INSTALLATION AND INSTRUCTION MANUAL

MGT

IMPORTANT: READ THIS MANUAL CAREFULLY BEFORE INSTALLING THE OPERATOR

Note:Place installation manual in an accessible place near the operator. For future reference record:

Model #

Serial #

Date #

Wiring Diagram #

WARNING

DO NOT CONNECT TO POWER SUPPLY WHILE INSTALLING, SERVICING OR ADJUSTING

THE ELECTRIC OPERATOR

2

IMPORTANT SAFETY INSTRUCTIONS

WARNING

TO REDUCE THE RISK OF SEVERE INJURY OR DEATH, READ AND FOLLOW ALL INSTRUCTIONS.

1. Never allow children to operate or play with or near door.

2. Check to see that the operator is proper for the type, size of door and frequency of use per the operator specifications.

3. If the door system is near a residential area, or pedestrian traffic is expected near the door system, additional equipment such as electric reversing edges, photocells, or similar devices must be installed as part of the system to prevent entrapment.

4. Reversing devices appropriate to the application must be installed as part of the system.

5. Outdoor or easily accessible controls must be of the security type to prevent unauthorized use of the system.

6. Place controls far enough from the door so that a user cannot touch the door when operating the controls.

7. Controls should be placed so the user has full view of the door when operating.

8. Always keep moving door in sight and away from people or vehicles until it is completely open or closed. NO

ONE SHOULD CROSS THE PATH OF THE MOVING DOOR.

9. If a person is trapped under the door, push the “OPEN” control button or use the emergency floor level disconnect mechanism.

10. Do not overtighten a clutch to compensate for a damaged door.

11. Test door and service monthly. If adjusting limit travel, retest the door opener. Failure to adjust the door may cause death or injury.

12. KEEP DOORS PROPERLY BALANCED. See owner's manual. An improperly balanced door could cause severe injury. Have a qualified service person make repairs to cables, spring assemblies and other hardware.

13. Use emergency manual operation mechanism only when operator has been electrically disconnected.

14. If possible, use the emergency release only when the door is closed. Use caution when using this release with the door open. Weak or broken springs may cause the door to fall rapidly, causing injury or death.

15. You are responsible for assuring that the owner of the door system understands its basic operation and safety. In particular, be sure the owner/end-user understands the location and operation of the manual disconnect.

16. Point out to the owner/end-user of the door system that children or pets should not be allowed to play on or near the door or any part of the system, and that the safety instructions supplied with this operator are the responsibility of the owner/end-user.

17. Leave the installation and maintenance manual for this operator as well as any additional information supplied with this operator or other components of the door system with the owner/end-user

18. If you have any questions about the safety of the door operating system, do not install this operator.

WARNING

IMPORTANT: PLEASE READ CAREFULLY THE ANNEX INSTALLATION MANUAL WHEN OPERATOR IS

SUPPLIED WITH AN ELECTRONIC CONTROL BOARD.

3

TABLE OF CONTENTS

Page

SPECIFICATIONS………………………………………………………………………………………………4

PRODUCT APPLICATION……………………………………………………………………………………..5

DELIVERY OF OPERATOR ...................................................................................................................5

HARDWARE ...........................................................................................................................................5

INSTALLATION.......................................................................................................................................6

OPERATOR START-UP AND TESTING GUIDE .................................................................................18

TROUBLE-SHOOTING GUIDE ............................................................................................................19

SCHEDULED MAINTENANCE.............................................................................................................21

MGT EXPLODED VIEW………………………………………………………………………………………22

MGT SINGLE PHASE ELECTRICAL DIAGRAM…………………………………………………………..23

MGT 3 PHASE ELECTRICAL DIAGRAM…………….…………………………………………………… 24

NOTES……………………………………………………………………………………………………….25-27

4

SPECIFICATIONS

GENERAL

SUPPLY VOLTAGE………………….. 115, 230 VAC single phase 208, 460, 575 VAC three phase

CONTROL VOLTAGE………………. 24VAC class 2 transformer, 2 amp fuse type ACG

MOTOR……………………………… Continuous duty motor 1/2HP, 3/4HP, 1HP & 1.5HP

OPERATOR OUTPUT SPEED……… 103.5 RPM

WEIGHT (net)………………………… 126 lbs (approx), 56.8 kg

STANDARD WIRING TYPE…………… C2 momentary contact to open and stop and constant pressure to close.

DIMENSIONS

1

1

1

2

1

1

11

2

1

6

1

2

9

5

THE TROLLEY OPERATOR (MGT)

IMPORTANT: UPON CMPLETION OF OPERATOR INSTALLATION, THIS MANUAL MUST BE GIVEN

TO THE END-USER

PRODUCT APPLICATION

The model MGT heavy duty trolley operator is designed for use on standard lift overhead sectional garage doors. All MGT door operators are designed and constructed in accordance with UL and CSA standards.

DELIVERY OF OPERATOR

Upon delivery of your heavy duty trolley operator, inspect the unit immediately for transport damage. Verify that you have received all the hardware requested with your order (Table 1). Other items may be present, such as radio controls or other types of optional equipment, if ordered. If any item is missing or if there is evidence of damage, call the transport company first.

* Check to make sure that the available power supply to be connected to the operator is of the same voltage, frequency, phase and amperage as indicated on the nameplate of the operator.

HARDWARE

TABLE1 STANDARD PARTS LIST FOR MGT TROLLEY OPERATOR

QTY PART # DESCRIPTION

2

3

4

6

Door lifting arm assembly

Set of trolley tracks (door height + 2’6”(0.75m))

Front end bracket

Trolley tracks spacer c/w 3/8” x 3/4” bolts & 3/8” lock washers

8

9

10

11

12

13

14

15

16

#41 chain package (2 x door height + 5’6”(1.65m)) w/connecting link

Hex head bolt 3/8-16unc x 1 ¼”

Hex head bolt 3/8”-16 x 2 ¼”

Take-up bolt 3/8” x 2 ½”

Eye bolt 1 3/8” x 3”

Hex nut 3/8-16unc

Nylon lock nut 10-32unc

Hex head cap screw 10-32unf x 1”

Lock washer 3/8”

Figure 1 Hardware

6

INSTALLATION

All heavy-duty trolley operators are tested and adjusted at the factory. They are factory set in the fully closed position before being placed in a box for shipping. When installing your unit, please note that the cams are resting on the close limit switches located on the Close side of the cam-shaft.

IMPORTANT INSTALLATION INSTRUCTIONS

WARNING

TO REDUCE THE RISK OF SEVERE INJURY OR DEATH, READ AND FOLLOW ALL INSTALLATION

INSTRUCTIONS.

1. Installation of this door operator must be done by a qualified installer.

2. Insure that the door is properly installed and works freely in both directions. Do not install the operator until all door problems have been corrected. If necessary, oil all moving parts (chains, rollers, guides, etc.).

3. Remove all old accessories (locks, bolts, etc.) before installing door operator.

4. Do not connect the operator to a source of power until instructed to do so.

5. Locate control push-button station within sight of the door, at a minimum height of 5 ft. (1.53 m) so small

children cannot reach it, and away from all moving parts of the door.

6. Ensure that emergency release tag is attached to emergency quick release disconnect arm (Figure 2).

Figure 2

Emergency release tag

WARNING

STAND CLEAR OF DOOR AND VERIFY THAT DOORWAY IS CLEAR, THEN PULL EMERGENCY

RELEASE DISCONNECT LEVER TO DISCONNECT OPERATOR FOR MANUAL OPERATION OF DOOR.

INSTALLATION OF MGT OPERATOR

7

IMPORTANT NOTE: THIS OPERATOR MUST BE INSTALLED A MINIMUM OF 8 FT (2.4 m) ABOVE FLOOR.

Before the operator is installed, ensure that door has been properly aligned and is working smoothly.

It is advisable to assemble the operator to the trolley tracks on the floor prior to installation.

1. Bolt the tracks to the operator using bolts provided (Figure 3).

Figure 3

Assembling operator and tracks

2. Place carriage on rails and slide to forward position, making sure that the chain eye bolt is facing the operator (Figure 4).

Figure 4

Inserting carriage in tracks

3. Attach front idler and rail spreaders as shown in Figure 5.

Figure 5

Front idler and spreaders

4. Attach chain to the take-up bolt with the provided chain links to the rear of the carriage (Figure 6). Run chain around front idler and continue around drive sprocket on operator. Loop chain through eyebolt.

Pass the chain through the eye-bolt and pull until taught. Now pass the 2 hardened Allen screws through the chain pitches and fasten with 2 nylon locking nuts. Chain can then be tightened by adjusting the takeup bolts in carriage. Properly adjusted chain should sag approximately 3” (7.6 cm) at halfway point on tracks.

8

Figure 6

Installing chain

Note: All trolley operators are designed to mount directly over the center of the door, and the operator tracks

should clear the door by approximately 2.5" (6.4 cm). If it is not possible to mount the operator exactly centered, it is possible to install it slightly off center for torsion spring doors.

5. Establish center line of door by measuring door width and marking a vertical line on the wall directly above the door.

6. Open the door manually to determine the high arc (highest point) of door travel (see Figure 7). Using a carpenter's level draw a line so that it will intersect with the vertical line determined earlier.

HIGH ARC POINT

Figure 7

Highest arc of travel

7. The wall mounting bracket has three bolt holes for mounting the front end of the trolley tracks. The bracket should be attached to the wall with these holes 2.5" (6.4cm) above the high arc of door (Figure 8). Wood blocking or angle iron framework may be installed on the wall to provide for the attachment of the front bracket.

Figure 8

Wall mount bracket

9

8. After securing the wall mounting bracket, allow the motor to rest on floor and raise the front end of the rails and secure (but not tighten) with 5/16” bolts and nuts (Figure 9). If torsion hardware is preventing the rails from lining-up with the wall bracket, secure temporarily with cord.

Figure 9

Installing tracks on wall bracket

9. Hoist rear of operator using block & fall or other suitable means above level of horizontal door tracks and temporarily secure in place using rope or chain. Tighten front end bracket bolts.

10. Carefully open door by hand and move rear of operator so that it is directly over center of door, with approximately 3" clearance between door and bottom of operator rails (Figure 10).

Figure 10

Adjusting height of operator

11. Hanging brackets may now be affixed from ceiling to operator (Figure 11). Two or more holes are provided in frame of operator for this purpose. Take care that unit remains centered over door during installation of hangar brackets. After vertical drops are made and secured, side braces should be installed.

12. Approximately 5 feet (1.5 m) from forward end of rails, locate set of 3/8" holes for angle iron braces to secure rails. Two drops pieces should be installed at this point to further strengthen installation (Figure 11).

Figure 11

Location and installation of hangers and side braces

10

13 Close door. Connect door arm to carriage using 3/8" x 2-1/4" bolt furnished. Fasten door bracket to arm and position on door as shown in Figure 12. Mount door bracket to center of door in such a way that the door bracket is also in line with the top rollers on the door.

Figure 12

Installing door arm to door

13. Door arm should always lean vertical (Figure 13).

Figure 13

Position of door arm

11

MINIMUM SUGGESTED WIRE SIZE FOR CONTROL CIRCUIT

The control circuit operates at 24 VAC. Due to the resistance in the wire used to carry the control circuit voltage, it is important to use the appropriate wire size with respect to the distance between the operator and the pushbutton station.

Below is a chart (TABLE 1) indicating the minimum recommended wire size with respect to the total distance between the operator and the push-button station. DO NOT exceed the maximum distance. If there are several push-button stations in series you must ADD all these distances before selecting the appropriate wire gauge for your operator.

If the wire gauge is not suitable for the distance, problems in operation will be encountered such as chattering relays and contactor, premature wear of the contacts and possible tripping of the motor's thermal protection.

If a greater distance is required, a long distance interface module is suggested (consult factory).

When large gauge wire is used, a separate junction box will be needed for operator power connection (not supplied).

All power wiring to the operator should be installed by a qualified electrician and may vary with respect to conduit size and type as specified in the National Electrical Code, Article 430, allowing 5% voltage drop. Power must also be connected in accordance with local codes.

TABLE 1 WIRE SIZE vs. DISTANCE

Minimum suggested

Wire gauge (AWG)

24 VAC CONTROL WIRING

Maximum distance between operator and all

Push-button stations feet (meters)

(15)

20 100

18 150

16 250

(105)

12 450

WIRING OF THE MGT OPERATOR

Do NOT connect any accessory controls until the limit switch adjustments have been completed and the operator is functioning properly.

Refer to the electrical diagrams on pages 23 and 24, the wiring specifications in TABLE 1 and the terminal input connections of Figure 22.

NOTE: For wiring of operators with Electronic Control Board, please consult the specific manual.

WARNING

EXERCISE CAUTION WHEN OPERATING MACHINE. THE DRIVE CHAIN AND LIMIT CHAIN, WHEN

EXPOSED AND TURNING, COULD CAUSE SEVERE INJURY.

NOTE: Wiring diagrams are found on the inside of the control box cover. If the diagram is faded or damaged, call the factory for a replacement. DO NOT INSTALL ANY WIRING OR ATTEMPT TO RUN THIS

OPERATOR WITHOUT CONSULTING THE WIRING DIAGRAM.

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Main Power Supply

Power to the operator is of the permanent connection type. Connect according to local electrical code. Ground the unit using the ground lug inside the control box.

For single phase operators, connect the power supply to terminals L (line) and N (neutral) on the main terminal strip.

For three phase operators, connect the power supply to terminals L1, L2 and L3 on the main terminal strip.

Single phase power supply

Three phase power supply

Ground

Ground

Figure 14

Power supply connection

WARNING

GROUND THE UNIT CORRECTLY USING THE COPPER GROUND LUG LOCATED INSIDE THE

OPERATOR CONTROL BOX.

Note: All other connections on the terminal strip (1 to 9) are low voltage class II 24 VAC.

1. External interlock between terminals 1 and 2. A jumper is factory installed between these two terminals. If an external interlock is used (such as interlocking between two doors), remove the jumper between 1 and 2 and wire the interlock between these two terminals.

Interlock Device With

Normally Close Contact

Jumper

Figure 15

External interlock

2. A 3 button push-button station (open/close/stop) can be wired to terminals 2, 3, 4 and 5. Two push-button stations can be wired to these same terminals by following the wiring diagrams on pages 22 and 23.

Stop

Open

Close

Figure 16

Three button push-button station

3. Three terminals are provided for the wiring of a radio-control receiver. Terminal #9 is Ground, #7 is 24 VAC

(common) and #8 is the relay contact provided by the radio-control receiver to activate the door to open or close. Furthermore, terminals 7, 8 and 9 are doubly available on the terminal strip inside and on a separate small terminal strip located on the side of the unit. This terminal makes it convenient to wire-up a standard single button radio receiver on the side of the unit. When the transmitter is activated, the door will open to the fully open position. From the fully open position, the door will close. If transmitter is activated while closing, the door will reverse to the fully open position.

13

NOTE: It may be required to reverse connections to 7 and 9 for other types or radio receivers

(Allstar, Linear, Pulsar ...).

Receiver

24 V a. c.

Contact

Ground

Figure 17

Radio-control

4. A single button open/close door device can be wired to terminals 7 and 8 to behave in the same way as the radio control receiver.

Figure 18

Single button device

NOTE: If several control devices are to be used, connect one and check for proper operation before connecting the next device.

5. A reversing edge can be wired up to terminals 3 and 6. These terminals can also be used for any other reversing devices such as loop detectors and photocells.

Normally open contact

Figure 19

Reversing edge or other device

IMPORTANT: Upon completion of all wiring connections, readjust limits as mentioned in section 20 using

"Open", "Close" and "Stop" buttons.

LIMIT SWITCHES

WARNING

TO AVOID THE DANGER OF POSSIBLE DAMAGE TO THE DOOR AND OPERATOR, LIMIT SWITCHES

MUST BE ADJUSTED TO THEIR APPROXIMATE POSITIONS BEFORE MANUALLY OPERATING THE

DOOR OR BEFORE APPLYING POWER TO THE OPERATOR.

There are 4 limit switches. Two are used as end of travel, one is for radio-control or one-button operation and one is for reversing devices. These switches are activated by the rotary cams travelling on a threaded shaft (Figure 20)

• The Open limit switch is the end of travel in the open position. Adjust the cam so that the door stops in the open position at the desired location.

• The Advanced Open limit switch is used for radio-control and for a one-button (open/close) feature. This limit switch is set to be activated slightly before the "Open" limit switch when opening.

• The Close limit switch is the end of travel in the closed position. Adjust the cam so that the door stops in the closed position at the desired location.

14

• The Advanced Close limit switch is used in the operation of the reversing edge or other reversing devices. This limit switch deactivates any reversing devices slightly before the door reaches its closed position to prevent the door from reversing when fully closed.

Advanced Open

Limit switch

Close limit switch

Figure 20

Limit switches

ADJUSTMENT OF LIMIT SWITCHES

1. Open the cover of the electrical enclosure.

2. Electrically

WARNING

NEVER PLACE HANDS OR TOOLS INSIDE OPERATOR OR NEAR DRIVE MECHANISM UNLESS

POWER IS OFF.

3. Depress the travelling cam retaining bracket and rotate the Open cam (Figure 21).

Note: Turning the cam towards the center of the shaft increases door travel.

Turning the cam towards the switch decreases door travel.

4. Manually rotate the Open cam until it depresses the Open limit switch sufficiently so as to hear the switch click.

5. Release retaining bracket. Make sure that the bracket engages in the slots of both limit cams after each adjustment.

6. Electrically lower the door to a nearly closed position and repeat steps 3 through 5 with the Close cam.

Press down on cam retaining plate to rotate

Rotate cams to desired positions

Figure 21

Adjusting the limit cams

15

OPTIONAL CONTROL ACCESSORIES

• Radio Controls: Consists of a radio receiver unit and remote transmitters. These controls consist of an RF signal being emitted on a "pulse" basis to a mated receiver tuned to the same "pulse" rate. Once the receiver accepts the code, a relay is activated closing a set of contacts.

• Photo-electric units: Can be used as opening and reversing devices. An infra red light is emitted from the control to a reflector and back. If, during closing travel of the door, the light beam is broken, the door will reverse to the fully open position.

• Digital Keypad: Consists of a control head which is pedestal mounted. Similar to a telephone touch pad it allows the selective coding of a four number series. Once the programmed series of numbers is received in their set order, a relay closes and completes a circuit.

• Card Reader: A magnetic-mechanical device which accepts sealed and coded cards. The cards trigger magnets to raise in the cartridge head, releasing a lock mechanism which allows a deeper insertion of the card. The card then contacts a switch that closes the circuit.

• Key Switch: Momentary contact will open door. Can be wall or post mounted for interior or exterior use.

Figure 22

Terminal Input Connections

CONNECTION OF A REVERSING EDGE DEVICE

IMPORTANT NOTE: If the door is controlled by any device other than a constant pressure push-button station, a

reversing edge must be connected.

CAUTION: Connect reversing device appropriate to installation.

Connection and installation of a reversing edge device is provided with the edge (see also Figure 23). Any such device that uses a normally open contact may be connected to terminals 3 and 6 on the low voltage terminal block

(Figure 19). When the door comes in contact with an object during downward travel, the circuit will cause the motor to reverse the door to the fully open position. In addition, there is a cut-off limit switch (advanced close limit switch) that will de-activate the reversing edge during the last few inches of the door's downward travel.

16

Reversing edge location

Figure 23

Reversing Edge

CLUTCH ADJUSTMENT

1. Loosen clutch set screws (Figure 24 A).

2. Back off clutch nut until there is insufficient tension on clutch spring to permit clutch to drive door (Figure

24 B).

3. Tighten clutch nut gradually until there is just enough tension on spring to permit operator to move door smoothly, but allow clutch to slip if door is obstructed.

4. When clutch is properly adjusted it should be possible to stop door by hand during travel.

5. Be sure to tighten clutch set screws each time operator is tested for clutch adjustment and that it is locked in place on completion of adjustments.

WARNING

THE FRICTION CLUTCH IS DESIGNED TO PROTECT VEHICLES AND DOOR HARDWARE AGAINST

DAMAGE. IT IS NOT INTENDED TO PROTECT PEOPLE. ALL DOORS SERVING PERSONNEL ARE TO BE

FITTED WITH AN APPROPRIATE REVERSING DEVICE OR REVERSING EDGE TO PREVENT INJURY OR

DEATH.

If an automatic reversing device is desired, several types are available as accessories. Consult your dealer for a recommendation.

Figure 24 A

Allen

Key

Figure 24 B

Set screw

&

Clutch nut

Reducer

Key is supplied

Figure 24

Reducer adjustment

BRAKE ADJUSTMENT

• The brake is factory set. However, after extensive use the brake may need to be adjusted.

• In order to obtain best performance and maximum life, the brake must be adjusted for:

Proper clearance between the brake band and the brake drum when the solenoid is energized.

Correct brake tensioning when the solenoid is de-energized.

17

TO ADJUST THE BRAKE SYSTEM:

1. Remove the solenoid cover.

2. Slightly unscrew the pivot nut (Figure 25)

3. To adjust the brake band tension, move the adjustment lever. To increase tension, move the lever away from the motor. To decrease tension, move the lever toward the motor

4. Tighten the pivot nut

5. Check clearance but manually holding the solenoid plunger. The brake drum should rotate easily by hand.

6. After adjustment is done, re-install the solenoid cover.

Pivot nut

Lever adjustment

Figure 25

Brake system

MANUAL OPERATION OF MGT OPERATOR

The MGT operator is equipped with trolley release disconnect mechanism to operate the door manually, if necessary. To manually operate the door:

1. Pull the disconnect chain downwards and disconnect trolley arm from carriage (Figure 26)

WARNING

DOOR ARM IS RELEASED FROM TROLLEY CARRIAGE WHEN DISCONNECT CHAIN IS PULLED. TO AVOID

BEING STRUCK BY DOOR ARM, DO NOT STAND DIRECTLY UNDER DOOR ARM WHEN PULLING CHAIN.

2. Operate the door manually (by hand).

3. To return to electrical operation merely re-attach trolley arm to carriage by pulling on trolley disconnect chain while re-inserting arm onto carriage (Figure 26)

18

WARNING

DO NOT ATTEMPT TO DISENGAGE THE OPERATOR WHILE OPERATOR IS RUNNING. DO NOT ATTEMPT

TO MANUALLY FORCE A MALFUNCTIONING DOOR TO OPEN OR CLOSE.

2. Disconnect trolley arm from carriage

1.Pull the disconnect chain

Figure 26

Disconnecting arm from carriage

OPERATOR START-UP AND TESTING GUIDE

This guide is a procedure you can follow to test every feature of your door operator.

If a 3 button push-button station is wired to the operator, disconnect it and then place a normally-close contact between terminals 2 and 3 to simulate a "Stop" push-button (use a spare limit switch or any such device). Interrupting the power between these terminals will stop the operator.

Using a small wire jumper, momentarily jump (short-circuit) the following terminals:

A. Momentarily jump terminals 3 and 4.

The door will open instantly. Allow it open completely.

B. Momentarily jump terminals 3 and 5.

The door will close instantly. Allow it close completely.

C. Momentarily jump terminals 7 and 8.

The door will open instantly. Allow it to open completely.

D. Momentarily jump terminals 7 and 8.

The door will close instantly. While closing, go to step E.

E. Momentarily jump terminals 7 and 8 again.

The door will reverse to open. Allow it to open completely.

F. Momentarily jump terminals 7 and 8.

The door will close. While closing, go to step G.

G. Momentarily jump terminals 3 and 6.

The door will reverse to open. Allow it to open completely.

H. Momentarily jump terminals 7 and 8 again.

The door will close. Allow it to close completely.

I. Momentarily jump terminals 3 and 6.

The door should remain still.

This procedure can be repeated using the radio-control terminal strip located on the outside of the control box by using terminals "24VAC" and "CONTACT" instead of terminals 7 and 8.

19

The following trouble-shooting guide (TABLE 2) will help you identify the source of the problem given a particular symptom.

TABLE 2 TROUBLE-SHOOTING GUIDE

SYMPTOM PROBABLE CAUSE SUGGESTED ACTION

Door will not

"open" or "close" push-buttons.

Motor has overworked and the overload thermal protection has tripped.

Reset the overload protection: press reset button located on the side of the unit for a single phase operator or inside the control box for a three phase operator. Is the door unbalanced?

Circuit breaker tripped (if used). Reset circuit breaker.

Replace fuse. If control circuit fuse keeps blowing:

Disconnect all external devices. Leave power terminals connected. (Remove power to power terminals). Run the operator artificially by using jumpers and shorting out the appropriate terminals as indicated in the Start-Up and

Testing Guide. Then reconnect the various external devices one by one until you find the one causing the short to ground.

OR: If you have an ohm-meter, use it to check all

incoming wires for continuity to ground. The meter should read infinity in all instances. If there is conduction between any control circuit wire and ground, this indicates a leak to ground and this is why the control circuit fuse blows when power is applied.

In some cases, the trouble is intermittent: i.e. the fuse only blows at certain times. This problem is more difficult to detect, but again: disconnect all wires going to external devices, and run the operator: if the fuse does not blow, this indicates that the trouble resides outside the operator.

Replace. Transformer defective.

Defective "stop" push-button.

Loose connection in one of the push-buttons.

Replace.

Verify, tighten or replace.

Defective "open" or "close" pushbutton.

Door will not Defective "open" push-button. respond to

"open" command, but will respond to

"close" command.

Door will not

Loose wire on "open" push-button,

"open" limit switch or coil of open contactor.

Defective "close" push-button. respond to

"close" command, but will respond to

Loose wire on close push-button, close limit switch or coil of close contactor.

"open" command.

Door moves in wrong direction

Incorrect phasing. with a three phase motor

Replace.

Replace.

Replace

Verify, tighten or replace.

Replace.

Verify, tighten or replace.

Interchange any two power leads.

Door closes by "close" contactor is defective. itself and operator does not shut-off at the end of closing travel.

"close" limit switch defective

Door opens by "open" contactor is defective. itself and operator does not shut-off at the end of opening travel.

"open" limit switch is defective.

Verify and replace.

Verify and replace.

Verify and replace.

Verify and replace.

Door coasts when stopped at any position.

Brake pad is worn out or requires adjustment.

Sensing edge does not reverse door.

Pneumatic hose broken, electrical wiring not connected.

Replace or adjust.

Contact a qualified installer.

SYMPTOM PROBABLE CAUSE

20

SUGGESTED ACTION

Reversing devices will open the door when the door is closed.

The advanced close limit switch is defective.

The advanced close limit switch is not being engaged by travelling cam.

Replace.

The advanced close limit switch needs to be adjusted just slightly ahead of the end of travel Close limit switch.

When door closes it reverses

The advanced close limit switch is defective. to fully open after it hits the floor.

The advanced close limit switch is not being engaged by travelling cam.

Replace.

The advanced close limit switch needs to be adjusted just slightly ahead of the end of travel Close limit switch.

A "Close" command is being given. Check "Close" push-button or any closing device for shortcircuit.

Radio-control does not function or hesitates for

It is normal for a radio receiver to take up to 10 seconds to "warm-up" before being fully operational.

10 seconds before working.

Therefore, when applying power for the first time, the radio-control will take 10 seconds before becoming fully operational.

Check protocol code pins of the transmitter and receiver: they must be the same. Press on the transmitter and listen to the receiver: you should hear a faint click. The transmitter battery may be dead or your receiver may need servicing. To test for radio-control function, short out momentarily terminals 7 and 8 on the terminal strip.

Operator should function normally. Have the radio-control verified: the mini-relay inside the receiver may be defective.

Replace Motor hums, starts when spun.

Capacitor defective.

Motor fails to

Defective limit switch. shut off at fully closed or opened positions.

Limit cams are not adjusted.

Limit drive chain broken.

Motor turns but door does not move.

Sprocket key is missing.

Drive chain is broken.

Clutch is slipping.

Motor hums or does not run.

Loose sprocket on limit shaft.

Limit shaft does not rotate.

Door locked or jammed.

Dead phase (three phase supply).

Operate limit switch manually while door is moving. If door does not stop, replace switch.

Verify and adjust.

Replace.

Tighten set screw.

Verify and replace accordingly.

Replace.

Replace.

Adjust clutch tension.

Verify manual operation of door.

Limit switches do not hold their setting.

Brake does not release.

Loose drive or limit chain allows chain to jump sprocket teeth.

Check power supply, fuses on each phase.

Check wires to brake solenoid. Verify and adjust brake tension.

Adjust chain to proper tension

Limit cam retainer not engaging slots in limit cams.

Limit cams are binding on shaft threads which allows them to jump position on retainer.

Be sure retainer is in slots of BOTH cams.

Lubricate shaft threads. Limit cams should turn freely.

Radio-control opens and reverses the door, but when the door is fully opened, will close the door a little and bounce back to the open position again.

Door cannot be closed except by the "close" pushbutton.

The Advanced Open limit switch is insufficiently advanced from the full

Open limit switch. The contact of the radio-control receiver is maintained for 1.5 seconds when a command is issued by the radio transmitter.

Therefore, when the door is fully opened, and a pulse is sent from the transmitter, the receiver maintains the contact closed for 1.5 seconds. If the door has closed and the

Advanced Open limit switch has returned to its normal state, the reversing relay will be activated, and the door bounces back to the open position.

Adjust the Advanced Open limit switch by bending the switch arm away from the Open limit switch arm and more towards the travelling cam.

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SCHEDULED MAINTENANCE

Inspection and service should be performed anytime a malfunction is observed or suspected.

WARNING

WHEN SERVICING - ALWAYS DISCONNECT OPERATOR FROM POWER SUPPLY

MECHANICAL

• The door area should always be kept clear of dirt, rocks or any other substance to insure proper operation.

EVERY 3 MONTHS - Check and adjust the clutch, if necessary.

EVERY 6 MONTHS

ONCE A YEAR

- Lubricate all moving parts, Bushing are oil impregnated and are lubricated for life.

- Verify that all mechanical parts function properly.

- Manually operate the door. If the door does not open or close freely, correct the cause of the malfunction.

- Inspect all bolts and screws and tighten if necessary.

- Check for any excessive slack in chains and adjust or replace them if necessary. The limit switches may have to be reset after a chain adjustment.

- Inspect the door for wear and damage.

- Run the operator a few cycles:

Make sure that the door rollers are rolling smoothly on the track.

Listen to the motor: The motor should hum quietly and smoothly.

Verify that the limit operates quietly and smoothly: investigate any unusual

noise.

- Verify that the mooring bolts are holding the unit securely.

- Inspect the unit for evidence of corrosion.

ELECTRICAL

WARNING

BEFORE OPENING THE CONTROL BOX COVER, DISCONNECT OPERATOR FROM POWER SUPPLY

•

•

•

•

•

•

Inspect the wiring compartment and remove any dirt from the control units.

Verify all the grounding wires and terminations for corrosion. Be particularly careful to check the ground wires.

Check the terminal strip to insure that all the screws are tight.

Verify that the security systems installed on the operator are fully operational.

Verify the voltage at the input terminals while the operator is running. The voltage must not drop more than

10% momentarily. If the voltage drop is too deep when running, the relays may chatter, the contact points will wear prematurely and may eventually weld. Verify the power terminations for corrosion.

Verify the current consumption of the unit with an amp-meter. The value of current should be consistent with the name-plate specifications. Investigate any anomaly.

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25

NOTES

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NOTES

27

NOTES

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Customer Service Technical Support

US Toll Free Number: 1-866-776-7372

CAN Toll Free Number: 1-800-361-2260

BOOK016 REV B 02/28/2002