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PROTECDOR
®
CLEAN
MODEL 8000CL
OWNER’S MANUAL
“Our mission is to improve industrial safety and productivity worldwide through quality and innovation.”
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.
Before returning any parts, you must contact RITE-HITE ® DOORS, INC Technical Support group to obtain authorization and an
RMA#. Returned parts will not be accepted without an RMA#.
This Manual Cover Doors Shipped
After 11-1-2002
Refer to Partslist Manual for
Exploded Views and Part Numbers
PRINTED IN U.S.A.
RITE-HITE PRINT SHOP
Publication No. 8000CLB
FEBRUARY 2004
PROTECDOR® CL Model 8000CL
PRODUCTION INTRODUCTION
TABLE OF CONTENTS
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .3
SIDEFRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4
ROLLER TUBE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .6
CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .8
LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .10
TROLLEY AND S/F COVER INSTALLATION . . . . . . . . . . . . .11
PHOTOEYE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .11
JUNCTION BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . .13
TURN-TITE® SEAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . .14
INPUTS & OUTPUTS ON PLC . . . . . . . . . . . . . . . . . . . . . . . .15
FINAL INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . .16
MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . .15
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
TROUBLESHOOTING, REPAIR, AND ADJUSTMENTS . . . . .20
ELECTRICAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
COUNTER BALANCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . .26
OPTIONAL INVERTER & THRU-WALL RELEASE . . . . . . . . .27
ARCHITECTURAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . .28
NOTICE TO USER
Your local RITE-HITE DOORS, INC. representative provides a
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 Protecdor system have been left out of this manual or are not complete, contact your local representative or
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: 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 including patents applied for, pending, or issued.
PRODUCT INTRODUCTION
Thank you for purchasing the Protecdor CL from RITE-HITE DOORS,
INC. The Protecdor CL door is a smooth opening, low maintenance door that is designed to provide superior environmental separation while reducing passage time and temperature loss. The door is designed for 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. This manual should be thoroughly read and understood, before operating or servicing this door.
RECOMMENDED SPARE PARTS LIST
Open Limit Switch
Closed Limit Switch
Proximity Magnet
Photoeye Internal
Photoeye External
Photoeye Reflector
Drive Belt
Wind Retention Clips
15650061
15650062
72700009
63900003
63900001
66400001
12550013
53700124
TOOLS AND MATERIALS REQUIRED
Tubes of RTV Silicone Caulk
9/16” Open End Wrench
Phillips Screwdriver
Hammer Drill
Forklift Lift and Scissors Lift
9/16” Socket
8’ or 10’ Step Ladder
Cordless Drill (3/8” or 1/2”)
Tape Measure 25’ Minimum
6’ Carpenters Level
Utility Knife
Plumb Bob
(2) 18” “C” Clamps Wire Strippers
Straps For Lifting Header (optional) 3/8” and 5/8” Masonry Bits
Hardware for mounting door and anchors for fastening sideframe to concrete are not supplied.
WARRANTY
RITE-HITE DOORS, INC. warrants that it’s Protecdor Clean, including electrical components, will be free from defects in design, materials and workmanship for a period of one (1) year, or 150,000 cycles, from the date of shipment, whichever shall first occur. It does not cover damage incurred from abuse, misuse or impact. Belting, fuses, bulbs and fogging or frosting of vision window, are not considered to be covered by warranty. 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 is 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. Any other manufacturer whose products are the subject of this transaction, nor any RITE-HITE DOORS, INC. representative 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.
To be sure that you receive the correct parts, always include your door serial or RHC # ( RITE-HITE CORPORATION) when ordering through Aftermarket or the Warranty department. The RHC and serial
# for your door is on a label located on the side of the control box.
The actual parts used on your door may be different than shown in this manual due to special engineering or product improvement.
FEATURES
- Soft-Edge™ safety system.
- Heat sealed FDA compliant fabric for a smooth, clean surface.
- Stainless Steel components withstand corrosion.
- Harsh Environment washdown motor and brake.
- Internal sensing system stops door immediately without coil cords or external electronics.
- Quick release hinged sideframe cover for cleaning and curtain re-feed.
- Standard Thru-Beam photoeyes
- Sealed electrical components
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. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
INSTALLATION INSTRUCTIONS
The following is basic information that you should review before beginning the installation.
It is important to verify the door opening to the door size before starting with the installation.
!
CAUTION !!!
Make sure to barricade the door opening on both sides to prevent unauthorized use until the door has been completely installed.
1.
Measure the overall width of the door opening near the floor and near the top (Dimensions A and B), Figure 1.
These measurements should be within ± 1/4" of the sizes listed on the Serial Number label for the door to be installed.
1.
Make sure that you have any special work or building permits.
2.
Make sure that you are working at the correct door location.
2.
Measure the height of the door opening at the left and right-hand sides (Dimensions C and D), Figure 1.
These should be within ±1" of the dimensions listed on the Serial
Number label. If the measurements do not agree, STOP!
Contact your RITE-HITE DOORS, INC. representative.
3.
Inspect the installation site to make sure that there are no overhead obstructions (sprinkler pipes, HVAC systems, electrical supply lines, etc.) that might interfere with the lifting of the header tube assembly during installation.
3.
Verify that the door jambs are plumb and perpendicular and that the horizontal header is level.
4.
Detour material handling equipment (fork lift trucks, etc.) during the installation of the door.
4.
Make sure that the floor is level using a 6’ carpenter’s level or water level. If the floor is not level to within 1/4", shimming of the sideframe assemblies will be required,
Figure 1.
5.
Move the entire crate of the door components as close to the door opening as possible.
SIDEFRAME INSTALLATION INSTRUCTIONS
6.
Make sure that the electrician is ready to bring the correct electrical power supply to the door control box.
7.
Make sure that the electrical power can be shut off without interfering with other plant operations.
8.
Verify that there is nothing buried in the floor (electrical supply, communication lines, etc.) where the anchor bolts will be installed.
1.
Measure the door opening width approximately 48" above the floor, Figure 1.
If the door opening width is narrower than the width of the door listed on the Serial Number label, subtract the door opening width from the door width.
The difference between these two numbers should be divided in half and added to each side of the door opening. These points will be used as the inside edge measurement AA and BB on Figure 4 between the sideframe assemblies of the door.
9.
When unpacking the door components remove the lighter items first (electrical components), then the side frame assemblies, and the roll tube assembly last.
Example:
NOTE:
Door width listed on the Serial Number label 12' 1"
Actual door opening width –12' 0"
Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 23-25.
Always check for electrical prints.
Difference 1"
For example, the 1" difference needs to be added to measurements AA and BB in, Figure 3.
Half of this dimension must be split between the centerline.
C
A
LISTING OF MEASUREMENTS AND
MARKINGS REQUIRED
Level
1. Door width at bottom
2. Door width at top
3. Door height left
4. Door height right
5. Mark left wall where water is level.
6. Mark right wall where water is level.
D
NOTE:
If the door is wider than the opening the breakaway magnets may not function properly.
2.
Snap a chalk line on the floor 3 1/4" from the wall and extending at least 12" to either side of the door opening,
Figure 2.
This will be the reference line used to keep the sideframes square with each other.
Center line
“E” B “E”
Wall
48”
High Side Low Side
3 1/4”
12” 12”
Hydro-Level
FIGURE 1
Chalk line
FIGURE 2
Pub. No. 8000CLB FEBRUARY 2004 3
PROTECDOR® CL Model 8000CL
SIDEFRAME INSTALLATION INSTRUCTIONS
Upper right hand sideframe
1/2” Max
Lower right hand sideframe
No bolts may interfere with track
This clearance to show mounting bolts above track only
Internal Sensing
System track
FIGURE 3
3.
Using a water level or string level, determine if the door opening is level,
Figure 1.
If the opening is not level, mark the wall where the level point is indicated. The measurement between the level mark the floor is the amount of shimming that needs to be done under the sideframe assembly that will be located on the “Low Side”
(greatest measurement) of the door opening.
Sideframe
Wedge type
Nut
Backing plate
Washer
IMPORTANT:
Thru-bolt or anchor head
MUST NOT stick out more than 1/2”
Thru-bolt
Sideframe
Backing plate
FIGURE 4
Nut
Washer
Thru-bolt
4.
Remove both sideframe covers and the motor shroud.
5.
Position the high side sideframe on the wall using the offset dimension from
Step 1
and using a 6’ level, make sure that the sideframe assembly is square and plumb in two directions. Use shims as required to square up the sideframe assembly to the chalk line.
NOTE:
If no shimming is required, mount the motor drive side sideframe assembly first.
6.
Using the predrilled holes in the sideframe assembly as a guide, drill the anchor holes for the wall bolts,
Figure 4.
If the anchor hole goes completely through the wall, use thru-bolts and backing plates to secure the sideframe assembly to the wall. Use all available anchor holes to secure the sideframe assemblies. It is especially important to fully secure the top hole of each sideframe assembly with a thru-bolt. Install the fasteners finger tight.
7.
Position the low side sideframe on the wall using the offset dimension from
Step 1.
Insert the required number of shims underneath the sideframe base plate to level the sideframe,
Figure 1.
Using a 6’ level, make sure that the sideframe assembly is square and plumb in two directions. Repeat Step 6 for the low sideframe.
Header Seal Assembly
Washers
Internal Sensing
System Cable
Thru-Beam
Photoeye Cable
3/8” Bolts
FIGURE 5
4 Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
SIDEFRAME INSTALLATION INSTRUCTIONS
8.
Be sure that the wires and connectors coming out of each end of the crossbeam and top of the sideframes are free and clear before fastening the crossbeam,
Figure 5.
NOTE: If this procedure is not followed, the sideframe assembly could be twisted slightly, causing the drive belt and limit switch belt to not track properly.
NOTE: Solid plastic or metal shims must fully support the sideframe base plate. Drill through the shims to allow for the proper installation of the anchor bolts
9.
Install the top seal crossbeam to the sideframe assemblies and secure with two 3/8" x 1" bolts and flat washers at each end,
Figure 5.
FIGURE 6
10.
Check the front edge of the sideframe assemblies for squareness by referencing the chalkline,
Figure 6.
NOTE: Front edge of sideframe assembly must be flush or within 1/8" inside of chalk line, if not install solid plastic or metal shims behind the sideframe assembly to align the sideframe with the chalk line.
11.
Using the predrilled holes in the sideframe assembly base as a guide, drill the anchor holes for the floor bolts into the concrete,
Figure 6.
If the installation requires the use of shims, predrill the shims to allow for the anchor bolt.
Install the anchor bolts and fully tighten.
12.
Fully tighten all remaining anchor bolts or thru-bolts on both sideframes. Check to see that the back of the sideframe is flush with the wall,
Figure 7.
Make sure to check that both the top of the sideframe and the top seal crossbeam above the motor are flush with the wall. If a gap on either side of the drive side sideframe of more than 1/16" is noticed, insert metal shims to fill the gap before tightening the thru-bolts. Make sure to position the shims as close to the thru-bolts as possible. This is important at the top of the drive side sideframe assembly to make sure that the drive motor and pulleys are aligned.
Pub. No. 8000CLB FEBRUARY 2004
FIGURE 7
ROLLER TUBE ASSEMBLY / DRIVE BELT
NOTE: When overhead fork truck mast clearance is a problem, additional support blocks will need to be added under the roller tube assembly. Securely attach wooden supports to the roller tube assembly and lift into position as stated in normal installation procedures.
IMPORTANT!!!
DO NOT remove the shipping bands from the roller tube assembly before completing installation.
!
CAUTION !!!
Secure the roller tube assembly to the lift truck forks before attempting to position the roller tube assembly, Figure 8 .
FIGURE 8
5
PROTECDOR® CL Model 8000CL
ROLLER TUBE ASSEMBLY / DRIVE BELT
Pillow block bearing w/ set screws
Roller tube assembly
Pulley
Lock Washer
Tapered Washer
Flat Washer
7/16” x 1” Bolt
7/16” x 1-1/4”
Bolt
1.
Use a lift truck, lift and position the roller tube assembly above the sideframes, Figure 8.
FIGURE 9
VIEW OF A RIGHT-HAND DRIVE
2.
Carefully lower the roller tube assembly into position on top of the sideframes by aligning the bolt holes in the pillow blocks and the mounting brackets, Figure 9.
3.
Align and fully tighten the drive side roller tube mounting bolts.
NOTE: The non-drive side uses 7/16" x 1 1/4" bolts, flat washers, and tapered washers; the drive side uses 7/16" x 1" bolts and lock washers.
4.
Align the roller tube mounting bolts and tapered washers on the non-drive side and fully tighten. If necessary, loosen the two set screws on the pillow block bearing to align mounting holes. Tighten the two bearing block set screws on the non-drive side to 66 to 80 in/lbs. of torque.
5.
Using a 12" long straight edge, check to see that the large pulley is square with the motor mounting plate. Place the straight edge perpendicularly along the outside face of the motor mounting plate and measure at the front and back of the pulley, Figure 11.
If these measurements are not within 1/16", shim behind the drive side sideframe assembly. Refer to Step 11 on Page 5.
6.
Install the drive belt onto the drive pulley on the motor and then position the belt on the large pulley on the roller tube assembly, Figures 10 & 11.
Make sure that the belt ribs are fully seated in the grooves of both pulleys.
7.
Engage the tensioning system by pulling the loose end of the tension spring downward and hooking the spring end over the anchoring peg, Figures 10 & 13.
Make sure to position both of the spring ends (top and bottom) in the grooves of the nylon bushing.
8.
Using a straight edge, measure the distance between the drive belt and the motor plate at the large pulley and at the motor pulley. The measurement taken at the motor pulley must be within 1/32" of the measurement taken at the large pulley. If an adjustment is required, loosen the motor pulley set screws and align the motor pulley as required. Tighten the set screws and recheck the measurement, Figure 11.
FIGURE 10
Bottom Edge
Brake
Release
Handle
3/4”
Drive Belt
Large Driven Pulley
Straight Edge
Motor Pulley with set screws
“X”
“X” =/- 1/32”
FIGURE 11
1”
6 Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
ROLLER TUBE INSTALLATION
9.
Remove the curtain shipping band. The curtain will not unroll because the brake is holding the curtain in position.
14.
Slide the 1" conduit fitting into the same bracket that the
3/4" motor conduit is secured to and tighten the lock nut,
Figure 10.
!
CAUTION !!!
15.
Connect and secure all mating wire connectors from the motor, photoeyes, limit switches, and sensing system.
Keep hands and loose clothing away from the pulleys and belts while manually releasing the brake.
10.
Using the manual brake release handle, disengage the brake and slowly lower the curtain until the bottom is even with the top of the door opening, Figure 11.
Release the manual brake lever to hold the door in this position.
NOTE: The two photoeye connectors are red in color.
These must not be plugged into any other color connector.
16.
The door ground wire is pre-attached at the factory to the door frame assembly by using the hex head screw and star washer attached to the conduit mounting bracket,
Figure 12.
11.
Rotate the large limit switch pulley to align the magnet assembly with the red OPEN limit switch, Figure 12.
17.
Secure all wires clear of moving parts with a wire tie.
18.
Pull the manual brake release handle to slowly lower the door until the curtain is 4" from the floor.
IMPORTANT!!!
Do not over tension the limit switch timing belt.
19.
Locate the close limit switch adjustment plate. Loosen the
1/4” thumb screw and rotate the limit switch plate until the black limit switch aligns with the magnet, Figure 12.
Lightly tighten the lock bolt.
12.
Install the limit switch belt over the small pulley on the roller tube and the large pulley on the limit switch assembly. Loosen the two 3/8" limit switch mounting bolts.
Make sure that the timing belt is seated in the grooves on both of the pulleys.
13.
Pull down slightly on the limit switch mounting plate to apply tension to the timing belt and tighten the two 3/8" bolts. In most cases, just the weight of the limit switch assembly will provide enough tensioning.
NOTE:
The white tipped limit switch deactivates the photoeye prior to the door fully closing.
VIEW OF A RIGHT-HAND DRIVE
Limit Switch Drive Belt
Open Limit Switch (Red)
Header Channel
Adjustment Slots
Limit Switch Mounting Plate
Limit Switch Mounting Bolts
Drive Belt
Motor Bolts
Driven Pulley
Photoeye Deactivate
Switch (White)
Closed Limit Switch
Adjustment Plate
Closed Limit Switch (Black)
Motor Drive Belt Tensioner
Drive Belt Tension Spring
Anchor Peg
Motor Cable
Ground Screw
FIGURE 12
Pub. No. 8000CLB FEBRUARY 2004 7
PROTECDOR® CL Model 8000CL
CONTROL BOX INSTALLATION
!
WARNING!!!
1. 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.
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.
2.
All control boxes should be mounted on the warm side regardless of door mount side.
3.
The incoming power terminals in the control box will not accommodate wires larger than 12AWG. 20 or 30 Amp service may be required for cable runs longer than 300’.
IMPORTANT!!!
The control box and all wiring should be installed by a qualified electrician in accordance with all national and local electrical codes.
4.
The control box is provided with class CC protective fusing for the incoming power.
5. Mount the control box on a wall adjacent to the door at approximately 54" above the floor level, Figure 13.
6. Run the control cable from the drive sideframe assembly through the conduit fitting in the bottom of the control box,
Figure 13.
IMPORTANT!!!
If rigid conduit is installed, bonding must be maintained between conduit connections by using ground bushings and a jumper wire.
!
CAUTION !!!
When drilling holes in the box, do not allow the drill to go too deeply into the box. Damage to the control systems may occur.
IMPORTANT!!!
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.
!
WARNING!!!
DO NOT turn control box upside down to drill any access holes. Debris may fall into electrical components causing failure or severe equipment damage.
Control cable (1 15/16” flex conduit), comes prewired ready to attach to conduit connector in the bottom of the control box. Individual wires need only be routed and secured to the proper terminals. (Length provided is specified on original door order).
Control box to activation (pull cords, motion detectors, etc.) conduit run (s), by others.
6” Min
Open/Reset
Button
Disconnect
Switch
Control box (shipped with door), recommended mounting location is approx. 54” from floor to bottom of box and minimum of 6” from door side frame (consult salesperson for planned mounting location.)
Fused disconnect (supplied by others), located next to where the door’s control box is or will be located. See Pages 23-25 for service amperage requirements given your specific line voltage.
Sideframe
Conduit
Fitting
54”
Control box to disconnect conduit run (by others).
Incoming voltage (see Pages 23-25 for acceptable voltages)
Floor
FIGURE 13
8 Pub. No. 8000CLB FEBRUARY 2004
NOTE:
PROTECDOR® CL Model 8000CL
CONTROL BOX INSTALLATION
Make sure to route the cable so that it does not interfere with the installation of the motor shroud.
7. Drill a hole for the power supply cable (by others) in the bottom of the control box using the proper connection to maintain the NEMA rating on the enclosure. All holes drilled through the control box must be through the bottom of the box.
If the flexible conduit is too long for the installation, cut the protective outer casing and leave 16" to 20" of wires. Do not connect the conduit to the fitting on the control box until correct conduit and wire length is achieved.
8. Connect wiring as indicated by the device field wiring located on Pages 23-25. Incoming 3-phase power must connect into terminals L1, L2, and L3. Ground must attach to the green/yellow terminal.
Local electrical codes may require the use of rigid conduit, rather than flexible conduit. If required, remove the control cables from the furnished flexible conduit, install the rigid conduit in its place and rewire. Make sure to remove and replace the conduit connector in the bottom of the control box.
NOTE: Route all field installed wires so that separation is maintained between line voltage wires and low voltage class II wiring. Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 23-25.
Always check parts or control box for prints.
Top Pot Switch is Reclose
Timer, Lower is
Preannounce
Hand Held
Programmer
Receptacle
Pub. No. 8000CLB FEBRUARY 2004
Illuminated
Input LED’s
GND L3 L2 L1 F2 F1 F4 F3 S4 S2 S3 S1 B2 B1 W V U GND
Illuminated
Run/Power
LED’s
Illuminated
Output LED’s
FIGURE 14
9
PROTECDOR® CL Model 8000CL
LIMIT SWITCH ADJUSTMENT
ADJUSTMENT OF LIMIT SWITCHES
6.
If the door jogs upwards, continue jogging until the door reaches the OPEN limit switch.
1.
Turn on the main power supply. Confirm that the correct line voltage is at terminals L1, L2 and L3, Figure 14.
2.
Make sure that fuses F1, F2, F3, and F4 are installed,
Figure 14.
7.
Continue to jog the door by momentarily pressing the
OPEN button, the door will now move downward toward the closed position. Continue until the door reaches the
CLOSE limit switch, approximately 4" off the floor.
3.
Turn the power to the door on using the disconnect switch located on the front of the control box. Verify that the PLC is in the run mode.
NOTE:
In the “jog” mode, when the door reaches the
CLOSED limit switch, it will reverse direction.
4.
Check PLC input 1, door close limit switch. This should be turned on. If this is not on, check the close limit switch to make sure that it is in alignment with the magnet on the limit switch pulley.
If the door reaches the 4" measurement and does not reach the Closed limit switch, turn off power to the door and adjust the Closed limit switch, Figure 13.
5.
Momentarily press the green OPEN button and observe the door. If the door jogs downward, lockout and tag the main electrical power and reverse the motor leads at terminals V and W, Figure 14.
Reconnect the power and verify the correct door movement.
8.
Continue to jog the door until it is fully open.
Door Opening 3/4” Max
Sideframe
Magnet
Right Side
Trolley
Internal Sensing System
Cable, On Back Side
Wheel
Attach Cables
With Screw Here
Snap Chain
Together Here Jumper Wire
FIGURE 18
Be sure not to pinch wires here
Connect wires here
10
FIGURE 19
Junction Box
Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
PHOTOEYE ADJUSTMENTS
installing external mounted photoeyes.
TROLLEYS
1.
Locate the left and right hand trolley assemblies. Make sure the trolley assembly has the wheels on the inside of the sideframe and towards the back wall.
EXTERNAL PHOTOEYE INSTALLATION
1.
Locate the thru-beam photoeye components
(source, receiver, and mounting brackets).
2.
Verify chain and cable are connected to the trolley, Figure 18.
NOTE:
2.
Install the source photoeye on the non-drive side sideframe. Install the photoeye receiver on the drive side,
Figures 22 & 23.
Covers must be installed with a 3/4" gap at the curtain edge for proper trolley operation, Figure 17.
3.
Insert the photoeye cable through the side of the sideframe at the bottom and connect the cables together at the connectors in the sideframe.
INTERNAL SENSING SYSTEM CABLES
1.
Make sure to route the wire from the non-drive sideframe thru the conduit of the header channel before putting on the front cover, Figure 19.
4.
With the power on, adjust the thru-beam photoeye by loosening the two mounting bracket screws and rotating the bracket and photoeye assembly until the red LED turns on.
2.
Connect the wires from the drive sideframe and header to the control box cable.
5.
Cable must be out of the inserts path.
3.
Be sure not to pinch the wires as the header channel is installed, also be sure to have wires down in the sideframe so the trolley does not catch on them.
PHOTOEYE INSTALLATION
IMPORTANT!!!
The PROTECDOR CLEAN will not operate until both the internal and external photoeye s have been installed and aligned.
1.
Locate the Thru-Beam photoeye assembly in the drive sideframe assembly, Figure 20.
Located on the back end of the photoeye assembly are three LEDs and one switch.
2.
The yellow “Power ON” LED should be on when the door power is turned on.
3.
The “Light/ Dark” operate switch has been preset in the
“Light” operate position.
4.
The red and green LED’s will be on when the photoeye receiver and the source are lined up correctly. If the red and green LED’s are OFF, either the beam is blocked or the photoeye is out of alignment. Adjustment using the screws on the sideframe assembly beneath the photoeye,
Figure 20.
The two top screws allow for horizontal adjustment and the single bottom screw adjusts vertical alignment. Rotate the screw until the LED’s turn ON. If after three turns the red and green LED’s do not turn on, reverse direction.
After the red and green LED’s turn ON, continue to turn the adjustment screw in the same direction, counting the turns. Note when the LED’s turn OFF.
Divide the number of turns in half and reverse the turning direction that number of turns to center the light beam.
Follow the same steps for the vertical adjustment until the light beam is centered on the reflector.
Note: This photoeye is for reversing only, not remote activation. Photoeye should be mounted at an elevation of 24" from the floor (pre-drilled holes on both sideframes). Disconnect power before
Pub. No. 8000CLB FEBRUARY 2004
Thru-Beam Photoeye
Assembly
Horizontal Adjustment
Vertical Adjustment
Drive Sideframe
Source
FIGURE 20
FIGURE 22
11
PROTECDOR® CL Model 8000CL
MISC INSTALLATION
Thru-Beam Emitter
Photoeye
Photoeye
Source
24 5/8”
Nut
Bracket
#10-24X1/2” Bolt w/Lock
& Flat Washer
FIGURE 23
STAND CLEAR INSTRUCTION LABEL
1.
Clean surface where label is to be placed.
2.
Peel off backing on label.
3.
Apply label in proper position, Figure 24.
12”
BREAKAWAY DETECTION SYSTEM
1.
Jog the door down until it is approximately 4’ off the floor.
2.
Attach the plastic magnet cup assemblies at each end of the tension assembly to the magnets, Figure 18.
3.
Remove excess slack by tightening the buckle.
4.
Reattach the bottom loop seal.
IMPORTANT!!!
In the “jog” mode (OPEN button light flashing), the door will raise as long as the OPEN button is pressed. In the downward direction, the door will only advance in short steps while the button is pressed. Do not press the contactor to jog the door.
5’-0”
Label Both
Sides
View of back Side Of Door
FIGURE 24
12 Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR®
POWER DOOR Model 8000
JUNCTION BOX INSTALLATION
7810E001 Rev B 5/22/2003
Junction Box Layout
Pub. No. 8000CLB FEBRUARY 2004 13
PROTECDOR® CL Model 8000CL
TURN-TITE SEAL ADJUSTMENT
TURN-TITE SEAL ADJUSTMENT CURTAIN RETENTION CLIPS
The PROTECDOR CLEAN is equipped with an adjustable
TURN-TITE seal that runs across the entire door opening. Cycle the door approximately 10 times to seat the door fabric.
Continue to cycle the door while standing on the back side of the door opening. Look upwards and observe the gap between the door opening and the roller tube assembly. No light should be visible in the gap when the door is fully closed. If light is visible, inspect the TURN-TITE seal from above. Adjust the seal so that the sealing edge is aligned about halfway down the angled face of the header seal and the TURN-TITE seal flexes into the gap, Figure 30.
Make sure to secure the hook and loop fastener along the entire length of the roller tube.
Vertical Side Seals are seals located in the top corners of the door when it is closed, Figure 30.
These seals fill the gap between the curtain fabric and the sideframe assembly just below the roll tube. If a gap is visible along either side edge, remove and re-install the seal.
1. Retention clips have been installed on the Protecdor curtain assembly for pressure resistance, Figure 31.
2. They are located above and below the vision panel at the edge of the curtain.
3.
There are four per door on doors under 11’ and six on any doors over 11’ tall.
!
WARNING!!!
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.
Header Wall
Seal
TURN-TITE Seal
Vertical Side
Seal
Correct TURN-TITE and Vertical Side Seal
Roller Tube
Move TURN-TITE Seal
Towards Top Of Roller Tube
FIGURE 30
Move TURN-TITE Seal
Towards Header Wall Seal
Retention Clips
Cutout View of Retention
Clip in sideframe
14
Must be set at 3/4” gap
FIGURE 31
Tension
Cable Internal Sensing
System cable
Top View of Curtain with
Retention Clip in sideframe
Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
PLC INPUT/OUTPUT & MAINTENANCE CHART
CUSTOMER:
RHC# SERIAL#
Periodic Cycle Check:
Planned Maintenance
Brake
Controls
Curtain
Drive Belt
Internal Sensing System
Limit Switches
Limit Switch Belt
Magnets
Photoeye
Pillow Block Bearings
Seals
Sideframes/Shroud/Header
RITE-HITE DOORS, INC. PLANNED MAINTENANCE
Model 8000 PROTECDOR®
1
•
•
•
•
DATE:
Recommended P.M. Intervals
(Time Shown In Months)
4 8 12 18 24 30 36
• • • •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Inspect and Perform the Following (See Manual)
•
•
•
•
•
•
•
•
•
•
With door in the open position, manually release the brake by pulling the handle, but DO NOT let it free fall to the bottom. Check that door stops on limits, if not check air gap of brake, must be .008”.
Clean, check all connections with disconnect off.
Inspect for wear or damage, clean with isopropyl alcohol or similar product.. Check retention clips.
Inspect for wear or squeaking, realign as required.
Replace if worn or frayed, must remove l/s belt.
Remove sideframe covers and perform visual inspection of chain and cable. Check operation by separating magnets from cups, door MUST stop and green lite flash.
Check open and close positions.
Inspect for wear, realign as required, DO NOT overtighten. When replacing, limits must be reset.
Inspect magnets and cups. Remove dirt and metal shavings from face of magnet and plate. Apply small amount of electrical grease if rust is present.
Check alignment, align as required. Clean reflector, emitter and receiver.
Grease as required.
Adjust Turn-Tite as required in closed position.
Inspect wear on wall and curtain wedge seals, replace as required.
Perform visual inspection for damage.
Tighten all hardware.
Check sideframe to cover gap at 3/4”
Pub. No. 8000CLB FEBRUARY 2004 15
PROTECDOR® CL Model 8000CL
OPERATING INSTRUCTIONS
STANDARD OPERATING CONDITIONS
Operate the door under normal conditions. Observe the door opening to make sure that it opens fully and does not interfere with the header. Observe the closing action to make sure that the door operates smoothly, and fully closes without excessive curtain ripple at the bottom. The bottom edge needs to rest completely on the floor for a good seal, adjust limits as required.
VERIFY DOOR OPERATION
1.
It is recommended that the operation of all controls on the
CLEAN door be verified monthly.
2.
A fault will occur when this condition exists: programmed during testing at the factory. Unless you are trained in PLC adjustments and are a RITE-HITE
DOORS, INC. authorized service technician, you should not attempt to change the factory set program.
2.
A quick way of determining that the door is ready to operate, is to open the control box and look at the PLC.
On the face of the PLC are two rows of small red lights called Light Emitting Diodes (LED’s). The top row of LEDs are numbered and called INPUTS, these are also referred to as X-Inputs. They indicate the condition of the inputs for door, such as #0 open limit switch, #1 close limit switch.
The bottom row of LEDs are also numbered and called
OUTPUTS, these are also referred to as the Y-OUTPUTS.
To return the CLEAN door to normal operation:
Both magnet cups must be properly connected.
3.
Refer to the state table of “Inputs and Outputs on PLC,” located on Page 15 of this manual, to verify the lights that are on or off are correct.
Press the OPEN button to reset.
4.
Figure 14 gives you an example of the standard PLC used in the control box and also an optional PLC.
3.
If the door fails to function, contact your local RITE-HITE
DOORS, INC. representative.
Run/Stop Switch
TEST ALL SAFETY FEATURES
1.
While the door is closing, block one of the reversing photoeyes. The door should stop immediately and reverse to the fully open position. Repeat this test for the second reversing photoeye.
The Run/Stop switch is located under the small cover on the lower edge of the PLC, Figure 14.
The Run/Stop Switch is normally in the Run position. The only time the switch is moved to the Stop position is when an authorized person reprograms the PLC. When the switch is in the Stop position the door will not function.
2.
Internal Breakaway Sensing System testing requires that the insert be broken away from the trolley. Do this while the door is OPENING. The door should stop and the open/reset button on the control panel will flash indicating a fault. Press the reset button and/or reattach the insert to the trolley magnet.
DISCONNECT SWITCH
Re-close Timer
The timer is part of the PLC. The adjustment for the timer is located under the small cover on the lower edge of the PLC,
Figure 14.
The timer controls the amount of time that the door remains open after activation by a remote device (pull cord, induction loop, etc.). When the amount of time set expires, the door automatically closes.
The red Disconnect Switch stops door operation. The control is rotated to the On position for normal door operation. To stop door operation rotate the control to the OFF position, Figure 13.
Whenever the door is stopped by using the Disconnect Switch, you must do the following to resume operation.
1.
Rotate the red disconnect switch to the ON position.
FINAL INSTALLATION CHECKLIST
1.
With the power on and the breakaway detection system installed, press the OPEN button. The door should open and close automatically after a short delay. To adjust the amount of door open time, locate and turn the adjustment screw on the front of the PLC, Figure 14.
2.
Press the open/reset button to reset and open the door.
GREEN OPEN BUTTON
The green OPEN button opens the door and resets the door after a fault condition. To open, press and release the button.
The PLC will automatically close the door after the preset time has expired, Figure 13.
2.
Operate the door several times and observe the opened and closed positions. If it is necessary to adjust either position, shut the power off and simply move the open or closed limit switch, Figure 12. Tighten the limit switches after adjustment is final.
REMOTE ACTIVATION DEVICES
3.
While the door is operating, break away the magnet on one side of the door to make sure that the breakaway detection system is working. The door should stop and the
OPEN button light should flash. Reattach the magnet and press the OPEN button to restart the door.
Operate the door system with any remote activation devices that are in use. Make sure that the door fully opens and then closes after the time set on the re-close timer has expired.
PROGRAMMABLE LOGIC CONTROLLER
1.
The door operations are controlled by a Programmable
Logic Controller (PLC), Figure 14.
The PLC is used to control all functions of the door. The PLC is set-up and
4.
While the door is closing, block the internal and external photoeyes. The door should reverse direction and move to the open position, and then continue to operate.
5.
Install motor shroud.
6.
Are door opening dimensions correct ?
16 Pub. No. 8000CLB FEBRUARY 2004
If the door is in jog mode (OPEN button flashing):
PROTECDOR®
POWER DOOR Model 8000
OPERATING INSTRUCTIONS
7.
Did you check for proper frame alignment when installing floor anchor bolts and shim as required ?
8.
Did you install a wall mounting bolt in the top hole of both sideframes and tighten all mounting bolts ?
the door to the top. Open the front covers and jog the door down to reassemble the magnets.
SHROUD INSTALLATION
1.
Run door to the full open position and disconnect the power and lock/out tag/out and barricade traffic.
9.
Did you tighten the pillow block bearing set screws on the non-drive side to 66 to 80 in.-lb. ?
2.
Position center shroud and fasten with 1/4” hardware.
10.
Did you check drive belt alignment to within 1/32" ?
11.
Are loose wires secured away from moving parts?
12.
Did you check for proper line voltage ?
13.
All wires connected for the internal sensing system and/or thru-beam photoeyes ?
3.
Position drive shroud and fasten with 1/4” hardware.
4.
Position non-drive shroud and fasten with 1/4” hardware, and self tap screw.
5.
Return power to door and verify operation, remove barricades and return door back to service.
14.
Sideframe covers adjusted to 3/4” gap clearance ?
TIPS FOR BREAKAWAY REASSEMBLY
The Protecdor Clean is equipped with a breakaway “Internal
Sensing System”. The system is a quick and easy re-assembly of the curtain after a breakaway occurs. When a breakaway condition is acknowledged the door will stop, the OPEN button will flash, and operation will convert to JOG mode.
The “Internal Sensing System” is a thru-wire closed loop circuit which monitors continuity through the breakaway system. When continuity is disrupted by the separation of one or both of the breakaway magnets, a breakaway condition is acknowledged.
To return to normal operation, if the magnets are separated, reattach and press the open button.
MISC PHOTOS
1.
See the two figures above for gaining access to the sideframe.
2.
The sideframe is opened by stepping on the Quick
Release system lever located on the outside edge of either sideframe and swinging the door open.
3.
In the event of the curtain coming out of the sideframe, the front cover will need to be opened to place the curtain back in the sideframe.
Junction Box
Problem: The door is broken away and one or more of the retention clips are outside the front cover.
Solution: Open the sideframe front covers. Jog the door to the top and back down to a convenient height for reassembly of the magnets. Close front covers.
Problem: The curtain bunches up enough to stall the motor.
Solution: Turn power off. Release the manual brake handle in short intervals until the curtain reaches floor or the wrinkles are cleared. Turn the power back on and jog
DRIVE SYSTEM
1/4” Bolt w/Washer
Non-Drive
Sideframe
Non-Drive
Shroud
Pub. No. 8000CLB FEBRUARY 2004
Center Shroud
FIGURE 36
Drive Shroud
Drive Sideframe
17
PROTECDOR® CL Model 8000CL
MISC DOOR PHOTOS
Step Down Latching
Mechanism
OUTSIDE FRONT COVER LATCHING MECHANISM
Trolley
Magnet & Cup
BREAKAWAY SYSTEM
BELT TENSIONER
Internal Sensing
System Cable
Sideframe
FRONT COVER EXTENSION
Front Cover
18
Latching Mechanism
INSIDE FRONT COVER LATCHING MECHANISM
Breakaway System
BREAKAWAY CHAIN & TRACK SYSTEM
Bottom Loop Seal
BOTTOM LOOP COVER
Photoeye & Internal
Sensing System Cables
FRONT COVER
LATCHING MECHANISM
Pub. No. 8000CLB FEBRUARY 2004
AIRGAP:
1.
In most applications, the brake needs practically no maintenance. However after a long period of operation, or if the brake has high duty cycles, adjustment of the air gap may be necessary.
2.
Check the air gap with a feeler gauge in three positions.
Note: the air gap is shown in Figure 33.
The normal setting is .008”. When the maximum dimension of .015” is exceeded, adjust the value back to the normal dimension of .008” using the instruction in Step 3.
3.
If air gap adjustment is necessary, loosen the bolts (9A), rotate the adjustment tubes (8) approximately 1/4 turn, retighten bolts (9A), and measure the air gap. If air gap is not within tolerance, repeat procedure.
TORQUE:
1.
The brake is supplied from the factory with the nominal torque setting. This torque can be reduced by unscrewing the torque adjustment ring (3) with a spanner wrench. Do not unscrew the ring further than it’s limit of .330” (approx.
5/16”) as shown as dimension “0”1 in Figure 34.
2.
The torque adjustment ring has detent action with torque variation of .443 ft-lb, per step.
BRAKE REPLACEMENT
1.
Run the door to the full open position and disconnect power to the door. Make sure that the power source has been locked and tagged out according to OSHA regulations and approved local electrical codes. Barricade the work area on both sides of the door to prevent unauthorized access while servicing.
2.
Loosen the brake release handle by unscrewing it, then loosen, but don’t remove the the three holding the cover to the brake, this cover can be reused, Figure 34.
3.
Disconnect the two white brake wires from the two blue motor wires.
4.
Using a 9/16” wrench, loosen and remove the two bolts holding the brake to the motor, note orientation before
PROTECDOR® CL Model 8000CL
BRAKE ADJUSTMENT
removing. Pull the brake straight off the motor, use extreme care when pulling the blue motor wires thru the holes in the brake to avoid stripping the insulation.
5.
If the spline hub needs replacing, loosen the set screw.
When installing the new spline, be sure to use a thread locking compound on the set screw and torque to 55 lb/in.
6.
Install the new brake by first inserting wires thru the hole in the brake and carefully pulling them thru as the brake is slid on, use extreme care to avoid pinching the wires between the motor and brake.
7.
Thread the (2) 3/8” bolts thru the brake and into the motor, torque to 22 lb/ft and reconnect the two white brake wires to the two blue motor wires. Polarity is not important.
8.
Replace the brake cover and tighten the three screws.
9.
Screw the brake release handle on the brake and tighten.
10.
Make sure there is play in the handle and it does not catch or drag on the brake cover.
11.
Reconnect power and check for proper operation.
FIGURE 34
Brake
Release
Handle
Remove 3/8” bolts
Brake Spline/Key
Motor/Brake Wires
Brake Wires
Pub. No. 8000CLB FEBRUARY 2004
FIGURE 33
19
PROTECDOR® CL Model 8000CL
TROUBLESHOOTING, REPAIR AND ADJUSTMENTS
DEFINITION
PLC input X0 Open limit switch
FUNCTION
PLC input X0 LED for the open limit switch will illuminate as the limit switch magnet is lined up with the red open limit switch. The LED will then go off as the magnet passes the open limit switch. The limit switch is a normally open switch and will close when the magnet and switch are aligned, thereby illuminating the X0 LED.
MUST HAVE 1/8” gap between the magnet and the switch. Faulty limit switch, replace. Brake did not engage, check wiring and proper 110VAC voltage.
PLC input X1 Closed limit switch PLC input X1 LED for the closed limit switch will illuminate as the limit switch magnet is lined up with the black closed limit switch. The LED will then go off as the magnet passes the closed limit switch. The limit switch is a normally open switch and will close when the magnet and switch are aligned, thereby illuminating the X1 LED. MUST HAVE 1/8” gap between the magnet and the switch. Faulty limit switch, replace. Brake did not engage, check wiring and proper
110VAC voltage.
PLC input X2 Breakaway System PLC input X2 LED for the breakaway system will illuminate if all reversing or breakaway mechanisms are functioning properly. This LED MUST BE ON for the door to run, if it is not illuminated the door will not run. Both trolley magnets, MUST BE hooked to the curtain magnet cups. A continuously monitored wire must be in contact all the time and not shorted to ground for the system to work. The following are reasons for X2 not being on.
a) Sideframe cover gap too wide, must be at 3/4” or trolley may short out to sideframe.
b) Internal Sensing System lacks continuity, must have continuity through wires from terminal 5 and 55, but not to ground.
c) Sensing System cable is to loose or tight. If cable is to tight it may pull apart the magnet from the cup.
d) F5 fuse is not closing after a breakaway-replace fuse.
PLC input X3 Reset button e) Trolley magnets are separated from the magnet cups.
f) Incorrect wiring or plug in connections, refer to electrical drawing for wiring.
PLC input X3 LED for the reset button and will illuminate when the button is pressed. If the input is not illuminated or the door will not open when pressed, check wiring from terminal 14 to input
X3 on the PLC.
PLC input X4 Photoeye limit switch PLC input X4 LED for the reversing photoeye will illuminate as the limit switch magnet is lined up with the white photoeye limit switch. The LED will then go off as the magnet passes the photoeye limit switch. The limit switch is a normally open switch and will close when the magnet
PLC input X5 Toggle activation
PLC input X6 Activation and switch are aligned, thereby illuminating the X4 LED. This switch will deactivate the reversing photoeye’s as the door closes, to prevent the door from reversing as it reaches the photoeye. Follow the reasons below, for why the X4 input light will not come on.
a) MUST HAVE 1/8” gap between the magnet and the switch.
b) Faulty limit switch, replace.
c) Check photoeye wiring, and plug in connections.
d) Raise the closed limit switch to deactivate the photoeye sooner.
e)If the X4 input light does not illuminate and deactivate the reversing photoeye’s, the bottom loop seal of the curtain will break the light beam of the photoeye and reverse the door. The bottom loop seal, may need to be raised on the hook and loop fastener, so the photoeye’s will be deactivated before the curtain reaches the photoeye’s.
PLC input X5 LED for the toggle mode will illuminate when activation devices are wired to terminal 13. The toggle mode allows the user to push or pull an activation device to open the door, and then push or pull a second device to close the door, rather than operating the door in an auto-reclose mode.
PLC input X6 LED for the activation and will illuminate when activation devices wired to terminals 63, 64, or 65 are triggered. The auto-reclose mode allows the user to push or pull an activation device to open the door, and walk away allowing the door to close after a preset time.
The X6 input MUST BE OFF for the door to close, if door is stuck open, remove all activation device wires until the faulty device is found.
PLC input X7 Photoeye PLC input X7 LED for the photoeye will be off when either of the reversing photoeyes are blocked or misaligned. Both reversing photoeyes MUST BE ALIGNED with all 3 lights on or door will stay open. X7 input MUST BE illuminated for the door to close.
PLC input X10 P.R.O. system fault PLC input X10 LED is illuminated when the door is faulted.
PLC input X11 I-Zone enable
PLC input X12 I-Zone sensor 1
PLC input X11 LED must be illuminated to enable the I-Zone.
PLC input X12 LED will be off when reversing and during holding open.
PLC input X13 I-Zone sensor 2 PLC input X13 LED will be off when reversing and during holding open.
PLC output Y0 User Out (interlock) PLC output Y0 LED is User defined for interlocking.
PLC output Y1 Reserved
PLC output Y2 Run Open
PLC output Y3 Run Close
PLC output Y4 User Out
PLC output Y5 Fault
PLC output Y6 I-Zone Alarm
PLC output Y1 LED is Reserved for future use. On when closed.
PLC output Y2 LED for the run open will illuminate when the door is running open.
PLC output Y3 LED for the run close will illuminate when the door is running close.
PLC output Y4 is User defined for pre-announce.
PLC output Y5 LED for the Fault will illuminate when the door is not in fault.
This LED MUST BE ON for door to run.
PLC output Y6 LED for the I-Zone will illuminate when the I-Zone alarm is on.
20 Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
TROUBLESHOOTING
DEFINITION FUNCTION
PLC output Y7 Brake (P.R.O. only) PLC output Y7 LED for the Brake will illuminate when the door is running.
PLC “Run Mode” light PLC run light must be on for the door to operate. Make sure the PLC is in the “Run Mode”, by opening the PLC cover door and switch to “Run”. If the PLC is in the “Stop Mode”, the PLC will have no output LED’s and will not run. If the switch is set to the run mode and the door still will not run, or if the “Run” light is off with an Allen Bradley PLC, call your local RITE- HITE DOORS,
PLC Re-Close Timer
Activation
Alternate Open
Brake
INC. representative for a handheld to re-program the door.
The door can be set to close from 2 to 28 seconds by turning the pot switch under the cover.
Clockwise for longer open times and counter-clockwise for shorter open times.
For activation questions, refer to the Activation Manual and inputs X5 & X6.
The option for an Alternate open requires the addition of an extra limit switch and PLC board.
If the brake is not functioning properly, check the following: a) Output Y7 MUST GO OFF when the door is fully open or closed.
b) Contactor MUST BE PULLED IN when the door is running or the open button is pressed.
Contactor K1M Open
Contactor K2M Closed
Disconnect Switch
D.Op.H./D.Op.W.
D.Or.H./D.Or.W.
Drive Belt
F1 Fuse
F2 Fuse
F3 and F4 Fuses
F5 Fuse
Interlock
Internal Sensing System
K0 Overload Relay
K3 Relay c) Faulty contactor or F1 fuse-replace.
d) Brake wiring at terminals B1 & B2 and plug in connections.
e) Air gap, see Page 19 for brake air gap adjustment procedures.
f) The brake rectifier should put out 90-110VDC.
g) Brake will have 350 ohms on normal readings. (must be checked after the rectifier).
K1M 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.
K2M contactor is the closed 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.
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.
Door Opening Height/Width
Door Ordered Height/Width
The drive belt tension is pre-determined by the spring. Check the following: a) If the drive belt is walking off the pulleys, move the drive pulley on the motor to align properly.
b) If the belt squeaks, remove belt dust from the idler pulley or properly align.
F1 Fuse is for 120VAC devices and receives power from the X1& X3 transformer taps.
The F1 fuse protects the PLC, the brake and 120VAC pre-announce devices at terminals
B1, S2, and S4. The fuse is a 1amp KLDR 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, PLC outputs and all 24VAC activation devices. The fuse is a 2amp KLDR 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 F5 fuse, is a resettable fuse that is for the breakaway mechanism. It is normally closed and opens up when the trolleys are contacting the sideframes. If the trolleys are ran up and down on the sideframes for a period of time, the F5 fuse may heat up need to be replaced.
The mechanical interlock prevents both the K1M & K2M contactor from being pulled in and voltage applied to both at the same time, shorting out the coil to contactors and the motor.
The door breakaway mechanism is continuously monitored with a thru-wire system. Low voltage is run through the wires coming from terminals 5 and 55. Each wire then runs down the sideframe and plugs into another wire that is run through a chain system that runs up and down with the trolleys. The trolleys then make contact with each other, through the sensing cable that runs through the bottom of the curtain. Check the following if door will not reset.
a) Trolley magnets hooked to breakaway cups.
b) Make sure magnet plates are not rusted, if so, apply electrical grease to the plate.
c) All plug in connections are tight.
d) Internal sensing system chain and cable are in tact and functioning properly.
e)Check troubleshooting section for PLC input X2 Breakaway System f) Press the open reset button to clear the fault and Illuminate PLC input X2.
The K0 overload relay is supply's 24VAC to the K4 relay and the open/reset button. If the overload trips, 24VAC to the K4 and 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 K0 overload relay before it reaches the K1M, K2M contactor's, if the contactor's are not receiving the correct voltage, check the K0 overload for proper voltage. The overload should be set to the following settings: a) 208V-240V-4 Amps b) 380V-415V-1.8 Amps c) 460V-480V-2.5 Amps d) 575V-1.6 Amps
K3-24VAC single pole relay is for the P.RO. system to energize the brake.
Pub. No. 8000CLB FEBRUARY 2004 21
PROTECDOR® CL Model 8000CL
TROUBLESHOOTING
K4 Relay
DEFINITION
K6 Relay
Limit Switches
Motor phasing
Motor will not run
Motor 208V-240V
Motor 460V-480V
Motor 400V
Motor 575V
Open/Reset Push Button
Reversing Photoeye’s
Terminals
Transformer
Turn-Tite Seal
Voltage Change
Wind Pressure
FUNCTION
K4-24VAC double pole relay is the Fault relay and one set of contacts is open when the door is in a fault mode and both sets of contacts are energized when the door is operating properly.
K6-24VAC single pole relay is an optional relay, that is required when the pre-announce to close option is chosen.
The Open, Closed, Photoeye, and Alternate open limit switches are a normally open device and should only be closed when the switch is in-line with the magnet. If the switch is closed when it is not in-line with the magnet, replace the switch.
a) To adjust open limit switch, run door in the open position, and align 120 groove pulley magnet with the (red) open limit switch, by loosening the bolts and belt.
b) To adjust the closed limit switch, pull the brake release lever and lower door so the curtain bottom loop is sealing on the floor. Loosen thumb screw and align (black) closed limit switch with the 120 groove pulley magnet. Tighten thumb screw.
c) Run door and test operation.
If open button is pressed and the door closes, the following needs to be checked: a) Check overload and contactors for proper voltage.
b) Phasing is reversed, reverse wires in terminals, V and W.
If door will run will given an activation, check the following: a) Faulty or tripped K0 overload relay.
b) Faulty K1M or K2M contactors.
c) Check voltage and for loose wires at terminals, U, V, and W and wires on the contactors and overload relay.
208V-240V motor will have 5-7 ohms on normal readings.
460V-480V motor will have 20-23 ohms on normal readings.
400V motor will have 23 ohms on normal readings.
575V motor will have 34 ohms on normal readings.
The open/reset push button has 2 functions. The first function is when the button is (not used with LCD display) pressed, an command to open the door is given. The second function is to reset the door when it has been broken away. When the door is broken away the light will flash and the door will not operate from an activation command. At this point the button can be used as a “Jog Button” to refeed the curtain back into the sideframes and to get the door at a workable height to hook the trolley magnets back up to the magnet cups. The light will continue to flash until the door breakaway mechanism is hooked up and the open/reset button is pushed.
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 3 lights on the photoeyes. Yellow is for power, red and green are for proper alignment, if the eyes are not aligned properly, turn the adjustment screws or loosen the mounting brackets. The photoeye’s are set to the “Light Operate” mode. The photoeye’s will reverse or hold the door open when the photoeye beam is blocked. When the beam is not broken, the door will auto-reclose.
The following are commonly used terminals: a) Terminals 63, 64, 65 are Auto-Reclose.
b) Terminals 1, 2, 3, 4, 57, 58, 59, 61 are common.
c) Terminals 53, 54 are 24VAC.
d) Terminal 13 is Toggle Mode.
e) Terminals L1, L2, L3 are the incoming power terminals. All 3 legs of the incoming power
MUST BE the same between each other for the door to operate.
The standard transformer is a tri-volt transformer that takes an incoming voltage of 208V, 230V, and 460V and converts it to 110VAC and 24VAC. An optional transformer is available for 380V,
415V and 575V doors.
a) 208V(Taps H1-H2) 6.8 Ohms c) 380V(Taps H1-H2) 18.4 Ohms e) 415V(Taps H1-H3) 20.5 Ohms g) 120V(Taps X1-X3) 4.4-4.8 Ohms b) 230V(Taps H1-H3) 7.5 Ohms d) 460V(Taps H1-H4) 27 Ohms f) 575V(Taps H1-H4) 29 Ohms h) 24V(Taps X1-X2) .4 to .6 Ohms
The Turn-Tite seal is used to seal the top of the door. It is adjusted by removing the seal from the hook and loop fastener on the curtain and positioning it so it makes solid contact with the wall seal.
To change the voltage, see step below: a) Change transformer taps, fuses, and overload settings per electrical diagram or see individual troubleshooting section.
b) Change motor wiring per junction box diagram.
c) P.R.O. system doors require a new inverter.
If the door is blowing out because of high wind or negative pressures, check the flowing: a)The sideframe cover to sideframe gap MUST BE at 3/4”, if it is larger than that, the wind clips will slip through the sideframes.
b) Check to make sure the curtain has all the wind clips in place.
c) The sideframes are mounted at the proper width distance.
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PROTECDOR® CL Model 8000CL
FIELD WIRING DIAGRAM
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PROTECDOR® CL Model 8000CL
STANDARD WIRING DIAGRAM
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PROTECDOR® CL Model 8000CL
INVERTER ELECTRICAL WIRING DIAGRAM
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PROTECDOR® CL Model 8000CL
OPTIONAL COUNTERBALANCE SYSTEM
The counterbalance system is an option for opening the door in the case of a power outage.
6.
Adjust limit switches as required and cycle door 10 times to verify operation.
1.
Operate door to the full open position and turn off power.
Make sure the power source has been locked and tagged out according to OSHA regulations and approved local codes. Barricade door to prevent vehicle traffic entry.
2.
Mount the counterbalance channel at 2 3/4” from the nondrive sideframe, Figure 37.
The centerline of the channel should be in line with the centerline of the pulley on the end of the roller tube shaft.
3.
Check that the number of pre-wraps of the counter weight belt is 1 1/2 turns. The belt should be routed off the front of the counterbalance pulley. Route the belt behind the idle pulley and drop to the floor.
4.
Position the counterweight on a block in front of the counterbalance channel and remove the clevis pin from the top of the counterweight. Route the belt through the buckle as shown to create a loop and locate as close to the weight as possible. Connect the strap to the counterweight using the clevis pin and clip.
7.
With door in closed position and power off, slide the pvc pipe over the counterweight and push it back into the channel. Cable tie pipe into position through the rings in the channel.
8.
Install the guard onto the channel using the 5/16”x3/4” fasteners provided. DO NOT install top bolt at this time.
9.
Install the non-drive shroud.
10.
Pull brake release handle to check for proper operation, it may be necessary to assist curtain.
5.
Reconnect the power to the door and run to the closed position. Watch so the counterweight buckle does not contact the idle pulley, if it appears that it will, stop the door immediately and adjust the buckle downward. With the door in the full closed position, mark the idle pulley position on the belt and adjust the buckle to rest as close as possible to the idle pulley, weight may hit floor before fully opening on certain size doors.
RH DRIVE SHOWN, LH OPPOSITE
2 3/4”
Wall
!
CAUTION !!!
Be careful when running the door prior to counterweight installation as the belting may
1 1/2 Turns of the
Counterweight Belt
become entangled.
Be prepared to stop the door before counterweight contacts the idle pulley or floor.
Counterbalance
Pulley
Counterbalance
Channel
Non-Drive Sideframe
FIGURE 37
Idle Pulley
Channel
Clevis
Pin
Buckle
Counterweight
Channel
Counterweight
26
Clip
FIGURE 38
Cable Ties
PVC Pipe
Pub. No. 8000CLB FEBRUARY 2004
PROTECDOR® CL Model 8000CL
OPTIONAL INVERTER & THRU-WALL BRAKE RELEASE
Counterweight Channel
Counterweight Guard
Non-Drive Shroud
5/16” x 3/4” Bolt
FIGURE 39
Motor Phase Rotation Verification
1.
Press the OPEN/RESET button to reset the door. The door should fully open and then automatically close after the reclose timer has expired, unless the door is setup with the full toggle mode option. The open/reset button will then need to be pressed again to close the door.
2.
If the door starts closing, turn the disconnect switch off and lock and tag out the power supply. Have a qualified electrician reverse any two of the three motor leads, terminals U, V or W in the control box, Figure 41.
Reconnect the electrical power and retest the door.
3.
The Inverter parameters are set to open the door at 50 inches/second and close at 20 inches/second.
4.
Adjustments should only be made by a RITE-HITE
DOORS, INC. training service technician. If the parameters are altered without consent, RITE-HITE DOORS, INC. will not be liable for problems or damage that may occur.
NOTE: Reversing the incoming power phases will have no effect on direction of travel.
Inverter
!
Center Shroud Bracket
CAUTION !!!
The first time that the door system is operated, it may move in the wrong direction if the motor power phase rotation is incorrect. Be prepared to turn the Disconnect
Switch if the door begins closing instead of opening.
THRU-WALL BRAKE RELEASE INSTALL
1.
Remove the lower bolt from the drive side shroud and reinstall it with the conduit clamp.
2.
Insert the two rope guide plugs into the shorter end of the two ‘L’ shaped conduit pieces.
3.
Using the conduit as a guide, mark the location on the wall. Check the other side of the wall for clearance, if clear, drill a 1” Ø hole through the wall, if not move the conduit left or right.
4.
Install one piece of conduit onto the clamp using the provided hardware, and attach the splice connector to the longer end of it.
5.
Insert the other piece of conduit through the wall into the other end of the splice connector. Cut conduit to desired length.
6.
Thread the rope through the conduit and tie it into the existing rope.
FIGURE 41
Motor Terminals U,V,W
Pub. No. 8000CLB FEBRUARY 2004
FIGURE 40
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PROTECDOR® CL Model 8000CL
ARCHITECTURAL DRAWING
28 Pub. No. 8000CLB FEBRUARY 2004

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