Service Door Industries HS-200 High Speed Fabric Door Installation Instructions & Service Manual

HS-200 High Speed Fabric Door

(Direct Drive Operator & Full Vision Panel)

INSTALLATION INSTRUCTIONS

&

SERVICE MANUAL

Serial No.: .

Customer: .

Opening Size: .

Overall Height of Guide: Inches

Guide Opening Width (tip to tip): Inches

Contents

¾ Preface

¾ Introduction

¾ Installation Instructions

¾ Maintenance and Repairs

¾ Parts List

¾ Warranty

Manufactured by

F-4000.doc

July 04, 2007

SERVICE INDUSTRIES

Mississauga, Ontario

L5T 2G8

Web site: www.servicedoor.com

PREFACE

The main purpose of this manual is to assist with the installation and maintenance of your new HS-200 High

Speed Fabric Door system with the emphasis on proper installation procedures, safety of operation, and replacement parts list. While various construction and electrical procedures are outlined, please refer to particular codes for you area.

INTRODUCTION

DOOR PARTS

The Shop Drawing on the following page shows the major components of the HS-200 High Speed Fabric

Door. (For more detail, please refer to the parts list near the end of this manual.)

Please define all parts by the names shown on this drawing and throughout this manual. When technical information and or replacement parts are required, please provide the following data to ensure prompt and efficient service.

1) The SERIAL NUMBER of your door system

2) The OPENING SIZE (width x height)

3) The TYPE & HANDING OF OPERATOR (left or right)

4) The operator motor voltage

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INSTALLATION INSTRUCTIONS

STEP “A” – PREPARATION OF THE DOOR OPENING

Although the actual mounting procedures are different between steel and masonry walls common prerequisites are required for all door systems.

All door systems will require a certain amount of headroom and sideroom clearances. See Shop Drawing supplied with each door for specific details

All door systems must be mounted level. Draw a reference line at a distance equal to the overall height of the guide (this measurement can be found on the front cover page), above the floor extending to the extremities of the sideroom clearances. Take extreme care to ensure that this line is straight and level because the entire door is positioned according to this reference line. A transit or water hose level is recommended.

All mounting surfaces must be flat and flush to each other.

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STEP “B” – INSTALLAING THE DOOR GUIDES

Regardless of which way YOU decide to attach the Guides to the existing wall (typical cross sections of Guide mounting suggestions are shown above), the Guides must be:

PERPENDICULAR (90°) to the reference line within 1/4” along the complete height of the Guide.

PARALLEL to each other within 1/4” along the complete height of the Guide.

LEVEL at the top of the Guide within 1/4” over the entire width of the door.

The top of the guides must be at the reference line height (see illustration above). The Guide Opening Width

(tip to tip) measurement can be found on the front cover page. (see illustration below for tip to tip location)

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STEP “C” – INSTALLING THE HEADER ASSEMBLY

The Header Assembly should be hoisted into position with two (2) slings around the Curtain and Drive Barrel

ONLY. Extreme care must be taken to avoid damage to the Curtain and the Reversing Edge. Once the door has been hoisted up into position, loosely bolt the Head Plates to the Guides using the four (4) bolts with flat washers, lock washers, and hex nuts which were supplied with door. The Header Assembly should be leveled (for guidance use the top of the Head Plates and the reference line). Tighten all four (4) mounting bolts.

This may require final adjustment after the Curtain is hanging in the opening.

CAUTION!! DO NOT UNTIE THE ROPES FOR THE CURTAIN AT THIS TIME.

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STEP “D” –INSTALLING THE DOOR OPERATOR

Carefully, tap the supplied Key into the keyway on the Drive Shaft. Slide the Operator onto the shaft. Loosely install the Operator Mounting Bolts. There is enough adjustment on the Torque Bracket to square the Operator to the wall. Tighten all bolts once the operator is hanging straight.

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STEP “E” – ADJUSTING THE CURTAIN

The ropes keeping the Curtain wrapped on the Drive Barrel can now be removed only if Step “D” has been completed. After the ropes have been removed manually feed the Bottom Bar and Curtain into the top of the

Guides and lower the door to the almost closed position.

The Drive Barrel must be centered at this time. To accomplish this, loosen the set screws in both of the Flanged

Bearings on the Head Plates and shift the Drive Barrel into position. Check to ensure the Drive Barrel is centered by measuring the space between the inside of the Head Plate and the edge of the Drive Barrel. This distance should be equal at both ends of the Drive Barrel. Re-tighten all set screws so that the Drive Barrel can not shift at a later date.

The Arms on the Bottom Bar should be centered within the Guide’s from side to side. If they aren’t raise and or lower the Head Plates as necessary. Once the Bottom Bar is centered and the Curtain is hanging straight in the guides, tighten the Head Plate bolts. Return the door to the midway point.

STEP “F” – CONNECTION OF THE REVERSING EDGE

Attach the preassembled Reversing Switch

Box to the Bottom Bar using the two (2) screws found inside the Switch Box.

Attach the Coil Cord to the Bottom Bar using the Coil Cord Clip found inside th

Switch Box. C e onnect the Coil Cord to the term inal strip located in the Control Panel.

Attach the coil cord strain relief to the co il cord strain relief bracket. The coi l cord strain relief bracket is mounted at approximately half opening height. Use the existing guide bolts. Once the coil cord strain relief bracket is attached to the door feed the coil cord through the str ain relief until there is enough coil cord for the bottom bar to travel the full opening heigh t without restriction. See diagram s below.

Caution!!

Too much slack in the coil cord may cause it to get caught or break the photocell beam and reverse the door.

Too little s lack in the coil cord may cause damage.

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S TEP “G” MOUNTING THE PHOTOCELL

The mounting procedures for both a thru beam photocell and reflective photocell are the same. For a thru beam photocell there will be a light source and a receiver. For a reflective photocell there will be a light source and a reflector. Preassemble the photocell and reflector to the brackets as illustrated below. The photocell mount attaches to the photocell bracket using the 1/4” bolts, flat washers, lock washers, and hex nuts supplied. The reflector mounts directly to the reflector bracket using the #10 screw and flanged lock nut supplied. All of the brackets mount to the guide the same way, using the existing guide bolts that are 25” up from the bottom of the guides. Remove the existing Guide Bolts and lock washers and place the bracket on the guide bolts and reinstall the Guide Bolts and lock washers that you just removed. Be sure to run the cord from the photocell through the supplied cord clip and attach the cord clip to the lower guide bolt as illustrated to keep the phot ocell c ord secure. Adjust the alignment of the photocell as necessary and tighten all of the mounting hardware.

STEP “H” – WIRING TO THE CONTROL PANEL

c

Exerc ause injury.

Consult local electrical codes before proceeding with permanent installation.

WARNING!

ise caution when engaging the electric operator. The drive and limit chains are exposed and if turning could

Wiring instructions can be found inside the Co ntrol Panel. Mount the Control Panel as required and connect the

C ontrol Panel to a properly grounded supply.

There are two cables connected to the operator. One is for the supply power and the other is for the control wiring. NOTE: DO NOT PUT THESE TWO CABLES

IN THE SAME CONDUIT AS IT WILL CAUSE INTERFERENCE,

A ND THE DOOR WILL NOT OPERATE PROPERLY.

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Make the motor connections as follow s:

#1 wire OR U connects to terminal 1

#2 wire OR V connects to terminal 2

#3 wire OR W connects to terminal 3

To reverse motor rotation reverse any two lea ds going f rom the control panel to the operator.

Make the brake connections as fo llows:

#7 wire connects to terminal 51

#8 wire connects to terminal “N”

*NOTE THE JUM

PER FROM TERMINAL 53 TO

TERMINAL “L”

See Dia gram #1

Diagram #1

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Make the photocell connections as shown in diagram #2.

Diagram

If you are using a remote push button station or an auxiliary open device, make all of the connections for al l of the open commands in parallel before connecting to the control panel if you are using more than one open device. Make all of the connections for all close commands in parallel before connecting to the control panel i f you are using more than one close device. Make all connections for stop commands in series if you are using more than one stop device before c onnecting to the control panel. Make the final connections to the control panel as illustrated in diagram #3.

Connect the reversing edge to terminals S1 and S2. If you remove the resistor co nnected to these terminals, be su re to reinsert it. Failure to do so will cause the door to not function properly.

If installing a ground loop make the contact connections to terminals S1a and S1b. If installing a second ground loop make the contact connections to terminals S2a and S2b. If you are not going to be using a ground loop, do n ot remove the jumper between terminals S1a and S1b, as well as the jumper between terminals S2a and S2b.

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Make the encoder connections as follows:

#6 wire connects to terminal 27

#3 wire connects to terminal 28

#2 wire connects to terminal 29

#4 wire connects to terminal 31

S

B elow is an overview of all inputs.

Make the chain hoist connection s as follows:

#5 wire connects to terminal 3

#1 wire connects to terminal 4

#7 wire not used

#8 wire not used

Diagram #4

N OTE:

THIS UNIT MUST BE PROPERLY GROUNDED

S TEP “I” – LIMIT SWITCH ADJUSTMENT

Once the door has been powered up and all of th e connections have been checked, the limits can be set. To set th e initial limits follow the instructions below.

1) Open th e control panel door and set the DIP switch, located in the upper right corner of the circuit board, to o n (UP).

2) Close the control panel door, turn the power on, and press the large emergency stop button on the control p anel door.

3) Using ▲ a nd ▼ buttons on the keypad on the control panel door, go to P.210 and press the stop button on th e keypad.

4) Go to 5 using the ▲ an d ▼ buttons on the keypad and press and hold the stop button until the question mark tu rns into a check mark.

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5 ) Pull out the emergency stop button on the control panel door.

6) Using the ▼ button b utton on the keypad. on the keypad, lower the door until it is at the desired closed position and press the stop

7) Using b utton.

the ▲ button on the keypad, raise the door until it is at the desired open position and press the stop

8 ) Return the DIP switch in the upper right corner of the circuit board to off (DOWN).

To fine adjust the limits once they have been set follow the instructions bellow. Before beginning, position the bottom bar at the limit you intend to adjust.

N OTE:

This adjustment is only meant to make minor corrections to the final positions.

1) Open th e control panel door and set the DIP switch, located in the upper right corner of the circuit board, to o n (UP).

2) Close the control panel door, turn the power on, and press the large emergency stop button on the control p anel door.

3) Using ▲ and ▼ buttons on the keypad on the control pan el door, go to P.221 for the upper limit and P.231 fo r the lower limit and press the stop button on the keypad.

4) Using the ▲ and ▼ buttons on the keypad, adjust the stopping position of the door. Each increm ent is a pproximately ½”. Press and hold the stop button until the question mark turns into a check mark.

5 ) Return the DIP switch in the upper right corner of the circuit board to off (DOWN).

T his process may need to be repeated until you are satisfied with the final position.

S TEP “J” – ADJUSTING THE TIMER TO CLOSE

1) Open th e control panel door and set the DIP switch, located in the upper right corner of the circuit board, to o n (UP).

2) Close the p anel door.

control panel door, turn the power on, and press the large emergency stop button on the control

3) Using ▲ a th e keypad. nd ▼ buttons on the keypad on the control panel door, go to P.010 and press the stop button on

4) ▲ and ▼ buttons on the keypad on the control panel door, set the h old the stop button until the question mark turns into a check mark. value for the timer to close. Press and

5 ) Return the DIP switch in the upper right corner of the circuit board to off (DOWN).

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Trouble Shooting

Although every situation that may occur can not be anticipated the following trouble shooting guide covers some of the more common circumstances.

Possible Cause Solution Problem

Curtain Hangs up

Door reverses when closing

Reversing edge does not reverse door

Photocell does not reverse door

Open button closes door/Close button opens door

Motor starts up but door does not move/trips overload

-Guide gap is too narrow

-Bottom Bar not centered between

guides

-Drive Barrel Shifted to one side

-Guides installed incorrectly

-Tripped breaker

-Tripped motor overload

-Door disconnect turned off

-Manual chain hoist not returning

properly

-Sensitivity on floor loop too high

-Sensitivity on reversing edge too

high

-Coil cord tripping photocell

-Photocells misaligned

-Sensing tube is kinked

-Sensitivity set too low

-Hole in reversing edge

-Wired incorrectly

-Faulty switch

-Faulty relay

-Sensitivity set too low

-Wired incorrectly

-Phasing from incoming power is

incorrect

-Brake is not releasing

Door slips when it stops -Brakes worn

For further assistance call (905) 670 1200 ext. 220

-Check and adjust guide gap if

necessary

-Raise or lower one side of the

header

-Center drive barrel between head

plates

-Reinstall guides

-Check fuses and replace if necessary

-Check circuit breaker in building

-Reset overload

-Turn on door disconnect

-Reset Chain Hoist

-Adjust loop sensitivity

-Adjust reversing edge sensitivity

-Ensure coil cord can travel

through full range of motion freely

and adjust/trim if necessary

-Realign photocells

-Check sensing tube for kinks in

box and from box to reversing

edge and replace if necessary

-Increase sensitivity

-Replace reversing edge

-Trace wiring

-Replace switch

-Replace relay

-Raise sensitivity

-Trace wiring

-Reverse any two Motor Leads at the Motor (L1, L2, L3)

-Check brake connections for loose wires and for correct wiring to terminals

-Adjust and/or replace brake

If the control panel gives you a fault code, refer to the charts on the following pages for assistance.

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Fault Codes

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MAINTENANCE & REPAIR

Due to the unique design features of your new HS-200 High Speed Fabric Door, the need for continual maintenance normally associated with conventional door systems (i.e.: guide rollers, hinges, door tracks, etc.) is virtually eliminated. The limited maintenance procedures listed below, when completed as indicated, will assure many years of trouble free operation.

MAINTENANCE

PROCEDURE

LUBRICATION

Flange Bearing (2)

Gear Reducer

ADJUSTMENTS

(Check and adjust if necessary)

Guide Opening – 7/8”

+/- 1/16"

All Fasteners – Tighten if necessary

AFTER INITIAL 1 500

CYCLES

EVERY 25 000

CYCLES OR 3

MONTHS

DO NOT GREASE CURTAINS OR GUIDES

No

No

No

Check Level

EVERY 100 000

CYCLES OR 12

MONTHS

Grease, one (1) shot

Check Level

(Change oil every 200 000 cycles)

No Yes Yes

Yes Yes Yes

Brake Pad Wear

Reversing Edge

Coil Cord (see below)

(Check for proper operation & signs of damage)

No

Yes

Yes

No

Every Month

Yes

Yes

Yes

Yes

Be sure to check the Coil Cord has not been stretched. If it has stretched trim the excess off of the Coil Cord to prevent it from becoming caught during normal operation ensuring that there is still enough cord for the bottom bar to travel the full opening height without restriction. Failure to do so could result in damage to the door.

IN CASE OF DOOR IMPACT

Prior to performing any repair to the door, DISCONNECT ELECTRICAL POWER to the door system. A close inspection of the Vision Panel Hinges, Bottom Bar and the Reversing Edge is necessary for any signs of damage. In addition to the procedures listed below, always check limit settings, adjust if necessary.

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IF CURTAIN IS PULLED OUT OF GUIDES

TURN THE ELECTRICAL POWER SUPPLY TO THE DOOR OFF.

Using the manual chain hoist, raise the door until the Bottom Bar is above the Front Guide Plate and just below the Drive Barrel. Lower the door ensuring that the Bottom Bar Arms and Curtain go into the Guides. Lower the door to the floor using the manual chain hoist. Cycle the door using the Operator being prepared to stop the door if it is not operating properly. Adjust the Limits if required.

DAMAGE TO THE BOTTOM BAR

TURN THE ELECTRICAL POWER SUPPLY TO THE DOOR OFF.

If the Bottom Bar is bent, remove and straighten it before commissioning the door for normal operation. If the

Bottom Bar is bent beyond repair, a new Bottom Bar must be ordered and installed before the door can be recommissioned for normal operation.

DAMAGE TO THE GUIDE

The Guide must be straightened or replaced. The Guide Opening (the gap between the Back and Front Plates) must be 7/8” from top to bottom within 1/16” either way. If this cannot be achieved, new Guide parts must be ordered and installed before the door can be re-commissioned for normal operation.

SET REVERSING EDGE SWITCH SENSITIVITY

1. Connect an OHM meter to the two (2) silver

terminals.

2. Turn the white nylon screw counter clockwise

until the meter shows the resistance to be

indefinite.

Do another half turn counter clockwise.

3. Slowly turn the white screw clockwise until the

meter shows resistance. This is a reference point.

4. Turn the white screw counter clockwise by 3 or 4

marks on the switch housing. This will register

indefinite resistance on the OHM meter and set

the contact gap.

5. Replace the Switch Box Cover and test the door

for proper operation.

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PARTS LIST

(See next page for descriptions)

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PARTS LIST (See previous page for diagram)

ITEM UNITS

1

2

3

4

5

Left Guide Assembly – Complete

(replacement Left Front Plate)

Right Guide Assembly – Complete

(replacement Right Front Plate)

Curtain – Complete

Complete Bottom Bar Assembly – (specify handing)

(replacement Bottom Bar only – non-handed)

(replacement Reversing Edge – non-handed)

(replacement Bottom Bar Arm – includes 2 pcs/side)

(replacement Coil Cord c/w Clip)

(replacement Reversing Edge Switch Assembly)

Free End Head Plate Assembly – (specify handing)

(replacement Free End Head Bracket only)

(replacement Drive Barrel Flanged Bearing)

1

1

1

1

1

2

1

1

1

1 each each each each each each each each each each

6

7

8

9

10

11

Drive End Head Plate Assembly – (specify handing)

(replacement Drive End Head Bracket only)

(replacement Drive Barrel Flanged Bearing)

Drive Barrel Assembly – Complete

(replacement Drive End Plug)

(replacement Free End Plug)

Operator – Model GFA Direct Drive – Complete

(see separate Operator Manual for replacement parts)

Control Panel – Complete

(replacement parts see separate Schematic Drawing)

Brush Lintel Weather Seal

Reflective Photocell c/w Bracket & reflector

1

1

1

1

1

1 each each each each each each

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LIMITED WARRANTY

All HS-200 door systems manufactured by Service Door Industries are warranted from the date of purchase against defects in material and workmanship as follows: door system in general…One (1) year; and curtain

(where applicable)…Two (2) year warranty against manufacturing defects.

If within this period of time any parts are found to be defective, new or re-manufactured parts will be furbished free of charge, F.O.B. our plant in Mississauga, Ontario, Canada, provided that the recommended installation and maintenance procedures (as outlined in this Installation Instructions and Service Manual booklet) have been followed.

This Limited Warranty does not include replacement parts due to normal wear and tear, damage beyond the control of Service Door Industries (i.e.: damage in transit, impacts etc.).

To validate your warranty the preventative maintenance schedule within this manual must be recorded and up to date.

Components such as counterbalance springs will have a specific warranty as per the specified cycles and be verified by a cycle counter.

This Warranty is limited, and in lieu of other warranties expressed or implied. There is no expressed liability due on the part of the seller.

An authorized Service Door Industries distributor from whom the purchase was made must make warranty claims, and the defective parts returned for verification within 15 days prepaid to:

Service Door Industries

1340 Midway Blvd

Mississauga, Ontario, Canada

L5T 2G8

Phone: (905) 670-1200

Fax: (905) 670-8830

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