RITE-HITE TRAKLINE 8920PL fold door Installation instructions
Below you will find brief information for fold door TRAKLINE 8920PL. The TRAKLINE 8920PL is a fast, smooth opening, low maintenance door that provides superior environmental separation while reducing passage time and temperature loss. The door comes with a counter-balance system that helps balance the door to reduce motor load and also assists the door open in the case of a power outage. The door also features a V-Flex™ Curtain Release System., i-COMM™ Universal Controller, exterior/interior folding door, one or two directional curtain breakaway and high wind package.
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TRAKLINE™ PL
FOLD DOOR
MODEL 8920PL
This Manual Covers Doors Shipped After 2-20-06.
PRINTED IN U.S.A.
EMAIL: [email protected]
PUBLICATION NO. 8920PLG
JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
PRODUCT INTRODUCTION
TABLE OF CONTENTS
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .3
SIDEFRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4
DRIVE ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . .5
HEADER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
V-FLEX STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .7
CURTAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
LIFTING STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . .9
PHOTOEYE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .10
LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .11
SHROUD / COVER INSTALLATION . . . . . . . . . . . . . . . . . . .12
ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13
I-COMM INPUTS & OUTPUTS . . . . . . . . . . . . . . . . . . . . . . .14
COUNTER BALANCE SYSTEM . . . . . . . . . . . . . . . . . . . . . .15
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . .16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . .20
ARCHITECTURAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . .24
NOTICE TO USER
Our mission is to “Improve Industrial Safety, Security and
Productivity Worldwide Through Quality and Innovation.”
Thank you for purchasing the TRAKLINE™ PL FOLD from
RITE-HITE DOORS, INC. The TRAKLINE PL FOLD is designed to be a fast, smooth opening, low maintenance door that provides superior environmental separation while reducing passage time and temperature loss.
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 PL FOLD 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
- 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
Tube of Anti-Seize or Grease Lubricant (IMPORTANT)
Caulk Gun and Caulk Tubes
1 1/4” Open End Wrench
1 1/2” Open End Wrench
1/2” & 9/16” Open End Wrench or Ratchet Wrench
1/2” & 9/16” Socket
Phillips Screwdriver
Straight Screwdriver (small 1/8” blade)
3/8” or 1/2” Masonry Bits
18” Long Drill Bits For Thru-Bolting
Cordless Drill (3/8” or 1/2”) w/Phillips Bit
5/16” Driver Bit For Drill
Tape Measure 25’ Minimum
Wire Strippers and Side Cutters
Set of Allen Wrenches (1/8”, 5/32”)
Four Large Clamps for Lifting Header
Straps For Lifting Roller Tube and Header (optional)
Forklift With High Boom
Retaining Ring Pliers
8’ or 10’ Step Ladder
3/16” Punch
Water Level
Hammer
Hole Saw
6’ Carpenters Level
20’ Extension Ladder
Utility Knife
Multi-Meter
Hammer Drill
Scissors Lift
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 PL
FOLD door 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. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
Qty
1
1
1
4
1
1
1
1/1
1
1
1
1
1
1
1
1
8/12
8/12
10/14
10/14
28
28
1
2 a/r
2
1
2
2 a/r
INSTALLATION INSTRUCTIONS
Description
Crate Containing the following
Header Assembly (w/ Roller Tube)
RH/LH Sideframe
Control Box (optional) w/Owner’s Manual
Motor/Brake/Gearbox/Limit Switch Ass’y w/Cables
Control Box Cable Assembly (optional)
Drive Shroud
Curtain
Counterweight
V-Flex Straps
PVC Tube
Curtain Retention Bar
Parts Box Containing the Following
Limit Switch Sprocket Large w/Set Screws (2)
Limit Switch Chain 17 1/8”
Limit Switch Chain Link
1/4” x 3/16” x 4 1/2” Key
Retaining Ring Exterior
Belting Pressure Plates
Belting Pressure Plate 5/16” Bolts
Belting Pressure Plate 5/16” Nuts
Belting Pressure Plate 5/16” Lock Washers
3/8-16 x 1 1/4” Carriage Bolts for Header
3/8-16 Hex Nylock Nuts for Header
#8-32 x 1/2” Self Tap/Drill Screw
#10 Int/Ext Lock Washer
#14 x 3/4” Self Tap/Drill Screws
1/4-20 x 1/4” Set Screw
Nylon Rope for Brake Release
Counterweight Pressure Plates
5/16” x 1 1/4” HHMS For Counterweight
Hardware, Straps and Plates for Curtain
Retention Assembly
!
D A N G E R ! ! !
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.
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 Integral sideframe controls or the control box 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 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.
!
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.
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.
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 14 3/4”
+1/4”/-0” and Perpendicular to Wall
ONE WAY BREAKAWAY
1/2 O.D.W. plus 7 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. 8920PLG JANUARY 2007 3
TRAKLINE™ FOLD Model 8920PL
SIDEFRAME INSTALLATION
9.
Measure the overall width of the door opening near the floor and near the top (Dimensions AA and BB),
Figure 1.
These measurements should be ± 1/4".
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.
11.
Verify that the door jambs are plumb and perpendicular and that the horizontal header is level.
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.
NOTE: For one directional breakaway the s/f’s are mounted at
O.D.W. plus 14 3/4”: +1/4” -0”.
TWO-WAY BREAKAWAY:
3.
From this centerline, measure 1/2 O.D.W. and place a mark on the floor on each side.
4.
Measure across the opening from sideframe mark to sideframe mark to double check the overall dimension.
This distance should not not vary more than +1/4/ -0".
SIDEFRAME INSTALLATION
NOTE: Handle sideframes with care as control components may be inside.
1.
Place the sideframes into position near the opening.
2.
The pre-attached covers need to be removed.
3.
If shims are required, shims must fully support sideframe base plate. Drill holes through shims to allow for anchors.
4.
Carefully lift the sideframes by hooking a chain to the sideframe. Caution should be used to insure chain is secure.
5.
Install sideframe that does not require shimming at the marks made on the wall. Using a 6’ carpenter’s level make sure that sideframe is plumb and square to the wall.
6.
Mark the mounting holes in the back of the sideframe and remove sideframe. Drill holes through the wall, reposition sideframe and fasten to wall using thru the wall bolts and a backing plate for each bolt.
NOTE: Anchors, wall fasteners and shims are not supplied.
For two way-directional breakaway the sideframes are mounted at O.D.W: +1/4” -0”.
Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 20-23.
Always check parts or control box for prints.
PREPARING THE JAMB
1.
When laying out 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, divide this measurement in half, mark the centerline on the wall and on the floor,
Figures 1.
Drop a plumb bob from the mark at the top of the jamb and place a mark on the floor. The distance should be within 1/8”, if not place a mark half way between these two marks.
ONE-WAY BREAKAWAY: OR
2.
From this centerline, measure 1/2 O.D.W. plus 7 3/8" and place a mark on the floor on each side. This will offset the location of the V-Flex™ Curtain straps,
Figure 2.
Fork Lift
Support Block
Roller Tube
Header Tube
If welding, the sideframe should only be tack welded in at this time. It is not recommended to weld sideframes securely in place until door has been tested to ensure proper operation.
7.
Repeat procedure for the opposite sideframe.
8.
Plumb the sideframe and double-check the overall width measurements at the bottom of the sideframes. There should not be more than +1/4” / -0”.
9.
The sideframe should be square to the header, if the sideframes twists when fastening to the wall, shim as required.
DRIVE ASSEMBLY INSTALLATION
1.
Place the header in front of the opening. Place support blocks on the lift forks and clamp header to lift. The blocks are needed since the roller tube is lower than the header.
Failure to do this may bend the roller tube,
Figure 2.
2.
Remove drive or non-drive shrouds.
3.
Locate the gearmotor assembly, limit switch chain, connector link, and 30 tooth sprocket.
Clamp
FIGURE 2-HEADER LIFTING
4.
For ease of gearbox installation and maintenance, apply a grease lubricant or anti-seize (not supplied) to the drive shaft, bumper block and motor bumpers.
5.
Turn roller tube to align the shaft and gear keyway.
6.
Place 1 1/2 pre-wraps of the lifting straps around the roller tube,
Figure 5.
The roller tube will be between the lifting straps and the curtain.
7.
Install gearmotor assembly onto the drive shaft, some force may be required to get the bumpers over the bumper blocks,
Figures 3 & 4.
4 Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
DRIVE ASSEMBLY INSTALLATION
8.
Route the limit switch cable through the hole in the back of the motor mount bracket and run down the length of the sideframe,
Figure 30, Page 19.
I M P O R TA N T ! ! !
I M P O R TA N T ! ! !
An anti-seize lubricant MUST BE applied to the shaft prior to motor installation. Failure to do this may result in a difficult time removing the motor for maintenance.
Rear Header
Brace
Front Header
Brace
Shaft
Sideframe
Bumper Brackets
Anti-Rotation
Bracket
FIGURE 3-MOTOR ASSEMBLY
Bumper Block
Anti-Rotation Bracket
Bumpers
Be sure retaining ring is fully seated in the groove.
Failure to do this, may cause the motor to move on the shaft during operation.
9.
Lubricate and 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 it is past the retaining ring slot.
10.
Gearbox case should be flush with the end of the retaining ring groove.
11.
Install retaining ring into shaft groove,
Figure 6.
12.
Install 30 tooth sprocket onto the drive shaft until it hits the shoulder. Sprocket needs to line up with the 10 tooth sprocket on the limit switch shaft, if not loosen and move the 10 tooth sprocket and use a short straight edge to align. When aligned, tighten the 1/4” set screws onto the flat spot of the shaft with an 1/8” allen wrench to 75 in/lbs and lock-tight.
13.
Install #35 chain onto sprockets, by lining up the chain so the connector falls onto the large sprocket,
Figure 7.
14.
Place connector link onto chain and lock in place,
Figure 7.
Adjust the chain so it does not slip over the teeth. Loosen the limit switch mounting bolts and adjust
Roller Tube
Drive Shaft
FIGURE 4-MOTOR ASSEMBLY
Motor Assembly
Retaining Ring
FIGURE 6
Straps MUST Roll off the Roller Tube on the
Opposite Side that the
Curtain is Hanging
Lifting Straps
1 1/2 Pre-Wraps
Roller Tube
Pub. No. 8920PLG JANUARY 2007
FIGURE 5-LIFTING STRAP INSTALLATION
Center Lifting Straps for
Doors > 21’ O.D.W.
Non-Drive Shaft
5
TRAKLINE™ FOLD Model 8920PL
HEADER INSTALLATION
so the chain deflects approximately 1/4” when pressure is applied. A chain that is too tight may cause wear on the limit switch shaft bearing.
15.
The limit switch assembly should be adjusted down in the slots to achieve proper chain tension.
NOTE: DO NOT place the limit switch assembly at the top of the slots. This may cause interference with the covers and make switch adjustment difficult.
16.
The limit switch plate Grade 2 bolts must be retightened to 66 in/lbs, if too loose, the plate may slip.
NOTE:
The motor and brake cables are pre-wired into the motor junction box, but need to be terminated to the control panel later in the installation process. The control box option will have a short cable coming out of the motor and limit switch with plugs on.
A door mounted on the exterior of a building or on the interior of the building, but not on the outside wall will have the curtain attached to the front header brace. A door mounted internally on an outside wall of the building will have the curtain attached to the rear header brace.
See
Figures 12 & 13
for proper mounting.
The lifting straps on the curtain will always be on the inside of the building.
HEADER INSTALLATION
NOTE:
If overhead clearance is available, the preferred method is to place cargo straps around the header tubes and lift.
Make sure to place clamps on the forks to prevent the straps from sliding off the forks. Use Caution not to bend the roller tube.
1.
Carefully raise the header and set onto the sideframes.
2.
Fasten the header to the sideframe using the 8 sets of
3/8” x 1 1/4” carriage bolts, washers and nuts provided,
Figure 8.
3.
The shroud may need to be removed to ease curtain and lifting strap installation,
Figure 16.
!
D A N G E R ! ! !
Use extreme caution when lifting the header unit. Be sure to secure header to the lifting device. It may be required to lift 600lbs or more and lift as high as 28’ in the air.
Header
Sideframe to
Header
Attachment Bolts
Sideframe
Washers and Nuts This Side
FIGURE 8-HEADER TO SIDEFRAME MOUNTING
Large Limit Sprocket
Bumper
Bumper
Block
6
Limit Chain Link
Connector
Bumper
FIGURE 7-MOTOR/LIMIT SWITCH ASSEMBLY
Small Limit Sprocket
Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
V-FLEX STRAP INSTALLATION
I M P O R TA N T ! ! !
The V-Flex straps Must not be installed until after the header has been installed, due to interference constraints.
V-Flex straps with not enough tension may result in premature breakaway and curtain wear.
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 9 & 11.
NOTE: DO NOT INSTALL FRONT V-FLEX STRAPS,
UNTIL AFTER INSTALLATION OF THE CURTAIN
AND OPTIONAL RETENTION BAR.
1.
Using a 1 1/4” and 1 1/2” wrench, loosen the nuts on the tension pins in the sideframe until they spin freely,
Figure 9.
!
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.
4.
Using a 1 1/4” and 1 1/2” wrench, turn the left hand tensioning pins clockwise to put tension on the V-FLEX straps 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 170 ft/lb. For taller doors, the tension will need to be increased.
6.
When the correct tension is applied to the V-Flex strap tighten down the locking nut using a 1 1/2” wrench. The use of a cheater bar may be required.
Header
Sideframe
Locking Nut
Tensioning Pin
Washer
FIGURE 10
Bolt
V-Flex Strap w/Plate
V-Flex Strap
Sideframe
Nut
V-Flex Strap Cover w/ Flap Away
From Curtain
FIGURE 9-TENSION PINS HARDWARE
2.
Locate two of the four V-Flex straps, pressure plates and hardware in the parts box and attach to the rear header braces with the sewing seam to the outside and the head of the bolts to the inside,
Figures 10 & 11
then lower the straps to floor.
3.
Wrap the 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 11.
Place Screw Thru Seal
Flap Approximately 2”
Above Guards To
Prevent Sliding
Right Hand
Tension Pin
Left Hand
Tension Pin
FIGURE 11-TENSION PINS
Tensioning
Pin Guard
Pub. No. 8920PLG JANUARY 2007 7
TRAKLINE™ FOLD Model 8920PL
CURTAIN RETENTION INSTALLATION
Curtain Retention
Plate and Hardware
Adjustment Bar Tabs
Adjustment Bar Holding Bolt
2”x6” Header Tube
Adjustment Bar Lock Down Bolt
Header
Dim “X”
Dim “X” Dim “X”
Dim “X”
Curtain Retention
Bracket and Hardware
Curtain
Retention Strap
Curtain
Retention Bar
V-Flex
Straps
Curtain Adjustment Bar
Curtain Slots
Curtain
8
When the Curtain Retention Assembly is used it should be installed prior to curtain installation,
Figure 12.
1.
Slide retention straps onto the retention bar, space equally, per DIM “X” across the width.
FIGURE 12
Sideframe
Curtain
Lifting
Straps
4.
Using a 1 1/4” wrench turn the nut on the end of the bar so the curtain is turned against the header brace. It may be required to have two people, one on each side of the header to turn the adjustment bar.
2.
Slide retention brackets into the ends of the retention bar.
5.
The curtain is properly rolled up when the slots are not visible under the front brace.
3.
Lift assembly to the top of the sideframes and attach to each sideframe with the hardware provided.
6.
Tighten the 3/8” hex head bolt and the 5/16” locking screws on each end of the adjustment bar with a socket wrench,
Figure 13.
4.
Attach retention straps to the header using the retention plates and hardware provided, access may be limited.
Straps should be fairly tight and not allow curtain to flex into roller tube.
I M P O R TA N T ! ! !
5.
The retention bar is designed to properly fit between the sideframes, if the bar is too long, check for proper sideframe spacing. Cutting of the bar can be done to achieve the desired fit.
CURTAIN INSTALLATION
1.
Place curtain on a fork lift so the curtain will unroll toward the wall with approximately 2’ to 3’ of loose curtain off the roll. Clamp the forks of the lift so the curtain will not fall off the lift.
2.
Lift the curtain in place and insert the adjustment bar into the brackets on the header and fasten with the 3/8” holding bolts and nuts,
Figures 12 & 13.
3.
To roll the curtain up, loosen the 3/8” holding bolts and the
5/16” locking screws on the adjustment bar,
Figure 13.
Care should be taken so as the curtain unrolls it does not tear. Failure to roll curtain on adjustment bar may result in curtain damage or failure of curtain
7.
Slowly lower the curtain to the floor to prevent damage to the curtain or injury to personnel. The curtain should be pushed against the rear V-Flex straps, so it will not roll off the forks.
8.
If the curtain has slack or is not sealed on the floor, loosen the 3/8” hex head bolt and the 5/16” locking screws on each end of the adjustment bar, and raise or lower the curtain,
Figures 12 & 13.
After the curtain is properly adjusted, tighten the bolts.
9.
Install the front V-Flex straps, per rear strap instructions.
Pub. No. 8920PLG JANUARY 2007
Lock Down Bolt
Curtain
Adjustment Bar
TRAKLINE™ FOLD Model 8920PL
LIFTING STRAP & SHROUD INSTALLATION
Hold Down Bolt
2”x6” Header Brace
V-Flex Mounting
Bracket
Lifting Straps Are Opposite the Curtain Adjustment Bar
Retention Strap
Curtain
I M P O R TA N T ! ! !
FIGURE 13-ADJUSTMENT
BAR FASTENING
LIFTING STRAP INSTALLATION
1.
Remove the lifting strap pressure plates and hardware from the parts box.
2.
The lifting straps are fastened to the roller tube,
Figures 5 & 12.
The lifting straps need 1 1/2 pre-wraps on the roller tube before attaching to the curtain.
3.
Insert the lifting straps through all the 2” strap rings, making sure they are not twisted,
Figure 14.
4.
Route the straps through the bottom short lifting strap ring and attach the pressure plates and clamp the straps,
Figure 15.
5.
Attach pressure plates to the strap, just above the strap rings, such that the rounded curve and the head of the bolt are toward the curtain,
Figure 15.
6.
The straps should be snug with little or no tension applied. The curtain should not raise off the floor.
7.
Repeat procedure on all the remaining straps.
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.
Retention Bar
2” Strap Rings
Lifting Strap
Curtain
FIGURE 14-LIFTING
STRAP ROUTING
Pub. No. 8920PLG JANUARY 2007 9
TRAKLINE™ FOLD Model 8920PL
PHOTOEYE ADJUSTMENT
Pressure Plates w/Hardware
Rounded Side Toward Curtain
Short Straps
Bottom Bar
FIGURE 15-PRESSURE PLATE FASTENING
SHROUD INSTALLATION
1.
The header shroud is pre-installed and may need to be removed for curtain installation.
2.
The shroud may include several pieces depending on door width,
Figure 16.
3.
After the shroud has been installed to the header, caulk the back end of the shroud to the wall to prevent rain seepage.
Header Shroud
Hardware
PHOTOEYE SPECIFICATIONS:
1.
Locate the photoeye assemblies in the sideframe(s) and make sure they are plugged in,
Figures 17 & 18.
Nondrive photoeye cable is located in the 2”x6” header tube.
2.
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 18.
NOTE: Steps 4 and 5 will be completed during the start-up procedure.
4.
The yellow LED should be on when the thru-beam photoeye (emitter) is powered up, if not check connections, and proper terminal connections,
Figure 19.
5.
If the red and green LED’s on the receiver 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,
Figure 17.
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.
Adjust photoeye beam so it is centered on the reflector to prevent false trips.
NOTE:
Make sure to secure electrical cables away from counter weight, belting and pulley.
Reversing photoeye must be set to “Light Mode”.
This photoeye is for reversing only, not remote 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 18.
Header Shroud
Top Photoeye
Header Front
Cover
10
FIGURE 16-HEADER SHROUD
Header
Shroud Brace
Bottom Photoeye
Photoeye Adjustment
Screws
Sideframe
FIGURE 17-PHOTOEYE ADJUSTMENT
Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
LIMIT SWITCH ADJUSTMENT
Header Grommet
Header
Grommet
Photoeye Cable
Runs Through
The 2x6 Tube
Thru-Beam Photoeye
Cable w/2 Plugs For
Integral Control Station
Thru-Beam Photoeye
Cable w/3 Plugs For
Control Box
Integral
Control
Panel,
Located in
Drive
Sideframe
Drive Side Thru-Beam
Photoeye w/Cable and
Plug For Control Box
Drive Side Thru-Beam
Photoeye w/Cable For
Integral Control Station
Yellow LED-
Power
Red and
Green LED-
Alignment
Pub. No. 8920PLG JANUARY 2007
Non-Drive Thru-Beam
Photoeye’s w/Plugs For Control
Box or Integral Control Station
FIGURE 18-PHOTOEYE CABLE ROUTING
Light/Dark
Switch
Sensitivity
Adjustment
FIGURE 19-PHOTOEYE DETAIL
INTEGRAL CONTROL STATION
For thru-beam installation with a integral control panel, 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 panel,
Figure 18.
LIMIT SWITCH ADJUSTMENT
NOTE: Setting the limits are based on drive location and interior or exterior mount, see following instructions.
1.
Loosen the two phillips screws and remove cover.
2.
Adjust the closed limit switch, by loosening the center screw and turning the cam screw labeled #1, past the first lobe and onto the second, until you hear the contact click. Input X1 LED will also be off,
Figure 20.
Control Box
3.
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.
4.
Making sure everyone is clear of the door, press both the open/reset and black jog button to raise the door to the full open position.
5.
Adjust open limit switch by turning the cam screw labeled
#2 until the contact is in line with the cam lobe, input X0
LED will also be off,
Figure 20.
6.
The limit switches are normally closed, the input LED’s will be on all the time, unless the limit cam lobe is made.
NOTE: Determine which drive and mount your door is to figure out which direction to turn the limits:
Right Hand Drive Internal door or a Left Hand Drive
External Mounted door.
Turn the #1 close/photoeye limit switch screw clockwise to raise the door and counter-clockwise to lower the door.
Turn the #2 open limit switch screw clockwise to raise the door and counter-clockwise to lower the door.
Right Hand Drive External door or a Left Hand Drive
Internal Mounted door.
Turn the #1 close/photoeye limit switch screw counterclockwise to raise the door and clockwise to lower the door.
Turn the #2 open limit switch screw counter-clockwise to raise the door and clockwise to lower the door.
11
TRAKLINE™ FOLD Model 8920PL
SHROUD / COVER INSTALLATION
7.
Fine tuning of the limits may be necessary. This will be determined by running the door up and down.
8.
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 21.
9.
For any reason if the limit switch plate adjustment bolts need to be loosened or replaced they should be Grade 8 bolts and torqued to 19ft/lbs.
Not Used
Partial Open L/S
Sideframe
Open L/S
Close L/S
FIGURE 21
INSTALLATION OF SHROUD / COVERS
1.
Locate drive shroud and hardware.
2.
Fasten drive shroud to drive sideframe by using the 6 tek screws provided,
Figure 22.
3.
Install brake release lever and cord.
4.
Fasten front cover by lining up holes to header brace brackets holes with the hardware provided.
SIDEFRAME COVER INSTRUCTION
1.
Install the sideframe covers that were previously removed during sideframe installation,
Figure 23.
2.
Repeat procedure to the opposite sideframe.
Sloped Shroud Conduit Holder for
Control Box Cable
Cover
FIGURE 23
STAND CLEAR INSTRUCTION LABEL
1.
Clean wall surface where label is to be placed.
2.
Peel backing away from label.
3.
Apply label in proper position,
Figure 23A.
12”
Drive Shroud
Fasten Front
Cover To
Header Braces
Mounting Holes
Sideframe
FIGURE 22-DRIVE SHROUD INSTALLATION
Center Adjustment Screw
Open Limit
Switch Cam
#2 Open Limit
Switch Screw
Contact Blocks
12
5’-0”
Label Both
Sides
View of back Side Of Door
FIGURE 23A
#1 Close Limit
Switch Screw
#3 Close/Photoeye Limit Switch
#1 Close/Photoeye Limit Switch
FIGURE 20
Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
!
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.
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.
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.
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.
ELECTRICAL INSTALLATION
the electrical wire from the header down to the control panel or control box. Make sure to route all conduit
through the bottom of the control box,
Figure 21.
Route all field installed wires inside the control box so that separation is maintained between line voltage wires and low voltage class II wiring.
1.
It is the responsibility of the installing electrician to be sure all local, state, and national electrical codes are met.
2.
It is the responsibility of the buyer to provide electrical service up to the control box with proper branch service protection and an approved means of disconnect.
3.
The control box is provided with class CC protective fusing for the incoming power.
4.
The incoming power terminals in the control box will not accommodate wires larger than 10AWG.
5.
If possible, all control boxes should be mounted on the inside of the building regardless of door mount side 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 21.
6.
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 and can be attached to the conduit bracket at the top,
Figure 24.
7.
The motor ground cable must be grounded to the sideframe at the conduit holder using the tek screw and star washer provided,
Figure 24.
!
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.
Motor/Brake Cables
Control Box
8.
Connect wiring as indicated by the device field wiring diagram on
Pages 20-23
. Incoming 3-phase power must connect into terminals L1, L2, and L3. Ground must attach to the green/yellow terminal,
Figure 26.
9.
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,
Figure 25.
10.
Turn power on and pull the E-Stop button out and press the jog (black) and open (green) button to get the door in the full open position.
Ground Cable
Connector
Limit Switch Cable i-COMM
TM
Integral
Control Box
Station
Drive Side Photoeyes
The Leading Edge in Door Safety.
Milwaukee, WI (800) 456-0600
Non-Drive Side Photoeyes
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.
Sideframe
Control Box Cable
FIGURE 24
NOTE:
The Integral control panel is standard on interior doors and is located in the drive sideframe . The control box is standard on externally mounted doors.
It may be required by local electrical codes that a junction box and rigid conduit be used when running
Push Button
Controls
E-Stop
Open Button
Jog Button
Example of
Mounting Electrical
Box Plate to
Sideframe for
Conduit Holder
(not supplied)
FIGURE 25
Pub. No. 8920PLG JANUARY 2007 13
TRAKLINE™ FOLD Model 8920PL
INPUT/OUTPUT CHART
Illuminated
Output LED’s
Illuminated
Input LED’s
Programming
Receptacle
FIGURE 26
Incoming Power Terminals
L1, L2, L3, Ground
Before start-up of the door, the following must be completed.
1.
All mounting hardware must be tightened.
2.
The correct motor phase of the door has been verified.
Door must open when the green open button is pressed.
3.
Open and close limit switches have been adjusted.
4.
Counterbalance system has been properly installed.
Test door to see that it functions properly, if the weight bottoms out or hits pulley at the top, re-adjust belting.
5.
Curtain is placed between the V-Flex straps.
14
6.
The lifting straps should be routed correctly and hardware tightened.
7.
All photoeye’s must be adjusted with the yellow, red, and green LED’s on.
8.
Make sure all activation is not wired until the door is operated to ensure that a faulty activation device is not causing the door to be inoperable.
9.
With the E-Stop button pulled out, press the open/reset button to allow the door to time out and close.
10.
Check that photoeye’s reverse the door.
Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
!
Lifting Straps
Would Be On the Front Side of the Roller Tube
In This Detail
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.
!
WA R N I N G ! ! !
Use caution when working with the counter weight.
Make sure the belting is properly fastened to prevent it from slipping.
COUNTER BALANCE SYSTEM
The TRAKLINE PL door by RITE-HITE DOORS, INC. is equipped with a counter-balance system that is used to assist the door open in the case of a power outage. It is also used to help balance the door to reduce motor load.
The Counter-Balance weight system operates in the non-drive sideframe.
The system is driven by a pulley on the non-drive roller tube shaft. The weight attaches to the belting by using pressure plates and hardware. To partially raise the door in case of a power outage, simply pull on the brake release cord. Some assistance may be required on large doors.
1.
The counter weight pulley is installed onto the shaft at the factory.
2.
With the door in the open position, fasten the belting to the pulley with hardware provided.
3.
Place 1 1/2 pre-wraps around the idle pulley making sure it comes off the pulley the opposite the direction that the lifting straps come off the roller tube.
4.
Install the weight on blocks approximately 12” off the floor.
5.
Route belting into a loop and tighten the pressure straps with the hardware provided,
Figure 27.
6.
Install the loop between the weight brackets and install pin and cotter pin.
7.
Jog the door closed so the weight lifts up in the air. Make sure the weight is not interfering with the pulley.
8.
Install the longer pvc tube over the weight, place the shorter piece on the floor and attach the two pieces.
9.
Make sure the thru-beam photoeye cable is clear of the counter weight belting.
10.
Proceed to adjust limit switches as required after operating the door. The counterweight must be installed before operating the door. Failure to do this may result in the overload relay tripping out.
THRU-WALL BRAKE RELEASE
The TRAKLINE can be equipped with an optional opposite
Thru-Wall Brake Release system that in the case of a power outage, can be used to partially open the door.
1.
Using the pulley as a guide, mark the location on the wall in line with the route of the rope,
Figure 28.
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.
Belting Pulley
Idler Pulley
Belting Pre-Wraps
(1 1/2) Roll Off
Opposite Side of
Pulley As The
Curtain Lifting
Straps
Pressure Plates
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 rope from the handle, through the shroud, around the pulley and through the conduit. Re-install the shroud.
Counter Weight
PVC Tube
FIGURE 27-COUNTER WEIGHT DETAIL
Pub. No. 8920PLG JANUARY 2007
FIGURE 28-THRU-WALL
BRAKE RELEASE
15
TRAKLINE™ FOLD Model 8920PL
MAINTENANCE PROCEDURES
TORQUE:
The brake is supplied from the factory with the nominal torque setting.
11.
Replace the brake cover and tighten the four phillips screws that hold it in place and the brake handle.
12.
Reconnect power and check for proper operation.
BRAKE REPLACEMENT
1.
Run the door to the full open position, tie the curtain in place so it will not unwind and disconnect power to the door. Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. Also barricade the work area on both sides of the door to prevent unauthorized access while servicing.
NOTE: Planned maintenance programs are available for the TRAKLINE PL door. Contact your local
Rite-HitE DOORS, INC. representative for details.
Misc: To remove open, jog or E-stop buttons, turn the latch to the left at the top of the button with a small screwdriver. The unit will pop off.
2.
Loosen and remove the brake handle and the four screws holding the cover to the brake, with a short phillips screwdriver,
Figure 29.
3.
Remove the snap ring and the fan.
4.
Disconnect the blue and brown brake wires from
terminals 5 and 6
on the rectifier.
5.
To remove the brake from the motor housing, loosen the
4mm allen head screws holding it in place.
6.
Take note of the orientation of the brake before removing.
Pull the brake straight off the motor.
7.
If the hex hub needs replacing, remove the snap ring.
8.
Install the new brake.
9.
Insert the 4mm allen head screws and tighten.
10.
Reconnect the blue and brown brake wires to the
#5 and #6 terminals on the rectifier. Polarity is not important.
FIGURE 29-BRAKE WIRING
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)
16
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 as required.
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.
Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
ITEM
Activation Devices
Brake
Contactor MC1 Open
Contactor MC2 Closed
Control Box
Counter-Weight Option
Curtain
Fold Door
F1 Fuse
F2 Fuse
TROUBLESHOOTING, REPAIR AND ADJUSTMENTS
D.O.H./D.O.W.
Door Operation and Controls
E-Stop Button i-COMM Controller™
F3 and F4 Fuses
Integral Interlock
Jog Push Button
Limit Switch Chain
Limit Switches
208-230V Motor
460V Motor
400V Motor
575V Motor
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 on
Page 23.
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 closed 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, a mushroom E-stop and auto-reclose are standard.
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 material is a one-piece heat sealed vinyl curtain. Oval Vision is optional on the Fold door. The curtain consists of fiberglass stabilizer bars that maintain the door in the guide straps under normal operation. The door comes standard with an 8 1/2” tall vision located 63” 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 14
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.
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 14.
Settings can be changed for re-close or preannounce timers, interlocks, special activation commands, among many others, refer to instructional manual included.
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.
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 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 mechanical interlock prevents both the MC1 & the MC2 contactor from being pulled in at the same time, thereby shorting out the motor.
The jog push button is 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 approx. 1/4”, less may cause wear on the bearings, 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.
208-230V 2 HP motor will have 2.4 ohms on normal readings.
460V 2 HP motor will have 9.2 ohms on normal readings.
400V 2 HP motor will have 6.6 ohms on normal readings.
575V 2 HP motor will have 13.4 ohms on normal readings.
Pub. No. 8920PLG JANUARY 2007 17
TRAKLINE™ FOLD Model 8920PL
TROUBLESHOOTING, REPAIR AND ADJUSTMENTS
ITEM
Motor Phasing
Motor will not run
O.D.H./O.D.W.
One-Way Breakaway
Open Push Button
Overload Relay O/L1
FUNCTION
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, U and W
If door will run will given an activation, check the following: 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 with the One-Way Breakaway can only be broken away from the wall. A door that is impacted toward the wall can be damaged. The inside edge of the sideframes are mounted at 1/2
O.D.W. plus 7 3/8” from the centerline of the door jamb. The length of the header braces will be
O.D.W. plus 14 3/4”. The opening is 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 d) 380V-415V-2.1 Amps e) 460V-480V-1.8 Amps f) 575V-1.5 Amps
CR2-24VAC single pole relay is optional and is required when pre-announce to close is chosen.
The door is equipped with 2 sets of thru-beam photoeyes that monitor each side of the door. When
Relay CR2
Reversing Photoeyes 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.There are three lights on the photoeyes. Yellow is for power. Red and green should be on for proper alignment, if the eyes are not aligned properly, turn the adjustment screws.
The receiver photoeye is 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 autoreclose.
T hru-Wall Brake Release Option
The door can be equipped with a Thru-Wall Brake Release option in conjunction with the counterweight option. In the event of a power outage, opening of the door can be completed from the opposite side of the wall.
Transformer The standard transformer is a tri-volt transformer that takes an incoming voltage of 208, 230, 460V and converts it to 110VAC & 24VAC. An optional transformer is available for 380V, 415V, 575V doors.
a) 208V(Taps H1-H2) 6.8 Ohms c) 380V(Taps H1-H2) 18.4 Ohms b) d)
230V(Taps H1-H3) 7.5 Ohms
460V(Taps H1-H4) 27 Ohms
Two-Way Breakaway
V-Flex™ Curtain Release System
Wind Pressure e) 415V(Taps H1-H3) 20.5 Ohms g) 120V(Taps X1-X3) 4.4-4.8 Ohms f) h)
575V(Taps H1-H4) 29 Ohms
24V(Taps X1-X2) .4 to .6 Ohms
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 7” the full height of the door by the “V”-Flex strap guides and 7 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. Verify Door Operation It is recommended that the operation of all controls on the TRAKLINE door be verified monthly.
If the curtain is blowing out because of high wind or negative pressures, check the following: a) The V-Flex belting straps should have a minimum of 70ft/lbs on doors 10’ D.O.H. and 170ft/lbs on doors 24’ D.O.H.
b) Check to make sure the curtain has all the stabilizer bars in place and not bent.
c) If wind or pressure exceeds 35 thru 45 mph, the door may blow out.
OPERATING PROCEDURE
1.
2.
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.
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.
18 Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
1.
Rewire motor per,
Figure 30.
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.
DRIVE SYSTEM INFORMATION
ACTIVATION DEVICE INSTALLATION
1.
Wire activation devices after door is operational.
2.
Verify operation of all activation devices.
Route Limit Switch Cable
Through the Back of the Plate
Spot Ground Flat on Limit Shaft for
Set Screw
Jumper Wires n/a
Alt Open L/S
Open L/S
Black Wire
Closed L/S
Red Wire
Green Wire
White Wire
OPTIONAL ALTERNATE
OPEN LIMIT SWITCH WIRING
Jumper Wire
Green Wire
Black Wire
White Wire
STANDARD LIMIT SWITCH WIRING
.31 Ref.
Must be
Aligned with the 30 Tooth
Sprocket
208V-230V
460V
FIGURE 30-MOTOR VOLTAGE WIRING
Pub. No. 8920PLG JANUARY 2007
400V/575V
19
TRAKLINE™ FOLD Model 8920PL
FIELD WIRING DIAGRAM-CONTROL BOX
20 Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
FIELD WIRING DIAGRAM-CONTROL PANEL
Pub. No. 8920PLG JANUARY 2007 21
TRAKLINE™ FOLD Model 8920PL
WIRING DIAGRAM-CONTROL BOX & PANEL
22 Pub. No. 8920PLG JANUARY 2007
TRAKLINE™ FOLD Model 8920PL
ACTIVATION WIRING DIAGRAM
Pub. No. 8920PLG JANUARY 2007 23
TRAKLINE™ FOLD Model 8920PL
ARCHITECTURAL DRAWING
24 Pub. No. 8920PLG JANUARY 2007

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Key features
- Fast opening, smooth operation
- Low maintenance
- Superior environmental separation
- Reduces passage time
- Reduces temperature loss
- Counter-balance system
- V-Flex™ Curtain Release System
- i-COMM™ Universal Controller
- Exterior/interior folding door
- One or two directional curtain breakaway