RYTEC Pharma-Roll Manuale utente

Pharma-Roll®

Installation Manual

[Revision: January 15, 2009, 0715009, ©Rytec Corporation 2007]

TABLE OF CONTENTS

PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TOOLS AND EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLOOR LOOP EQUIPMENT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BASIC JOB REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICIAN’S RESPONSIBLITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

GENERAL ARRANGEMENT OF DOOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SIDE COLUMN MOTOR SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SPREADER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Door without Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Door with Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALL ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Caulking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

PHOTO EYE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ELECTRICAL WIRING ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Coil Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . .13

OPEN AND CLOSE DOOR LIMIT POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Close Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Open Limit Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . .14

Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . .14

Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 14

PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 15

Kill Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Kill Switch Air Bleed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Kill Switch Sensitivity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

PHOTO EYE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Photo Eye Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Photo Eye Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

RESETTING BOTTOM BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

INSTALL HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

INTRODUCTION—DOOR SERIAL NUMBER(S)

INTRODUCTION

The information contained in this manual will allow you

to install your Rytec Pharma-Roll®Door in a manner

that will ensure maximum life and trouble-free opera-

tion.

Any unauthorized changes in procedure, or failure to fol-

low the steps as outlined in this manual, will automati-

cally void the warranty. Any changes in the working

parts, assemblies, or specifications as written that are

not authorized by Rytec Corporation, will also cancel

the warranty. The responsibility for the successful oper-

ation and performance of this door lies with the owner of

the door.

DO NOT OPERATE OR PERFORM MAINTENANCE

ON THIS DOOR UNTIL YOU READ AND UNDER-

STAND THE INSTRUCTIONS CONTAINED IN THIS

MANUAL.

If you have any questions, contact your Rytec represen-

tative or call the Rytec Customer Support Department

at 800-628-1909. Always refer to the serial number of

the door when calling the representative or Customer

Support. The serial number plate is located inside one

of the side columns.

The wiring connections in this manual are for general

information purposes only. A wiring schematic is pro-

vided with each individual door specifically covering the

control panel and electrical components of that door.

That schematic was shipped inside the control panel.

DOOR SERIAL NUMBER(S)

Yo u r DOOR SERIAL NUMBER information can be

found in three universal locations. These are at the

inside of either side column (approximately eye level),

on the drive motor, and on the inside door of the System

3 control panel. (See Figure 1.)

IMPORTANT: When installing multiple doors

of the same model but in differ-

ent sizes, verify the serial num-

ber in the control panel with the

one in the side column.

Figure 1

HOW TO USE MANUAL

Throughout this manual, the following key words are

used to alert the reader to potentially hazardous situa-

tions, or situations where additional information to suc-

cessfully perform the procedure is presented:

WARNING is used to indicate the potential

for personal injury, if the procedure is not

performed as described.

CAUTION is used to indicate the potential

for damage to the product or property

damage, if the procedure is not followed

as described.

IMPORTANT: IMPORTANT is used to relay

information CRITICAL to the

successful completion of the

procedure.

NOTE: NOTE is used to provide additional infor-

mation to aid in the performance of the

procedure or operation of the door, but not

necessarily safety related.

A7500253

Drive Motor/Gearbox

Left Side Column

Right Side

Column

Rytec

System 3

Control

Panel

INSTALLATION—TOOLS AND EQUIPMENT REQUIRED

INSTALLATION

TOOLS AND EQUIPMENT REQUIRED

1. Socket and wrench set

2. ½-in. diameter concrete anchor bolts (See

“ANCHORING METHODS” on page 3.)

3. ½-in. diameter threaded rod (See “ANCHORING

METHODS” on page 3.)

4. Two ladders (taller than the door opening height)

5. Forklift

6. Carpenter’s level (4-ft.-long minimum)

7. Carpenter’s square

8. Hammer drill

9. ½-inch diameter masonry drill bit

10. Three or four, 1-ft.-long bar clamps

11. Hammer and mallets

12. Crowbar or prybar

13. Assorted hand tools (pliers, tape measure, etc.)

14. Assorted shim stock

15. Water level, line level, or transit

FLOOR LOOP EQUIPMENT REQUIREMENTS

1. Wet-type concrete saw.

2. Wet vac.

3. 200–500 feet of 16-gauge, 19-strand, type XLPE,

copper, crosslink polyethylene jacket wire (or equiv-

alent). The length of wire is determined by the size

of the loop.

4. Bondo P606 flexible embedding sealer (or equiva-

lent) — required to fill grooves in floor. For cold tem-

perature sealing applications, Bondo P610 speed

set must be added to the P606 to ensure proper

curing of the filler.

5. Water supply and garden hose (for concrete saw).

NOTE: For complete floor loop installation instruc-

tions, refer to the installation instructions

provided with your floor loop.

BASIC JOB REQUIREMENTS

1. A forklift must be supplied by the customer, dealer,

or installer.

2. Two installers are required.

NOTE: One installer must be a qualified electrical

technician and all electrical work must

meet applicable codes. If the installer is

not qualified, an electrician must be

present during installation.

3. The customer must guarantee 100% access to the

door opening during the installation. No traffic

should be allowed through the door during the

installation.

4. If an electrician is used, that person must make all

electrical connections. The electrician should be

present one hour after installation begins.

5. The Rytec control box and a fused disconnect

should be installed prior to the start of the door

installation. (See Figure 2 for layout.)

ELECTRICIAN’S RESPONSIBLITIES

For complete details on the responsibilities of the elec-

trician, refer to the Rytec System 3 Drive & Control

Installation & Owner’s Manual.

GENERAL ARRANGEMENT OF DOOR PARTS

Figure 2 shows the location of the major components of

your door. This illustration should be used as reference

only and should not be used as part of the installation

instructions.

Figure 2

NOTE: The above illustration shows the front side

of the door. Left and right are determined

when viewing the front side of the door.

A7500253

Fused Left Side Column

Fabric Roll

Right Side

Column

Bottom Bar

Photo Eye ‚

Front and Rear

Disconnect

Drive Motor/Gearbox

Rytec

System 3

Control

Panel

Photo Eye ‚

Front and Rear

INSTALLATION—ANCHORING METHODS

ANCHORING METHODS

Correct anchoring of the side columns to the wall and

the floor is important for the smooth and safe operation

of the door. The wall material should be strong enough

to support the weight of the door and all wall anchors.

Figure 3 through Figure 6 show anchoring methods for

various types of walls. Use the method that is best

suited for your particular installation site.

All necessary anchoring hardware and material required

for the installation of this door is the responsibility of the

door owner. If you have any questions, call your Rytec

representative or the Rytec Customer Support Depart-

ment at 800-628-1909.

NOTE: Use ¹₂-in. diameter threaded through bolts

or ¹₂-in. diameter threaded rods to anchor

the door to all wall applications. Use ¹₂-in.

diameter concrete anchor bolts to anchor

the door to a concrete floor or wall.

If expansion anchors are used, a quarterly

inspection should be implemented for safe

and secure door operation.

Concrete, Block, or Brick Walls

Figure 3

Wood, Block, Brick, or Insulated Walls

Figure 4

Insulated Wall

Figure 5

Insulated Wall

Figure 6

A0500005

Side

Expansion

Concrete Wall

Column

Anchor

A0500037

Side

Through Bolt

or Threaded Rod

Crush Plate

Wood

Column

Wall

A0500039

Insulated Wall

Aluminum-Clad Lumber

(Back Side — Full Length)

Through Bolt

or Threaded Rod

Side

Column

A0500038

Through Bolt

or Threaded Rod

Insulated

Aluminum-Clad Lumber

(Back Side — Full Length)

Wall

Side

Column

INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING

LOCATING CENTERLINE OF DOOR OPENING

NOTE: Accurate measurements are critical for the

proper installation and operation of your

Rytec door. Verify all measurements.

1. Measure the width of the door opening.

2. Divide the measurement in half to locate the center-

line. Then mark the centerline along the floor.

(See Figure 7.)

Figure 7

LOCATING SIDE COLUMNS

1. Locate the layout drawing of the door. It should be

attached to the small parts carton packed inside the

shipping crate. This drawing identifies the produc-

tion width of your door.

2. Using the centerline as a reference point, lay out

and mark half of the door’s production width along

the floor. (See Figure 8.)

This door is equipped with a breakaway

bottom bar assembly. To ensure that it

works properly, the width of the door

opening must not be smaller (narrower)

than the production width of the door. If

the width of the opening is narrower than

the width of the door, do not proceed with

the installation. Contact your Rytec repre-

sentative or Rytec Customer Support

Department at 800-628-1909.

Figure 8

3. With a carpenter’s square placed against the wall,

mark both sides of the door along the floor. Extend

the line along each edge.

4. Check the floor for level across the door opening.

The floor must be level within 0.12 in. from side-to-

side. If one side of the opening is higher than the

other, a shim under the side panel will be required.

Figure 9 and Figure 10 show two methods that can

be used to ensure level side columns.

NOTE: Contact the Rytec Customer Support

Department if the floor is more than 1 in.

out of level.

Figure 9

A0500001

Centerline of

Opening

Overall Width

of Door Opening

Half Width of

Door Opening

A0500002

Half of Door Centerline of

Opening

Production

Extend and Mark

Edges of Door Along Floor

Width

A0500003

Line Level

This Dimension Must Be

Equal on Both Sides of

Door Opening

Shim Plate

(If Required)

INSTALLATION—SIDE COLUMNS

Figure 10

SIDE COLUMNS

NOTE: DO NOT change the location of the drive

motor without first contacting your Rytec

representative or the Rytec Customer

Support Department at 800-628-1909.

1. Remove the drive motor side column from the ship-

ping crate. The drive motor side column is identified

by the seal edge that faces inward during installa-

tion for a left-hand-side motor mounting.

(See Figure 11.)

Figure 11

2. Stand the drive motor side column on the floor and

tight against the wall to determine which side of the

door to place the side column.

3. Align the inside edge of the side column with the

production width line laid out earlier on the floor.

The side column must be located on the outside

edge of the layout line. (See Figure 12.)

Figure 12

It is critical that the side columns are

mounted level and square to the wall and

floor, both vertically and horizontally. A

4-ft. level and carpenter’s square are rec-

ommended for this procedure.

The use of bar clamps to secure the side

columns to the wall during installation is

recommended, as these hold the columns

securely in place, while allowing for slight

adjustments of either side column during

the installation of the head assembly.

NOTE: All necessary anchor hardware and mate-

rial is the responsibility of the door owner.

A0500004

This Dimension

Must Be Equal

on Both Sides

of Door Opening

Water Level Shim Plate

(If Required)

A3000090

Seal Edge

Motor Mount

Side Column

Top

Bottom

A3000091

Anchor Holes

(Two Anchors

Required)

Production Width Line

(Side Column Must Be

Located on Outside

Edge of Line)

Seal

Anchor Holes

(Three Anchors

Required)

Left Side Column

Top

Bottom

INSTALLATION—SIDE COLUMN MOTOR SUPPORT

4. Once the side column is properly positioned, secure

it to the wall using the appropriate anchors. (See

“ANCHORING METHODS” on page 3.) Anchor

holes have been provided in the side column. (See

Figure 12.) DO NOT tighten the anchor hardware at

this time.

NOTE: Use ¹₂-in. diameter expansion shell stud-

type anchors for concrete walls or ¹₂-in.

diameter threaded through bolts for brick

walls and other applications where expan-

sion bolts are not acceptable.

Use a tape measure to ensure that proper

width alignment is maintained between the

side columns, at the top and bottom ends

of each column. DO NOT tighten the

anchors at this time.

5. Mount the other side column to the wall in the same

manner as outlined above for the first side column.

SIDE COLUMN MOTOR SUPPORT

On doors greater than 14 feet tall (or wide),

a side column motor support will be sup-

plied with the small parts box as seen in

Figure 13. Failure to install this part prop-

erly may result in equipment failure and/or

personal injury.

Figure 13

IMPORTANT: For doors that are oversized

beyond 14 ft. in height (or width)

should have a side column

motor support included in the

small parts box.

SPREADER ASSEMBLY

Door without Hood Assembly

1. Attach an L-shaped support bracket to each end of

the spreader extrusion using two ³₈-16 x 1¹₄-in.

serrated-flange hex screws and nuts. The brackets

and mounting hardware were shipped in the small

parts carton. (See Figure 14.)

Figure 14

2. Attach the spreader assembly to the inside face of

each side column using two ³₈-16 x 1¹₄-in. serrated-

flange hex screws and nuts at each end of the

assembly. Face the spreader so the brush is toward

the front of the door. (See Figure 15.)

A7600056

A8500004

Serrated-Flange

Hex Screw (Two

L-Shaped Support

Bracket (Mounted to

Top of Header

Spreader

Extrusion

Serrated-Flange Hex

Nut (Two on Each End)

on Each End)

Extrusion)

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