving hole next to the set screw until it is snug.
Tighten the 5/16-18 set screw with a 5/32” allen wrench to lock in place, Figure 4.
1a.
FOLD DOOR - If the curtain is on the rear header brace, the center brace is pre-attached and will need to be fastened to the front header brace later, Figures 7 & 8.
Center Brace
Bracket
I M P O R TA N T ! ! !
Make sure the lock collar does not overhang the shoulder on the shaft. If the collar is overhanging the shoulder on the shaft, make sure the roller tube shaft is seated correctly. Failure to do so, will not allow the retaining ring to be seated in the groove on the shaft after the gearbox is installed.
Set Screw
Lock Collar
Header Braces
These 3 Flange Bearing Bolts are Shipped Loose For Self-
Alignment and MUST BE
Tighten Later In The Installation
Drive Shaft
5/16” Bolts
FIGURE 5-ROLL
Driving Hole
Roller Tube
FIGURE 4
Pre-Welded
Spacer
Pub. No. 891020G JANUARY 2007 5
TRAKLINE™ ROLL / FOLD Model 8910/20
HEADER BRACE INSTALLATION
“L” Brackets
Shown w/o roller tube in place.
Holes Toward the Top
Bearing Plate
Hole
Sideframe
Header Braces
Center Brace
Bracket
5/16” Bolts
FIGURE 7 - FOLD
FIGURE 6 - ROLL
2.
Position rear header brace with the two center holes at the top and the V-Flex straps at the bottom.
3.
Align the attached “L” bracket holes with the sideframe holes. Fasten with the six 3/8” x 1” hex head bolts, lock washers and nuts provided in the parts box, Figure 6.
Fold Door Only: If the curtain is on the front brace, there will be only four bolts.
NOTE: The motor is not attached to the sideframe during shipment and must be installed onto the drive shaft.
If a lift is not available, install the motor per details below. If a lift is available, the motor can be installed after the door is mounted to the wall.
NOTE: On Left Hand drive doors, attach the front header brace to the sideframes before installing the motor. This must be done now to gain access to the mounting bolts.
Curtain Adjustment Bar
Exterior/Exterior Mount Exterior/Interior Mount
Jamb
Adjust Curtain by
Turning Nut on Shaft
6
Rear V-Flex Strap
Lifting Straps MUST ALWAYS
Be Toward Inside of Building
Curtain
FIGURE 8 - FOLD
Front V-Flex Strap
Pub. No. 891020G JANUARY 2007
Ext/Ext Door: Curtain Adjustment
Bar on Front Header Brace
Int/Ext Door: Curtain Adjustment
Bar on Rear Header Brace
Int/Int Door: Curtain Adjustment
Bar on Front Header Brace
Holes Toward the Top
TRAKLINE™ ROLL / FOLD Model 8910/20
DRIVE SYSTEM INSTALLATION
“L” Brackets
Shown w/o roller tube in place.
Bearing Plate
Hole
Sideframe
1.
Apply a grease lubricant or anti-seize (not supplied) to the drive shaft, bumpers and bumper block for ease of gearbox installation and maintenance removal.
2.
ROLL DOOR - Turn roller tube to align the shaft and gear keyway, Figure 10.
2a.
FOLD DOOR - Turn the roller tube to get 1 1/2 pre-wraps on the lifting straps, Figure 18.
The lifting straps will always be on the opposite side of the roller tube as the curtain.
3. Install spacer onto the roller tube drive shaft, Figure 10.
4.
Install gearmotor assembly onto the drive shaft, some force may be required to get the bumpers over the bumper block, Figures 10 & 11.
5.
Route the limit switch cable through the hole in the back of the motor mount bracket and run down the length of the sideframe.
S/F Anti-Rotation Bracket Gearbox
Spacer
FIGURE 9 - FOLD
V-Flex Strap
6.
Install 1/4”x3/16”x 4 1/2” key into the keyway. DO NOT force the key. The key should slide freely, forcing the key may cause distortion. Tap key into keyway slot until they it is past the retaining ring slot.
7.
Install spacer onto the roller tube drive shaft, Figure 12.
8.
Gearbox case should be flush with the end of the retaining ring groove. Install retaining ring into shaft groove, Figures 10 - 12.
9.
Install 30 tooth sprocket onto the drive shaft until it hits the shoulder. Loosen limit switch bracket and align 10 tooth sprocket on the limit switch shaft using a short straight edge. When aligned, lock-tight and tighten the
1/4” set screws onto the flat spot of the shaft with an 1/8” allen wrench to 75 in/lbs.
Bumper
Bumpers Retaining Ring
Header
Braces
Bumper
Block
Drive
Shaft
Bumper
Block
Bumper
Sideframe
Motor
Assembly
Optional Bracket for
Mounting Control
Box Conduit.
FIGURE 10
Pub. No. 891020G JANUARY 2007
FIGURE 11
7
TRAKLINE™ ROLL / FOLD Model 8910/20
HEADER / V-FLEX STRAP INSTALLATION
10.
Install #35 chain onto sprockets, by lining up the chain so the connector falls onto the large sprocket, Figure 12.
11.
Place connector link onto chain and lock in place,
Figure 12.
To adjust the chain, loosen up the limit switch mounting bracket bolts and adjust so the chain deflects approximately 1/4”. More than 1/4” may cause wear on the limit switch shaft bearing assembly. Make sure chain is tight enough so it does not slip over the teeth. Tighten the Grade 2 bolts to 66 in/lbs.
NOTE: The motor and brake cables are pre-wired into the motor junction box, but need to be terminated into the Integral control panel or the control box later in the installation.
NOTE: When overhead forklift mast clearance is a problem, additional support blocks may need to be added under the roller tube assembly. Securely attach wooden supports to the roller tube assembly and lift into position. Use caution not to bend or twist the header braces, Figure 13.
FIGURE 13
I M P O R TA N T ! ! !
!
C A U T I O N ! ! !
DO NOT lift the assembly from either the rear or front braces, as they are not designed to be lifted and may bend.
New
Gearbox
Front Spacer
Snap Ring
Limit Chain Link
Connector
Small Limit Sprocket
FIGURE 12
Large Limit Sprocket
Place cardboard or some material around the curtain before fastening the lifting straps to the curtain. Failure to do so may leave imprints or soil the fabric.
1.
If overhead clearance is available, secure the roller tube to the fork lift forks and lift.
2.
Forklift should be slightly off center toward the drive side when lifting, as this side will be heavier. Make sure to place clamps on the forks to prevent the straps from sliding off the forks.
3.
Make sure sideframes slide easily on the floor when lifting. It is helpful if the sideframes can be walked up with one person on each side, Figure 13.
4.
When the door is in place, make sure to square and level the door and that the sideframes are parallel, if not raise or lower using shims as necessary. If shims are required, shims must fully support sideframe base plate. Drill or cut holes through shims to allow for anchors.
5.
The sideframe should be square to the header braces, if the sideframes twists when fastening to the wall shimming may be required.
NOTE: If equipped with integral controls, DO NOT use mounting hole if it falls behind controls.
6.
Mark the holes to be drilled, remove the door assembly from the wall and drill holes through the wall. RITE-HITE
DOORS, INC. recommends that the sideframe thru bolts use a backing plate for each bolt.
7.
Replace door assembly against the wall, plumb, level and double-check the overall width measurements at the bottom of the sideframes. There should not be more than
+1/4” or -0”. See Dimensions AA and BB on Figure 1.
Anchor the door to the wall and floor using the holes provided in the back of the sideframe and the bottom plate.
NOTE: If your door is a left hand drive, the (3) sideframe anti-rotation bracket bolts need to be loosened or taken off to mount the header brace to the sideframe. Make sure the bracket is not rotated while loosening bolts.
8 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
FRONT HEADER BRACE INSTALLATION
FRONT HEADER BRACE INSTALLATION V-FLEX STRAP INSTALLATION
1.
Install front header brace with the V-Flex straps at the bottom and the two holes in the center at the top and aligning the “L” bracket holes with the sideframe holes,
Figures 5 & 6.
2.
Fasten with the four 3/8” x 1” hex head bolts, lock washers and nuts provided, Figure 6.
The “L” brackets may need to be loosened to get the header braces attached to the sideframe.
NOTE: When standing in the opening between the sideframes and looking at the sideframe, the left hand threaded pin goes on the left hand side.
Likewise, the right hand threaded pin goes on the right hand side. The left hand pins will have a narrow groove machined into the hex shape near the end of the pins, Figure 15.
1.
Loosen the nuts until they spin freely, Figure 14.
3.
The center brace should be pre-attached and will need to be fastened to the front header brace.
2.
Install V-Flex straps with seam toward the outside,
Figure 16.
4.
Fasten the header brace supports together with the center bracket and two 3/8” x 1” bolts with lock washers and nuts provided, Figure 6.
5.
ROLL DOOR- Remove the curtain shipping straps that hold the curtain in place, the brake will prevent the curtain from dropping to the floor.
3.
Wrap the guide straps around the tension pins, so that the straps are being wound up when the pin is turned clockwise for the left hand threaded pins and counterclockwise for the right hand threaded pins. The straps will always be on the inside of the pins, Figure 15.
Sideframe
Bottom Plate
6.
Place the lock collar on the non-drive shaft and make sure the bearing plate bolts are tightened on the drive and non-drive sides, Figure 4.
Washer
7.
FOLD DOOR - If the curtain is on the rear header brace, align the “L” bracket holes with the sideframe holes and fasten with the four 3/8” x 1” hex head bolts, lock washers and nuts provided, Figure 9.
The “L” brackets may need to be loosened to get the header braces attached to the sideframe.
Locking Nut
Tensioning Pin
8.
FOLD DOOR - If the curtain is on the front header brace, align the “L” bracket holes with the sideframe holes and fasten with the six 3/8” x 1” hex head bolts, lock washers and nuts provided.
9.
FOLD DOOR - If the curtain is on the rear header brace, the center brace is pre-attached and will need to be fastened to the front header brace.
10.
FOLD DOOR - DO NOT remove the curtain shipping straps that hold the curtain in place until the “V”-Flex straps have been attached to the tension pins.
11.
FOLD DOOR - To adjust curtain, loosen the 5/16” bolts on the adjustment bar while holding nut on the end of the bar with a 1 1//4” wrench, Figures 7 - 9.
FIGURE 14
V-Flex Strap
Sideframe
V-Flex Strap Cover w/ Flap Away
From Curtain
Place Screw Thru Seal
Flap Approximately 2”
Above Guards To
Prevent Sliding
I M P O R TA N T ! ! !
Right Hand
Tension Pin
The bearing plate fasteners must be tightened now.
Left Hand
Tension Pin
Tensioning
Pin Guard
FIGURE 15-TENSION PINS
!
WA R N I N G ! ! !
Use Caution when winding up tension pins, as substantial force is being applied to the pins and the belting.
9 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
V-FLEX STRAP INSTALLATION
4.
Using a 1 1/4” and 1 1/2” wrench, turn the left hand tension pins clockwise to put tension on the V-FLEX belt and counter-clockwise for the right hand tension pins.
5.
Turn tensioning pin until the strap is very tight or to a total of approximately 70 ft/lb.
6.
When the correct tension is applied to the belt tighten down the locking nut using a 1 1/2” wrench.
7.
Repeat this procedure for the 3 remaining tensioning pins.
8.
The straps are tensioned properly if the curtain will stay in the “V” groove when pushed against with force.
9.
ROLL DOOR - The door is equipped with a Speed Feed system, Figure 17. That allows the curtain to be placed between the V-Flex straps when an impact occurs.
9a.
FOLD DOOR - Remove the curtain shipping straps that hold the curtain in place and slowly lower the curtain to the floor to prevent damage to the curtain or injury to personnel.
10.
FOLD DOOR - Using the 1 1/4” wrench, turn the nut on the end of the bar so the curtain is turned toward the header brace. When the slack has been taken out of the curtain and the curtain is sealed on the floor, tighten the
5/16” hex head bolt with a 1/2” socket wrench on each end of the adjustment bar, Figure 9 Page 7. It may be required to have a person holding the opposite side of the adjustment bar to prevent slipping.
NOTE: If V-Flex straps are not taut, the curtain may be damaged when refeeding.
Speed Feed
Without Curtain
FIGURE 16 - ROLL
Place
Seam
Toward the
Outside
FIGURE 17 - ROLL
Speed Feed
10 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
FOLD DOOR LIFTING STRAP INSTALLATION
LIFTING STRAP INSTALLATION
1.
Locate strap pressure plates and hardware from parts box.
7.
The straps should be snug with little or no tension applied. The curtain should not raise off the floor. Repeat for remaining belts.
2.
The lifting straps are riveted to the roller tube near the end of the roller tube closest to the sideframe, Figure 18.
The lifting straps will have 1 1/2 pre-wraps.
3.
Insert the lifting straps through all the 2” strap rings, making sure it is not twisted, Figure 19.
4.
Repeat procedure on all straps.
5.
Route the straps around the bottom stabilizer bar and attach the pressure plates and clamp to the straps.
6.
Attach pressure plates to the strap, just above the bottom stabilizer bar, such that the rounded curve and the head of the bolt are toward the curtain, Figure 20.
I M P O R TA N T ! ! !
If one side is tighter than the other, the curtain may fold up at an angle and cause undue friction on the end of the curtain and sideframe.
Pressure Plates w/Hardware
Rounded Side Toward Curtain
Straps MUST Roll off the Roller Tube on the
Opposite Side that the
Curtain is Hanging
Roller Tube
FIGURE 20 - FOLD
Non-Drive Shaft
FIGURE 18 - FOLD
Lifting Straps
1 1/2 Pre-Wraps
Retention Bar
Lifting Strap
Curtain
2” Strap Rings
Lifting Strap
FIGURE 19 - FOLD
LIFTING STRAP ROUTING
Pub. No. 891020G JANUARY 2007 11
TRAKLINE™ ROLL / FOLD Model 8910/20
HEADER COVER / SEAL INSTALLATION
HEADER TOP SEAL INSTALLATION - ROLL DOOR
1.
Locate the header top seal in the door crate.
2.
Attach the top seal to the header braces using the hook and loop fastener to provide a seal between the curtain and the header as shown in Figure 21.
Extrusion
Cover
Hook and Loop
Fastener Each
Side
Header Seal
Roller Tube
Header Braces
Sideframe
FIGURE 21 - ROLL
HEADER TOP COVER INSTALLATION
1.
Locate the plastic extrusion and the covers.
2.
The covers will be labeled “HEADER TOP COVER” and may include one or two pieces depending on door width.
The plastic extrusion will be labeled “HEADER
CHANNELS”.
3.
Starting at the end of the header attach the plastic extrusion to the header brace lip, Figures 22 & 23.
FIGURE 23 - FOLD
4.
Repeat procedure to the opposite header brace lip.
5.
Place one side of the top covers into the slot on the rear extrusion and then the front side. It may be helpful to use a wide blade screw driver to feed the cover into the second extrusion after the first side is held captive,
Figures 22 & 23.
STAND CLEAR INSTRUCTION LABEL
1.
Clean wall surface where label is to be placed.
2.
Peel backing away from label and apply in proper position, Figure 23A.
Extrusion
Cover
12”
Header Braces
5’-0”
Label Both
Sides
View of back Side Of Door
FIGURE 23A
Pub. No. 891020G JANUARY 2007 12
FIGURE 22 - ROLL
TRAKLINE™ ROLL / FOLD Model 8910/20
COUNTER BALANCE/THRU-WALL BRAKE RELEASE
OPTION
When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes.
!
!
WA R N I N G ! ! !
WA R N I N G ! ! !
NOTE:
The rest of this procedure requires power to the door. Proceed to Electrical Installation and Limit
Switch Adjustment on Pages 14 & 18.
6.
Jog the door closed so the weight lifts up in the air and place the weight inside the pvc tube.
7.
The pvc tube does not get tied done.
8.
Install sideframe covers and return door to operating condition. Test door to see that it functions properly, if the weight bottoms out or hits pulley at the top, re-adjust belting loop.
9.
If thru-beam photoeyes are used, make sure cable is clear of counter weight belting.
To raise the door in case of a power outage, simply pull on the brake release cord. Some assistance may be required on certain sized doors to achieve full open height clearance.
Use caution when working with the counter weight.
Make sure the belting is properly fastened to prevent it from slipping.
The optional Counter-Balance weight system operates in the non-drive sideframe and may be used to open the door in the case of a power outage. Install after door installation is complete.
1.
With the door in the open position. Slide counter weight pulley onto the non-drive shaft, align keyway, install key and tighten the 2 set screws onto the key with the pulley flush against the end of the shaft. Install bolt, lock and flat washer.
2.
Route the belting off the back side of the pulley with the hardware provided and add 1 1/2 pre-wraps.
3.
Place the weight on blocks approximately 6” or more off the floor.
4.
Route belting into a loop and tighten the pressure straps with the hardware provided, Figure 24.
5.
Place the loop between the weight brackets and install pin and cotter pin.
THRU-WALL BRAKE RELEASE OPTION
The TRAKLINE door can be equipped with an optional Thru-
Wall Brake Release system that can be used to open the door easily in the case of a power outage.
1.
Using the pulley as a guide, mark the location on the wall in line with the route of the rope, Figure 25.
2.
Check the other side of the wall for clearance, if clear, drill a 1” Ø hole through the wall. If not clear, move the conduit left or right. For additional clearance while drilling, remove the shroud.
3.
Insert the conduit through the wall. It may be necessary to cut the conduit to length to achieve desired end results. Insert plugs into each end of the conduit.
4.
Thread the rope from the brake handle, through he shroud, around the pulley and through the conduit. Reinstall the shroud.
1 1/2 Pre-Wraps of Belting On
Opposite Side of
Pulley As The
Curtain Lifting
Straps
Belting
Clamps
Weight
Inside of
PVC Tube
FIGURE 24
PVC Tube
Inside
Sideframe
Pub. No. 891020G JANUARY 2007
FIGURE 25
13
TRAKLINE™ ROLL / FOLD Model 8910/20
ELECTRICAL INSTALLATION
2.
The control box is provided with class CC protective fusing for the incoming power.
!
WA R N I N G ! ! !
3.
The incoming power terminals in the control box will not accommodate wires larger than 10AWG.
When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes.
4.
All control boxes should be mounted on the inside of the building regardless of door mount side.
5.
All drilled holes, and conduit run into the control box must be through the bottom of the.
I M P O R TA N T ! ! !
A qualified electrician should install the wiring in accordance with local and national electrical codes. Use lockout and tagout procedures to avoid injury.
INTEGRAL CONTROL PANEL:
1.
For an Integral control panel, run the power supply cable
(by others) into the sideframe at the control panel height.
The control panel is covered with a PVC material for protection.
I M P O R TA N T ! ! !
To reduce risk of injury or death, an earth ground connection MUST BE made to the green/yellow control box ground terminal. If metal conduit is used as the ground connector, an N.E.C. approved ground bushing and green/yellow wire MUST BE properly attached to the conduit for connection to the ground terminal.
CONTROL BOX:
2.
Mount the control box on a wall adjacent to the door at approximately 54" above the floor level. All holes drilled through the control box must be through the bottom of the box, Figure 27.
3.
Cables with connectors on one end are provided for the motor, brake, limit switches and photoeye’s and will need to be terminated to the control panel. The cables will be enclosed in flexible liquid tight conduit. A conduit mounting bracket is provided in the sideframe, Figure 28.
I M P O R TA N T ! ! !
In freezer and cooler applications where a conduit passes from a warm to cold temperature zone, the conduit must be plugged with epoxy. This will help prevent condensation from forming in the conduit. For more information, see Section 300-7a of the National
Electric Code.
4.
The motor ground cable must be grounded to the sideframe at the conduit holder using the tek screw and star washer provided.
5.
Connect wiring as indicated by the device field wiring schematic on Pages 23-26 (if standard) or inside the parts or control box. Incoming 3-phase power must connect into terminals L1, L2, and L3. Ground must attach to the green/yellow terminal, Figure 27.
!
C A U T I O N ! ! !
When drilling holes in the box, DO NOT turn control box upside down or go too deeply into the box. Damage or debris may fall into electrical components causing failure or severe equipment damage.
The TRAKLINE door has been factory tested. The electrical cables from the door need to be connected to the control panel.
Wire per the electrical wiring diagrams.
NOTE:
Route all field installed wires inside the control box so that separation is maintained between line voltage wires and low voltage class II wiring.
NOTE: Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 23-26.
Always check parts or control box for prints.
i-COMM
Motor/Brake and limit switch cables are prewired to the drive unit and need to be wired into the control panel. Consult local codes for conduit requirement.
Control box to activation (pull cords, motion detectors, etc.) conduit run, by others.
TM
Suggested fused disconnect box location
(supplied by others).
The standard Integral control panel located in the drive sideframe. Control box is optional.
Local electrical codes may require the use of a junction box and rigid conduit. Make sure to route all conduit through the bottom of the control station, Figure 26.
The door frame is grounded via the motor ground wire provided.
1.
It is the responsibility of the installing electrician to be sure all local, state, and national electrical codes are met and to provide electrical service up to the control box with proper branch service protection and an approved means of disconnect.
The Leading Edge in Door Safety.
Milwaukee, WI (800) 456-0600
OPERATING PROCEDURES
The OPEN/RESET Button activates the door to the full open position.
Door will close automatically.
RESET PROCEDURE
Press the OPEN/RESET button to activate the door to the full open position and to reset the controls.
The door must be reset whenever power is restored.
JOG/REFEED PROCEDURES
Hold the JOG button in while pressing the OPEN/RESET button to run the door through the open and close cycles. The door must be reset whenever the jog button is pressed.
Recommended mounting location is approximately
54” from floor to bottom of box and a minimum of 6” from door side frame.
Incoming voltage
(see chart on Pages 23-26 for acceptable voltages)
FIGURE 26
14 Pub. No. 891020G JANUARY 2007
Illuminated Input LED’s
TRAKLINE™ ROLL / FOLD Model 8910/20
ELECTRICAL INSTALLATION
Illuminated
Output LED’s
Programming
Receptacle
FIGURE 27
Incoming Power Terminals
L1, L2, L3, Ground
Pub. No. 891020G JANUARY 2007 15
TRAKLINE™ ROLL / FOLD Model 8910/20
PHOTOEYE ADJUSTMENT
Integral
Control Box
Station
Push Button
Controls
E-Stop
Open Button
Jog Button
Shroud
Sideframe
Example of
Mounting Electrical
Box Plate to
Sideframe for
Conduit Holder
(not supplied)
FIGURE 28
Optional
Conduit Holder for Control Box
Cable
FIGURE 29
!
WA R N I N G ! ! !
When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes.
1.
Make sure all photoeyes are plugged in. If the thru-beam option is chosen, the non-drive photoeye cable will be run across thru d-rings on the rear header brace.
2.
Locate the photoeye assemblies in the sideframe,
Figures 30 & 31.
3.
Plug in the cable from the non-drive sideframe to the header cable. Plug in the header cable and the the drive side cable into the control box cable, Figure 30.
4.
The yellow LED should be on when the thru-beam photoeye (emitter) is powered up, if it is not on, check plug in connections, and proper wire terminal connections, Figure 30.
5.
If the red and green LED’s are OFF, either the beam is blocked or the photoeye is out of alignment. If necessary re-aim the photoeye by using the adjustment screws on the sideframe assembly around the photoeye,
Figures 30 & 31.
The bottom screw allows for vertical adjustment and the two side screws adjust horizontal alignment. Rotate the screw until the red and green
LED’s turns ON.
Header Grommet
Header
Grommet
Photoeye Cable
Runs Through
D-Rings On
Rear Header
Brace
Thru-Beam Photoeye
Cable w/2 Plugs For
Integral Control Station
Thru-Beam Photoeye
Cable w/3 Plugs For
Control Box
Drive Side Thru-Beam
Photoeye w/Cable and
Plug For Control Box
Drive Side Thru-Beam
Photoeye w/Cable For
Integral Control Station
Non-Drive Thru-Beam
Photoeye’s w/Plugs For Control
Box or Integral Control Station
FIGURE 30-PHOTOEYE CABLE ROUTING
Optional Control
Box and Cable
16 Pub. No. 891020G JANUARY 2007
PHOTOEYE SPECIFICATIONS:
NOTE: Reversing photoeye must be set to “Light Mode”.
These photoeyes are for reversing only, not activation. Disconnect power before wiring photoeyes.
CONTROL BOX
For thru-beam installation with a control box, all photoeyes will have plugs that attach to the plugs on the cables that run back to the control box, Figure 30.
INTEGRAL CONTROL STATION
For thru-beam installation with a integral control station, the non-drive sideframe photoeyes will have plugs that attach to the plugs on the cable that runs back to the control station, the driveside photoeyes, will be wired directly to the control station, Figure 30.
NOTE:
Make sure to secure electrical cables away from counter weight, belting and pulley.
Photoeyes are preset at the factory for sensitivity and light/dark mode. Field adjustment should not be required.
TRAKLINE™ ROLL / FOLD Model 8910/20
PHOTOEYE ADJUSTMENT
SIDEFRAME COVER INSTALLATION
1.
Plastic extrusions are pre-assembled onto each sideframe edge.
2.
Locate the proper sideframe covers labeled “DRIVE,
NON-DRIVE, UPPER, LOWER” and slide into the groove.
3.
Locate the proper length of lower sideframe cover and slide down into the groove.
4.
The bottom section is easily removable to gain access to items at the bottom of the sideframe, Figure 33.
5.
Repeat procedure for the opposite sideframe.
NOTE: If the steel sideframe cover option is chosen, simply tek screw the steel sideframe covers at the holes provided to the sideframe lip.
Adjustment Screws
Photoeye
Sideframe
Slide Bottom
Cover Into
Groove to
Install
FIGURE 31-PHOTOEYE ADJUSTMENT
Extrusion
Light/Dark
Switch
Yellow LED-Power
Red and Green
LED-Alignment
Sensitivity
Adjustment
FIGURE 32-PHOTOEYE DETAIL
FIGURE 33
Snap Edging Onto
Front Surface
Pub. No. 891020G JANUARY 2007 17
TRAKLINE™ ROLL / FOLD Model 8910/20
LIMIT SWITCH ADJUSTMENT
NOTE: Setting the limits are based on drive location, see following instructions.
1.
Loosen the two phillips screws and remove cover.
NOTE: STEPS 2 - 10 ARE FOR A ROLL DOOR.
12.
For a Right Hand drive door turn the #1 close/photoeye limit switch screw counter-clockwise to raise the door and clockwise to lower the door. The first lobe #3 will be the photoeye shut-off, input X1 LED will pulse off then on as it goes by and will stay off when it hits the second lobe for the closed position.
2.
Measure from the floor to the bottom of the curtain with the door in the full open position, adjust the curtain to manufactured opening size.
3.
Loosen the center locking screw and turn the open limit switch cam locking screw labeled #2 until you hear the contact click, input X0 LED will also be off, Figure 34.
13.
For a Left Hand drive door, turn the #1 close/photoeye limit switch screw clockwise to raise the door and counter-clockwise to lower the door. The first lobe #3 will be the photoeye shut-off, input X1 LED will pulse off then back on as it goes by and will stay off when it hits the second lobe for the closed position.
4.
For a Right Hand drive door turn the #2 open limit switch screw clockwise to raise the door and counter-clockwise to lower the door.
14.
Measure from the floor to the door manufactured height opening size.
5.
For a Left Hand drive door, turn the #2 open limit switch screw counter-clockwise to raise the door and clockwise to lower the door.
15.
Making sure everyone is clear of the door, jog the door by pressing both the green open/reset and black jog button on the front of the s/f or control box to raise the door to the height opening size.
6.
Tighten center lock screw.
7.
Manually lower the door to the closed position. Adjust the closed limit switch, by loosening the center locking screw and turn the cam locking screw labeled #1 until you hear the contact click, input X1 LED will also be off,
Figure 34.
Tighten the center locking screw.
16.
Loosen the center locking screw and turn the open limit switch cam locking screw labeled #2 until you hear the contact click, input X0 LED will also be off, Figure 34.
17.
For a Right Hand drive door turn the #2 open limit switch screw clockwise to raise the door and counter-clockwise to lower the door.
8.
For a Right Hand drive door turn the #1 close/photoeye limit switch screw counter-clockwise to raise the door and clockwise to lower the door. The first lobe #3 will be the photoeye shut-off, input X1 LED will pulse off then on as it goes by and will stay off when it hits the second lobe for the closed position.
18.
For a Left Hand drive door, turn the #2 open limit switch screw counter-clockwise to raise the door and clockwise to lower the door.
19.
The limit switches are normally closed, the input LED’s will be on all the time, unless the limit cam lobe is tripped or activated.
9.
For a Left Hand drive door, turn the #1 close/photoeye limit switch screw clockwise to raise the door and counter-clockwise to lower the door. The first lobe #3 will be the photoeye shut-off, input X1 LED will pulse off then back on as it goes by and will stay off when it hits the second lobe for the closed position.
20.
Fine tuning of the limits may be necessary. This will be determined by running the door up and down.
21.
If the door has an optional alternate open, adjust to the desired alternate height using the same procedures as with the open and close limits, Figure 35.
10.
Making sure everyone is clear of the door, jog the door by pressing both the green open/reset and black jog button on the front of the s/f or control box to raise the door to the height opening size.
Not Used
Alt. Open L/S
Open L/S
NOTE: STEPS 11 - 18 ARE FOR A FOLD DOOR.
Close L/S
11.
With the door in the closed position, adjust the closed limit switch, by loosening the center locking screw and turn the cam locking screw labeled #1 until you hear the contact click, input X1 LED will also be off, Figure 34.
Tighten the center locking screw.
FIGURE 35
Center Adjustment Screw
Open Limit
Switch Cam #2 Open Limit
Switch Screw
#1 Close Limit
Switch Screw
Contact Blocks
#3 Close/Photoeye Limit Switch
#1 Close/Photoeye Limit Switch
FIGURE 34
Pub. No. 891020G JANUARY 2007 18
TRAKLINE™ ROLL / FOLD Model 8910/20
3.
2.
MAINTENANCE PROCEDURES
DRIVE SHROUD INSTALLATION
1.
Locate drive shroud and the hardware from the parts box.
4.
Open and close limit switches have been adjusted.
5.
Optional counterbalance has been properly installed.
Fasten to drive sideframe by sliding the back side of shroud under the 3 screws and using the 3 tek screws provided, fasten the front side, Figure 36.
6.
Curtain is placed between the V-Flex straps, hanging straight and it is not angled and rubbing the sideframe.
7.
Do not wire activation devices until the door is operated.
Install top cover (not included on Interior mounted doors) to the top of the sideframe using screws provided.
Top Cover and Fasteners
ACTIVATION DEVICE INSTALLATION
1.
Proceed to install activation devices and verify operation.
NOTE: Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Page 23-26.
Always check parts or control box for prints.
OPERATING PROCEDURE
1.
To operate the door, simply press the green open button on the front of the control box, the door should go to the full open position.
FIGURE 36
Drive Shroud and Fasteners
START-UP PROCEDURES
Before start-up operation of door can be done, all of the following must be completed.
1.
All mounting hardware must be tightened.
2.
Both photoeye’s must be adjusted with red, green and yellow LED’s on.
3.
The correct motor phase of the door has been verified.
With the E-Stop button pulled out, press the open/reset button. Door must open when the green open button is pressed, allow the door to time out and close, if MC2 pulls in reverse two motor leads.
2.
Normal settings are set to auto-reclose, and once the open button is pressed the door will open, time out per the setting of the re-close timer on the i-COMM and close.
3.
The door can be equipped with several types of activation devices that can open or close the door and can be setup to either auto-reclose or toggle mode.
4.
For toggle mode, the door can be setup such that if a device is used to open the door, it or another device needs to be reactivated to close the door.
CUSTOMER:
Periodic Cycle Check:
Planned Maintenance
Brake
Chain
Controls
Covers
Curtain
Gearbox
Header
Limit Switch
Motor
Photoeyes
Seals
Sideframe
Stabilizer Bars
Straps
Strap Clamps (Fold Door Only)
Pub. No. 891020G JANUARY 2007
1
RITE-HITE ® DOORS PLANNED MAINTENANCE
Model 8910/20/PL TRAKLINE™ TRAKLINE™ PL
SO# SERIAL#
Recommended P.M. Intervals
(Time Shown In Months)
4 8 12 18 24 30 36
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DATE:
Inspect and Perform the Following (See Manual)
Perform manual test by releasing brake and making sure door stops in the desired position.
Inspect for wear, tighten or replace as required. Lubricate.
Clean and check all connections.
Make sure sideframe and header covers are installed.
Clean with Isopropyl alcohol or warm soapy water. DO
NOT use abrasive cleaner on vision. Make sure curtain is tracking straight.
Check for unusual noise. Check fluid level.
Check mounting hardware connections. Blow dust and debris from the header.
Check open and close positions, and chain is tight.
Check for normal operation, check connections.
Check alignment, adjust as required. Check all connections. Wipe lens or reflectors clean.
Check for wear and tear. Make sure seals are sealing at the header and sideframe locations.
Inspect for damage. Check all mounting hardware.
Inspect bars for damage, straighten or replace.
Inspect for wear and tear, replace as required. Make sure straps are tight, and tension pin nuts are tight.
Make sure lifting straps and clamps are tight and curtain is sealing at the floor.
19
TRAKLINE™ ROLL / FOLD Model 8910/20
TROUBLESHOOTING
ITEM
Activation Devices
Brake
Contactor MC1 Open
Contactor MC2 Closed
Control Box
Counter-Weight Option
Roll Door Curtain
Fold Door Curtain
D.O.H./D.O.W.
Door Operation and Controls
E-Stop Button
F1 Fuse
F2 Fuse
F3 and F4 Fuses
Header Top Seal i-COMM Controller™
Integral Interlock
Jog Push Button
Limit Switch Chain
Limit Switches
Motor
Motor Phasing
FUNCTION
Operate the door system with all activation devices. Make sure that the door fully opens and closes after the time set on the re-close timer has expired. If you have wired the devices in toggle mode, operate the device twice to verify that the door will open with an activation and close with an activation. All activation devices use a set of normally open contacts. For activation questions, refer to the Activation Manual or Page 26 .
If the brake is not functioning properly, check the following: a) Check F1 fuse-replace.
b) Brake wiring at terminals B1 & B2 and plug in connections.
c) The brake rectifier should put out 90-110VDC.
d) 120V brake will have 290 ohms on normal readings. (must be checked after the rectifier). (Previous generation brakes will have 350 ohms)
MC1 contactor is the open contactor, and when an open command is given the contactor pulls in and opens the door. The contactor must have the same voltage on all 3 legs going in and out in order for the motor to run.
MC2 contactor is the closed contactor, and when an close command is given the contactor pulls in and closes the door. The contactor must have the same voltage on all
3 legs going in and out in order for the motor to run.
The control box is a fuse protected NEMA 4X. Standard controls include open/reset button, curtain jog button and a mushroom E-stop.
Voltages can be 208V, 230V, 400V, 460V, and 575V 3-phase.
The door can be equipped with a Counter-Weight option and in the event of a power outage the door can be opened.
The curtain is a heat sealed vinyl material. The curtain consists of fiberglass stabilizer bars that maintain the curtain in the guide straps under normal operation. The door comes standard with an 18” tall vision located 57” off the floor.
The curtain is a heat sealed vinyl curtain. The curtain consists of fiberglass stabilizer bars that maintain the curtain in the guide straps under normal operation. The door has optional 13” tall oval visions located 56” off the floor.
Door Opening Height or Door Opening Width
The door operations are controlled by an i-COMM Universal Controller. The i-COMM is set-up and programmed during testing at the factory. Unless you are a RITE-HITE
DOORS, INC. authorized service technician, you should not attempt to change the factory set program. A quick way of determining that the door is ready to operate normally is to open the control box and look for the green LED lights to be ON
(Illuminated) at the X INPUTS and the Y OUTPUTS. Refer to the Input/Output logic table located on Page 15 of this manual. If the door fails to function, contact your local
RITE-HITE DOORS, INC. representative or Technical Support at 563-589-2722.
The disconnect switch is in line with terminals L1, L2, L3, and removes power from the entire control box, except for terminals L1, L2, L3.
F1 Fuse is for 120VAC devices and receives power from the X1& X3 transformer taps.
The F1 fuse protects the brake and 120VAC pre-announce devices at terminals
B1, S2, and S4. The fuse is a 1amp slow blow fuse.
F2 Fuse is for 24VAC devices and receives power from the X1& X2 transformer taps.
The F2 fuse protects the photoeyes, relays, outputs and all 24VAC activation devices. The fuse is a 2amp slow blow fuse.
F3 and F4 Fuses are fuses for the incoming power and they protect the Transformer, the contactor's, overload, motor and the entire control box. The fuse is a 1/2amp for 380V-
575V and 1 amp for 208V-240V KLDR slow blow fuse.
The header top seal is used to seal the top of the door. It can be adjusted by removing the seal from the hook and loop fastener on the curtain and positioning it so it provides a good seal.
The i-COMM controller is a circuit board that controls the actions of the door. There is a digital display that shows the cycles, status and position of the door at any time during its travel. For input and output function signals, refer to chart on Page 15.
Settings can be changed for re-close or pre-announce timers, interlocks, special activation commands, among many others, refer to instructional manual included.
The mechanical interlock prevents both the MC1 & the MC2 contactor from being pulled in at the same time, thereby shorting out the motor.
When the jog push button is pressed, it acts as a constant pressure button and the door will move only when the button is pressed. It must be pressed in conjunction with the open button. When the both buttons are pressed the door will always move in the closed direction.
The limit switch chain length is determined at the factory, it should be 16” long for a RHD and 18” long for a LHD door. If there is concern, check the following: a) If the chain is not aligned properly, move the smaller sprocket to align.
b) If the chain makes noise, lubricate as needed.
c) Chain should deflect approximately 1/4”, less may cause wear on the bearings, more may cause chain wear or slipping.
The Open, Closed, Photoeye, and Alternate open limit switches are a normally closed device and should only be open when the limit switch lobe is in-line with the contact. If the switch is open when it is not in-line with the lobe, check wiring or replace the switch.
Ohms for the following motor voltages.
a) 208V-240V 1 HP motor will have 5-7 ohms on normal readings. (208V doors <12’ d.o.h.) b) 208V 1.5 HP motor will have 13.3 ohms on normal readings. (208V doors =>12’ d.o.h.) c) 460V-480V 1 HP motor will have 20-23 ohms on normal readings.
d) 400V 1 HP motor will have 23 ohms on normal readings.
e) 575V 1 HP motor will have 34 ohms on normal readings.
If open button is pressed and the door closes, the following needs to be checked: a) Check overload and contactors for proper voltage.
b) Phasing is reversed, reverse wires in terminals, V and W.
20 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
TROUBLESHOOTING
ITEM
Motor will not run
FUNCTION
If door will run will given an activation, check the following:
O.D.H./O.D.W.
One-Way Breakaway
Open Push Button
Overload Relay O/L1
Relay CR2
Photoeyes
Roll Door
Fold Door a) Faulty or tripped O/L1 overload relay.
b) Faulty MC1 or MC2 contactors.
c) Check voltage and for loose wires at terminals, U, V, and W and wires on the contactors and overload relay.
d) Check limit switch, if the 2 screws holding the contacts in place are too tight, it may cause the contact to stick, thereby causing the door not to run.
Ordered Door Height or Ordered Door Width
A door built for One-Way Breakaway can be impacted away from the wall only. A door impacted toward the wall may be damaged. The inside edge of the sideframes are mounted at 1/2 O.D.W. plus 5 3/8” from the centerline of the door jamb. The length of the header braces will be O.D.W. plus 10 3/4”. The opening is totally clear of any door components.
When the open push button is pressed, a command to open the door is given.
The O/L1 overload relay supply's 24VAC to the CR1 relay and the open/reset button. If the overload trips, 24VAC to the open/reset button will be lost. The overload is set to
“Automatic Mode” to reset, if it is tripped, reset the relay to restore power. The incoming power also goes through the O/L1 overload relay before it reaches the MC1, MC2 contactor's, if the contactor's are not receiving the correct voltage, check the O/L1 overload for proper voltage. Fuses may blow if pins are not clipped.
The O/L1 overload should be set to the following settings: a) 208V 4.2 Amps (Size > 144) b) 208V 3.8 Amps (Size =< 144) c) 230V-240V-3.7 Amps e) 460V-480V-1.8 Amps d) 380V-415V-2.1 Amps f) 575V-1.5 Amps
CR2-24VAC single pole relay is an optional relay, that is required when the pre-announce to close option is chosen.
The door is equipped with 2 sets of retro-reflective photoeyes that monitor each side of the door. Thru-beam photoeyes are available as an option. When either option is used and the beam is broken or blocked, the door will reverse and stay open until the object blocking the photoeye beam is removed or the photoeyes are lined up to send a signal to the i-COMM to allow the door to close. The photoeyes are wired to the 24VAC circuit and are wired as normally closed when there is power to the unit and the photoeye is aligned with the reflector or the source photoeye on a thru-beam device. Red, yellow and green lights should be on for proper alignment, if the eyes are not aligned properly, turn the adjustment screws. The photoeye’s are set to the “Light Operate” mode. The photoeye’s will reverse or hold the door open when the photoeye beam is blocked. When the beam is not broken, the door will auto-reclose.
The Roll door is designed for interior use only. The curtain is pre-attached to the roller tube and rolls off the front of the tube (away from the wall). It has a standard Integral control panel located in the drive sideframe with an option for a control box.The Roll door can be either One-Way breakaway or Two-Way breakaway as described in this section.
See architectural drawing for more details located on Page 27.
The Fold door is for exterior or interior use. A Fold door that is mounted on the exterior of a building or any interior wall except the outside wall will have the curtain attached pre-attached to the header front brace. A Fold door that is mounted internally on an outside wall of the building will have the curtain pre-attached to the header rear brace.
A Fold door is standard with s/f integral controls unless it is an external mounted Fold door, which a control box is standard. The option for a control box is available on internally mounted doors. The Fold door can be equipped with either One-Way
Breakaway, Two-Way breakaway or High Wind package.
Speed Feed™ Curtain Reinsertion System The Speed-Feed System is equipped on the Roll door model only. Upon impact the curtain is released from the V-Flex straps. Upon breakaway, the curtain will automatically re-fed back into the V-Flex strap guides.
Thru-Wall Brake Release Option
Transformer
The door can be equipped with a Thru-Wall Brake Release option in conjunction with the counter-weight option. In the event of a power outage, opening of the door can be completed from the opposite side of the wall.
The standard transformer is a tri-volt transformer that takes an incoming voltage of 208V,
230V, and 460V and converts it to 110VAC and 24VAC. An optional transformer is available for 380V, 415V and 575V doors.
a) 208V(Taps H1-H2) 6.8 Ohms b) 230V(Taps H1-H3) 7.5 Ohms c) 380V(Taps H1-H2) 18.4 Ohms e) 415V(Taps H1-H3) 20.5 Ohms g) 120V(Taps X1-X3) 4.4-4.8 Ohms d) 460V(Taps H1-H4) 27 Ohms f) 575V(Taps H1-H4) 29 Ohms h) 24V(Taps X1-X2) .4 to .6 Ohms
Two-Way Breakaway
V-Flex™ Curtain Release System
Wind Pressure
A door built for Two-Way Breakaway can be impacted in either direction. The inside edge of the sideframes are mounted at 1/2 O.D.W. from the centerline of the door jamb. The opening will be infringed upon by 5” the full height of the door by the “V”-Flex strap guides and 5 3/8” at the bottom by the guide brackets on each side of the door. The length of the header braces will be O.D.W.
The door is equipped with the V-Flex curtain release system. The system of straps run vertically along the sideframe and guide the curtain. When impacted the V-Flex straps will flex allowing the curtain to be released with little or no damage to the door or customer product. These straps MUST BE kept taut to prevent damage to the curtain.
If the curtain is blowing out because of high wind or negative pressures, check the following: a) The V-Flex straps should have a minimum of 70 ft/lbs.
b) Check to make sure the curtain has all the stabilizer bars in place.
c) If wind or pressure exceeds 15 mph, the door may blow out.
Pub. No. 891020G JANUARY 2007 21
TRAKLINE™ ROLL / FOLD Model 8910/20
DRIVE SYSTEM INFORMATION
See Figure 38 for motor details and procedure for changing voltages in the field.
1.
Rewire motor per Figure 38.
2.
Replace overload per voltage change.
3.
Change transformer taps per electrical diagram and according to the power supply available.
4.
Change fuse sizes per control box drawing.
Route Limit
Switch Cable
Through the Back of the Plate
Spot Ground Flat on Limit Shaft for
Set Screw
.31 Ref.
Must be
Aligned with the 30 Tooth
Sprocket
RH DRIVE
LH DRIVE
22
208V-230V
Jumper Wire
Black Wire
Green Wire
White Wire
STANDARD LIMIT SWITCH WIRING
460V 400V/575V
Jumper Wires n/a
Alt Open L/S
Open L/S
Closed L/S
Black Wire
FIGURE 38
Red Wire
Green Wire
White Wire
OPTIONAL ALTERNATE
OPEN LIMIT SWITCH WIRING
Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
FIELD WIRING DIAGRAM-CONTROL PANEL
Pub. No. 891020G JANUARY 2007 23
TRAKLINE™ ROLL / FOLD Model 8910/20
FIELD WIRING DIAGRAM-CONTROL BOX
24 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
WIRING DIAGRAM
Pub. No. 891020G JANUARY 2007 25
TRAKLINE™ ROLL / FOLD Model 8910/20
ACTIVATION WIRING DIAGRAM
26 Pub. No. 891020G JANUARY 2007
TRAKLINE™ ROLL / FOLD Model 8910/20
ROLL DOOR ARCHITECTURAL DRAWING
Pub. No. 891020G JANUARY 2007 27
TRAKLINE™ ROLL / FOLD Model 8910/20
FOLD DOOR ARCHITECTURAL DRAWING
28 Pub. No. 891020G JANUARY 2007

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Key features
- Fast smooth opening
- Universal controller
- V-Flex curtain release system
- Heavy-duty industrial materials
- Low Maintenance