Icontrols PULSE Manuale utente

PB 1

18 - 50 West Wilmot Street, Richmond Hill, Ontario Canada L4B 1M5

905-597-8989 •www.icontrols.ca •[email protected]

PULSE TECHNICAL SUPPORT LINE: 1-833-PULSEDC (1-833-785-7332)

PULSE

Commercial Direct Drive Door

Operator for Balanced Sectional

and Rolling Steel Doors.

Installation Manual and

Setup/User Instructions

U.S. Patent No. 11105138

TABLE OF CONTENTS

General Overview................................................................................................................... Page 3

Meeting UL 325 Requirements...............................................................................................Page 3

Box Inventory...........................................................................................................................Page 3

Operator Technical Overview ...............................................................................................Pages 3-4

Pre-Installation Assembly Requirements ..............................................................................Pages 5-7

Mounting Installation Instruction ..........................................................................................Pages 8-10

Wiring Instructions...................................................................................................................Pages 11-12

Wiring Diagrams .....................................................................................................................Pages 13-17

Startup Procedure...................................................................................................................Page 18-20

Testing for Spring Balance............................................................................................ Page 18

Accessing STARTUP MENU .............................................................................................Page 18

Set Closing Timer ...........................................................................................................Page 18

Set Voltage......................................................................................................................Page 19

Set Motor Position ..........................................................................................................Page 19

Set Door Limits................................................................................................................Page 19

Set Door Speed..............................................................................................................Page 19-20

Jog Mode.......................................................................................................................Page 20

Exiting STARTUP MENU & Testing....................................................................................Page 20

ADVANCED MENU Programming ..........................................................................................Page 21

Set Reversing Timer........................................................................................................Page 21

Set PWM Frequency ......................................................................................................Page 21

Set Dynamic Brake........................................................................................................Page 21

Set Opening Force ........................................................................................................Page 21

Set Closing Force...........................................................................................................Page 22

Set Open Slow Speed ................................................................................................... Page 22

Set Close Slow Speed....................................................................................................Page 22

Set Open Rampdown Distance...................................................................................Page 22

Set Close Rampdown Distance................................................................................... Page 22

Set Open Limit Options (Push Button & Remote).......................................................Page 22

Set Output Relay............................................................................................................Page 23

Set Calibration ...............................................................................................................Page 23

Set Maintenance Schedule .........................................................................................Page 23

Set Red Flashing ............................................................................................................ Page 23

Set Advanced Red ........................................................................................................ Page 23

Set Open Limit Switch....................................................................................................Page 24

Set Factory Reset ...........................................................................................................Page 24

Exiting ADVANCED Menu ..............................................................................................Page 24

Power Outage Operation ...................................................................................................... Page 25

Battery Information.................................................................................................................Page 25

Car Wash/Water Resistant Applications............................................................................... Page 25

Components............................................................................................................................Page 26

Troubleshooting Guide ..........................................................................................................Page 27-29

Warranty................................................................................................................................... Page 30

GENERAL OVERVIEW

Thank you for purchasing this Pulse Direct Drive Door operator. This dependable operator is

designed for continuous-cycle duty for your Commercial Door and can extend the life of your

counter-balanced sectional door with its integrated so-start/so-stop capability.

It also features adjustable opening speeds of up to approximately 24” per second, battery

backup that can operate the door in case of power failure, over-current protection, and

adjustable auto-reversing force monitoring, along with many other programmable functions.

MEETING UL 325:2017 REQUIREMENTS

The Pulse Operator is provided with a Polarized Reﬂective Photo-Eye or Thru-Beam Photo-Eye (1

& 2HP model only), which is connected into Terminal 1 of the ‘Reversing Devices’ input on the

Control Panel. Once the Close button is activated, the operator veriﬁes that the Photo-Eye is

connected and functional, and it continues to monitor the sensor as the door closes.

A dedicated terminal (Terminal 2 Reversing Devices) is provided to operate with Monitored

Reversing Devices.

Input (Terminal 3 Reversing Devices) for non-monitored reversing devices (i.e. standard

pneumatic edge).

The Pulse Operator will initiate Push/Hold to CLOSE protocols should devices in Terminal 1 and

2 be found non-functional, misaligned or unconnected (at least one functional device must be

connected and veriﬁed in either Terminal 1 or Terminal 2). Note that during Push/Hold to Close

protocols, the door will reverse should it not fully reach the closed limit per UL 325.

BOX INVENTORY

Before beginning installation, please verify that all components are accounted for:

1. Motor, Gearbox, Encoder, Junction Box Assembly

2. Control Panel

3. Limit Brackets and Hardware (Angle Brackets for Stop Limit to mount on door tracks)

4. Torque Arm, Mounting Bolts, Mounting Bracket

5. Sha Collar and Sha Key

6. Reversing Device – Reﬂective Photo-eye (Thru-Beam Photo-Eye included on Pulse 1000/2000)

7. Two 12V, Lead-Acid Rechargeable Batteries (3 Batteries fo Pulse 2000)

In case any of the above items is missing, please contact iControls and provide us with details of

the missing part(s), as well as the serial number of your operator.

OPERATOR TECHNICAL OVERVIEW

Motor

HORSEPOWER: Pulse500 = ½ HP Pulse750 = ¾ HP Pulse1000 = 1 HP Pulse 2000 = 2 HP

SPEED: 1750 RPM

CURRENT (FLA): ½ HP = 5A ¾ HP = 7.6A 1 HP = 10A 2 HP = 10A(208-240Vac)

OUTPUT TORQUE: Pulse500 = 54Nm, Service Factor 1.6

Pulse750-1 = 80Nm, Service Factor 1.1

Pulse750-1.25 = 108Nm, Service Factor 2.0

Pulse1000 = 147Nm, Service Factor 1.5

Pulse 2000 =

Electrical

SUPPLY VOLTAGE: 110-130 or 208-240V Vac, 1ph Input (All incoming power to be

connected in provided junction box)

BATTERIES: ½ HP= 2 x 5Ah, ¾ HP= 2 x 7Ah, 1 HP= 2 x 9Ah, 2 HP= 3 x 9Ah

CONTROL VOLTAGE: 24Vdc, 1A Power/Connections supplied for activation and

reversing devices

AUX RELAY: 1 SPDT Programmable Relay (factory default to activate on Open

Limits)

Safety

PHOTO-EYE or THRU-BEAM Polarized Photo-eye Sensor/Reﬂector with Bracket or Thru-Beam

SENSOR: sensor provided with unit as non-impact reversing device protection.

POWER OUTAGE Battery Backup to open/close the door in case of power-outage.

OPERATION: 3/8” ratchet socket for manual crank open/close as added

redundancy.

Maximum Recommended Counter balance Sectional Door size

Pulse 500: up to 200 Square Feet

Pulse 750: up to 350 Square Feet

Pulse 1000: up to 500 Square Feet

Pulse 2000: over 500 Square Feet

IMPORTANT

WARNING – These instructions are intended for experienced personnel trained for service and

installation of sectional doors and operators. All safety precautions and local codes must be

followed.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Have qualiﬁed service personnel make necessary repairs to ensure door is operating

smoothly without any unusual noise. Install operator only on a smoothly operating and well

balanced door.

3. Remove all pull ropes and remove locks (unless mechanically and/or electrically

interlocked to the power unit) connected to the door before installing the operator.

4. A commercial/industrial door operator that has exposed moving parts capable of causing

injury to persons or employs a motor deemed indirectly accessible by clause 10.6 by virtue

of its location above the ﬂoor shall include:

a. Install the door operator at least 2.44m (8 ) or more above the ﬂoor: or

b. If the operator must be installed less than 2.44m (8) above the ﬂoor, then exposed

moving parts must be protected by covers or guarding; or

c. Both a. and b.

5. Do not connect the operator to the supply power until instructed to do so.

6. Locate the control station: (a) within sight of the door, and (b) at a minimum height of 1.53m

(5 ) above ﬂoors, landings, steps, or any other adjacent walking surface and (c) away from

all moving parts.

7. Install an Entrapment Warning Placard next to the control station in a prominent location.

PRE-INSTALLATION ASSEMBLY REQUIREMENTS

BEFORE INSTALLATION, ENSURE THAT YOUR DOOR IS PROPERLY BALANCED AND RUNNING

SMOOTHLY. ALSO ENSURE THAT THE LIMIT BRACKETS (SUPPLIED) ARE INSTALLED AND

SECURED PROPERLY. BUMPER/PUSHER SPRINGS MAY BE USED IN PLACE OF, OR IN ADDITION TO

LIMIT BRACKETS FOR PULSE OPERATORS, BUT MUST BE INSTALLED PRIOR TO OPERATION.

Operator Mounting Requirements

Pulse operators are mounted directly on the door sha. Before installing the operator, please en-

sure following criteria is met:

The door is well balanced, is tested for

smooth functioning without any unusual

noise.

Provided Limit Brackets must be installed

4"-5" past door's desired open position (and

within allowable maximum cable height) to

prevent the doors from over-travel. (See Fig.

1A)

The door has a solid keyed sha with a

minimum exposed length of 4.5” on the

operator side.

Clearance of at least 12” horizontally from

the side of the door (or 9” from end of sha),

and 24” vertically below the sha. There

is adequate structural support surface to

securely install the torque arm mounting

bracket, the torque arm and the junction

box. For more details, see mounting

installation instructions

Fig: 1 & 7.

Mounting space for the operator Control

Panel (Min. 5 . from ground level, within

clear sight of the door but far enough away

as to prevent users from contacting moving

parts).

Le Hand Mounting:

The factory default mounting as shown

(Shown in Fig: 2) is for le-hand side of the

door, hence no modiﬁcation is required.

FIGURE: 1

FIGURE: 2

Magnet on

this side

Encoder

FIGURE: 1A

Right Hand Mounting:

The soware and hardware must be modiﬁed for right-hand side mounting.

Refer to “OPERATOR START-UP/SET-UP, MOTOR POSITION.

Field Adjustment of the Encoder for Right-Hand Mounting:

Instructions to adjust the hardware for right hand

mounting: See Fig: 3.

Remove the 4 bolts, spacers that secure the

encoder on the le-side of the gearbox and set

the encoder mounting plate, bolts and spacers

aside.

Remove the cable tie that secures the cable to

the gearbox. DO NOT ATTEMPT TO REMOVE/

DISCONNECT CABLE!

Insert a long screwdriver through the hollow sha

from the right side of the gearbox and gently tap

out the encoder magnet assembly wedged in

the le side of the gearbox hollow sha.

Align the key and insert the magnet assembly

into the right side of the hollow sha and gently tap with a rubber mallet until it is slightly

recessed 1 mm (1/32”) in the hollow sha (level with the inner bevel edge of the hollow sha).

ENSURE THAT THE MAGNET IS VISIBLE AND FACING OUTWARDS FIG: 3 PRIOR TO INSERTION.

Attach the encoder mounting plate to right-side of the gearbox, so that it covers the encoder

magnet assembly, ensuring that the cable is facing towards the bottom of the operator, use

existing bolts and spacers. Ensure that bolts are fully

tightened. DO NOT TWIST THE CABLE.

Please note that the face of the encoder should not

be more than 1mm (1/32”) from the magnet. If too

far, the encoder may not detect the magnet. If too

close, friction will lead to limit retention issues.

Assembling Torque Arm to Gearbox

The torque arm must be assembled onto the gearbox

on the opposite side of encoder using the enclosed

4 bolts. There are 6 possible positions for the torque

arm, and its optimal mounting position should be

pre-determined prior to assembly. Tighten bolts

appropriately. THE TORQUE ARM IS AN INTRINSIC

COMPONENT OF THE OPERATOR’S SAFETY AND

FUNCTIONALITY AND MUST BE INSTALLED SECURELY. See

Fig: 4

See Fig; 4A-F For recommendations on how

to mount Torque Arm to Operator/Mounting

Bracket in relation to Sha O-set.

FIGURE: 3

FIGURE: 4

Magnet on

this side

Encoder

TORQUE ARM POSITION IN RELATION TO OPERATOR

WARNING

• TO REDUCE THE RISK OF PERSONAL INJURY OR DEATH, DO NOT CONNECT ELECTRICAL POWER UNTIL

COMPLETE OPERATOR, JUNCTION BOX AND CONTROL PANEL ARE INSTALLED, SECURED AND PROTECTED PER

FOLLOWING INSTRUCTIONS.

• ENSURE THAT AREA IS CLEAR OF PERSONNEL AND CORDONED OFF TO ACCESS WHILE INSTALLING

OPERATOR.

• USE PROPER SAFETY PROTOCOLS ACCORDING TO INTERNAL, LOCAL AND FEDERAL REQUIREMENTS.

MANDATORY FIRST STEP - Limit Bracket Installation

If your door is not already equipped with bumper/pusher springs, it is mandatory to install the

supplied Limit Brackets. Mount one bracket to the top of each track (See Figure 1A) to prevent

over-travel of the door, and enable automatic encoder recalibration prior to setting limits and aer

a power-loss. These should be mounted inside the door-tracks at the door’s maximum allowable

travel point, and are required to be located at the same exact position on both tracks so that the

top rollers of the door rest against them in a level position.

To install, manually open the door to the uppermost opening position allowable by the cables,

clamp the door in place, and secure the brackets to the track as shown Figure 1A using the top

rollers as the reference points for the brackets.

IN THE ABSENCE OF BUMPER/PUSHER SPRINGS, INSTALLATION OF LIMIT BRACKETS IS

MANDATORY PRIOR TO OPERATOR INSTALLATION. WITHOUT PHYSICAL LIMITS, THE DOOR CAN

RUN OUT OF ITS TRACKS AND CAUSE SEVERE PERSONAL INJURY AND/OR CAUSE SEVERE DAMAGE

TO THE DOOR. FURTHERMORE, YOU WILL BE UNABLE TO SET THE LIMITS.

MOUNTING INSTALLATION INSTRUCTION

Sha Collar/Key Installation

The Sha Collar serves as an end-stop for the gearbox on the sha to prevent possible damage to the

encoder magnet. It is important that it is securely fastened prior to installation of the operator, and needs to

be mounted in conjunction with the key as shown in Fig: 5.

Adjust the door so that the sha keyway is facing up (you

may have to open/wedge/clamp the door open slightly to

achieve this).

Loosen the Sha Collar set screw and slide it over the sha

approximately 3 ½” from its end.

Insert the 3 inch long key (provided with operator) into the

door sha keyway with one end ﬂush to the end of the sha.

Slide the collar back so that it touches the key, which should still be ﬂush with the sha end on its opposite

side (the key sits in the keyway between the collar and the end of the sha), see Fig: 5.Firmly tighten the

set screw of the collar onto the sha. Fasten the Torque Arm to the gearbox on the opposite side as the

encoder, and at an appropriate position as suggested on Drawing Figs: 4A-F)

Please note that in order to keep this collar as close to the door frame as possible and to

accommodate fastening of the torque arm, you may be required to cut the sha to an appropriate

length.

FIGURE: 5

WARNING

WARNING: THE OPERATOR ASSEMBLY IS HEAVY AND CAN CAUSE SERIOUS INJURY OR DEATH SHOULD IT BE

DROPPED DURING INSTALLATION. TAKE ALL NECESSARY SAFETY PRECAUTIONS TO AVOID DROPPING THE

OPERATOR (I.E. TETHER/TIE DOWN) PRIOR TO ATTEMPTING INSTALLATION. SCAFFOLDING OR SCISSOR-LIFTS/

PLATFORM-LIFTS ARE ADVISED FOR OPERATOR INSTALLATION. NEVER ATTEMPT TO INSTALL AN OPERATOR

ABOVE EYE-LEVEL OR FROM A LADDER.

Operator Installation

ENSURE THAT PREVIOUS STEPS FOR SHAFT COLLAR/KEY INSTALLATION HAVE BEEN PROPERLY FOLLOWED

BEFORE PROCEEDING. FAILURE TO DO SO COULD RESULT IN DAMAGE TO THE ENCODER DURING

OPERATOR INSTALLATION.

Align the keyway of the gearbox with the pre-mounted

key (see Key Sha Collar/Key Installation on previous

page) located on the mounting side of the sha.

Slide the gearbox onto the sha until it makes contact with

the Key Sha Collar.

Assemble the Torque Arm Bracket to the Torque arm

using the fastener provided. NOTE: DO NOT TIGHTEN THE

NUT FULLY). Anchor the Torque Arm Bracket to the solid

structural support.

Fasten the torque arm to structural support by means of

the supplied bolt, locking nut and washers. The supplied

bracket may be required. If the torque arm does not align

with structural support, you may try adjusting the torque

arm position on the gearbox (see Assembling Torque Arm

to Gearbox) accordingly or use the Torque Arm Bracket.

Junction Box Mounting

The junction box contains terminals for power

connections, as well as battery/communication

connections for the control panel. Mount the junction box,

by means of the mounting ﬂanges and in accordance

with the electrical code, in a conspicuous location

that will provide access for both electrical power and

control panel wiring connections. The junction box is pre-

wired with 2 feet of ﬂexible conduit, if longer lengths are

required, consult with factory. Do not mount the junction

box near moving parts or in an inaccessible area.

FIGURE: 6

FIGURE: 7

FAILURE TO SECURELY FASTEN TORQUE ARM COULD RESULT IN DAMAGE, SERIOUS INJURIES OR

DEATH AND WILL VOID THE WARRANTY.

10 11

Control Panel Mounting

The control panel should be securely mounted at

or around eye level (minimum 5 . from ﬂoor) on

the same side as the operator/junction box. Ensure

that the control panel is mounted far enough away

from the door as to avoid user contact with the

door while in operation, but close enough that the

user has clear view of the door at all times. Four (4)

control mounting brackets are provided to facilitate

mounting. See Fig: 8

Photo-Eye or Thru-Beam Sensor Mounting

The included reﬂective photo-eye or thru-beam

sensor should be mounted so that it scans area

that spans the entire width of the door at a height

of no more than 6 inches from the ground. The

sensor (reﬂective photo-eye) or receiver (thru-beam)

should be mounted on the operator side (as it will

be wired into the control panel), while the reﬂector

or transmitter should be mounted on the opposite

side of the door, facing the sensor/receiver so that its

center meets the beam. Use the included mounting

bracket(s) to secure to either the door tracks or the

wall. Refer to the speciﬁc mounting details provided

with the sensor. For ﬁnal alignment of the sensor, put

unit in STARTUP MENU (see page 18) to apply power to

the sensor (aer WIRING – see page 13 for additional

wiring diagram). Once properly aligned in STARTUP

MENU, the indicator will light up in conﬁrmation. Note

that upon exit from the STARTUP MENU, the sensor will

only become active when the door is closing.

See Fig: 9 for mounting reference.

FIGURE: 8

FIGURE: 9

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