Current Generation Owners Manual, Trakline Plus Publication 8920plg, January 2007

Transcript

TRAKLINE™ PL FOLD DOOR MODEL 8920PL This Manual Covers Doors Shipped After 2-20-06. PRINTED IN U.S.A. EMAIL: [email protected] PUBLICATION NO. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL PRODUCT INTRODUCTION TABLE OF CONTENTS TOOLS AND MATERIAL REQUIRED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .3 SIDEFRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4 DRIVE ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . .5 HEADER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 V-FLEX STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .7 CURTAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 LIFTING STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . .9 PHOTOEYE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .10 LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .11 SHROUD / COVER INSTALLATION . . . . . . . . . . . . . . . . . . .12 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13 I-COMM INPUTS & OUTPUTS . . . . . . . . . . . . . . . . . . . . . . .14 COUNTER BALANCE SYSTEM . . . . . . . . . . . . . . . . . . . . . .15 MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . .16 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . .20 ARCHITECTURAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . .24 Tube of Anti-Seize or Grease Lubricant (IMPORTANT) Caulk Gun and Caulk Tubes 1 1/4” Open End Wrench 1 1/2” Open End Wrench 1/2” & 9/16” Open End Wrench or Ratchet Wrench 1/2” & 9/16” Socket Phillips Screwdriver Straight Screwdriver (small 1/8” blade) 3/8” or 1/2” Masonry Bits 18” Long Drill Bits For Thru-Bolting Cordless Drill (3/8” or 1/2”) w/Phillips Bit 5/16” Driver Bit For Drill Tape Measure 25’ Minimum Wire Strippers and Side Cutters Set of Allen Wrenches (1/8”, 5/32”) Four Large Clamps for Lifting Header Straps For Lifting Roller Tube and Header (optional) Forklift With High Boom Retaining Ring Pliers 6’ Carpenters Level 8’ or 10’ Step Ladder 20’ Extension Ladder 3/16” Punch Utility Knife Water Level Multi-Meter Hammer Hammer Drill Hole Saw Scissors Lift NOTICE TO USER Our mission is to “Improve Industrial Safety, Security and Productivity Worldwide Through Quality and Innovation.” Thank you for purchasing the TRAKLINE™ PL FOLD from RITE-HITE DOORS, INC. The TRAKLINE PL FOLD is designed to be a fast, smooth opening, low maintenance door that provides superior environmental separation while reducing passage time and temperature loss. 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. 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. The serial # for your door is on a label located on the side of the control box and sideframe. This manual should be thoroughly read and understood before beginning the installation, operation or servicing of this door. Complete Final Checklist prior to leaving site. Refer to partslist manual for exploded views and part numbers. Your local RITE-HITE DOORS, INC. Representative provides the 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 TRAKLINE PL FOLD door have been left out of this manual or are not complete, contact 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, including patents applied for, pending, or issued: 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, 6,574,832, 6,598,648, 6,612,357, 6,615,898, 6,659,158 FEATURES 2 i-COMM™ Universal Controller Exterior/Interior Folding Door. V-Flex™ Curtain Release System. Fast smooth opening with a maximum speed of up to 40 in/sec. Motor options of 3 Phase 60 Hertz-208V, 230V, 460V, 575V Motor option with 3Ø 50 Hertz 400V may have slower speeds One or Two directional curtain breakaway. High Wind package. Heavy-duty industrial materials for high cycles and minimal wear. Hardware for mounting the door to the wall, shimming and anchoring to the floor are not provided. WARRANTY RITE-HITE DOORS, INC. warrants that it’s TRAKLINE PL FOLD door will be free from defects in design, materials, and workmanship for 150,000 cycles or for a period of one (1) year from the date of shipment. The panel fabric warranty covers material failure under normal wear conditions; it does not cover labor or damage incurred from abuse, misuse or impact. Warranty does not cover wear items such as seals, belts, fuses, and bulbs. 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 are 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, RITEHITE 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., RITE-HITE DOORS, INC. representatives or any other manufacturer whose products are the subject of this transaction, 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. RITE-HITE DOORS, INC. 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 Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL INSTALLATION INSTRUCTIONS Qty 1 1/1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 8/12 8/12 10/14 10/14 28 28 1 2 a/r 2 1 2 2 a/r Description Crate Containing the following Header Assembly (w/ Roller Tube) RH/LH Sideframe Control Box (optional) w/Owner’s Manual Motor/Brake/Gearbox/Limit Switch Ass’y w/Cables Control Box Cable Assembly (optional) Drive Shroud Curtain Counterweight V-Flex Straps PVC Tube Curtain Retention Bar Parts Box Containing the Following Limit Switch Sprocket Large w/Set Screws (2) Limit Switch Chain 17 1/8” Limit Switch Chain Link 1/4” x 3/16” x 4 1/2” Key Retaining Ring Exterior Belting Pressure Plates Belting Pressure Plate 5/16” Bolts Belting Pressure Plate 5/16” Nuts Belting Pressure Plate 5/16” Lock Washers 3/8-16 x 1 1/4” Carriage Bolts for Header 3/8-16 Hex Nylock Nuts for Header #8-32 x 1/2” Self Tap/Drill Screw #10 Int/Ext Lock Washer #14 x 3/4” Self Tap/Drill Screws 1/4-20 x 1/4” Set Screw Nylon Rope for Brake Release Counterweight Pressure Plates 5/16” x 1 1/4” HHMS For Counterweight Hardware, Straps and Plates for Curtain Retention Assembly ! DANGER !!! 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. PRELIMINARY INSTRUCTIONS Here are a few things to verify before getting started: ! CAUTION !!! 1. Make sure you are working at the correct door location and that you have any required work or building permits. 2. Make sure the electrician is ready to bring the correct electrical power supply to the door Integral sideframe controls or the control box and the electrical power can be shut off without interfering with other plant operations. 3. Barricade the work area on both sides of the opening. 4. Detour material handling equipment (fork lift trucks, etc.) during the installation of the door. 5. Verify there is nothing buried in the floor where the anchor bolts will be installed. 6. Inspect the installation site to make sure there are no overhead obstructions (sprinkler pipes, HVAC systems, electrical supply lines, etc.) that might interfere with the lifting of the door assembly during installation. 7. Move the crate as close to the opening as possible. 8. When unpacking the door components remove the smaller items first, electrical components, parts box, gearmotor, roller tube, header braces/curtain assembly, and the sideframe assemblies last. Make sure to barricade the door opening on both sides to prevent unauthorized use until the door has been completely installed. TWO-WAY BREAKAWAY Must Be Equal to O.D.W. +1/4”/-0” and Perpendicular to Wall Wall AA Sideframe Sideframe CC Level LISTING OF MEASUREMENTS AND MARKINGS REQUIRED DOOR OPENING Door width at bottom Door width at top Door height left Door height right FLOOR LEVEL Mark left wall where water is level. Mark right wall where water is level. DD BB Wall ONE-WAY BREAKAWAY Must Be Equal to O.D.W. Plus 14 3/4” +1/4”/-0” and Perpendicular to Wall Water Level Low Side High Side TWO WAY BREAKAWAY 1/2 O.D.W. ONE WAY BREAKAWAY 1/2 O.D.W. plus 7 3/8” FIGURE 1-SIDEFRAME MARKING Pub. No. 8920PLG JANUARY 2007 “AA” & “BB” Dimension must be the same DOOR MUST BE: -Plumb/Perpendicular -The door must be installed level, even if floor is not level. 3 TRAKLINE™ FOLD Model 8920PL SIDEFRAME INSTALLATION 9. 10. Measure the overall width of the door opening near the floor and near the top (Dimensions AA and BB), Figure 1. These measurements should be ± 1/4". Measure the height of the opening at the left and righthand sides (Dimensions CC and DD), Figure 1. These should be within ±1/2" of the dimensions listed on the Serial Number label. If the measurements do not agree, STOP! Contact your RITE-HITE DOORS, INC. representative. Compare these measurements to the sizes listed on the Serial Number label for the door to be installed. Make sure to match the door serial# with the correct serial# on the control box, in case of multiple doors. TWO-WAY BREAKAWAY: 3. From this centerline, measure 1/2 O.D.W. and place a mark on the floor on each side. 4. Measure across the opening from sideframe mark to sideframe mark to double check the overall dimension. This distance should not not vary more than +1/4/ -0". SIDEFRAME INSTALLATION NOTE: Handle sideframes with care as control components may be inside. 1. Place the sideframes into position near the opening. 2. The pre-attached covers need to be removed. 3. If shims are required, shims must fully support sideframe base plate. Drill holes through shims to allow for anchors. 11. Verify that the door jambs are plumb and perpendicular and that the horizontal header is level. 4. 12. Make sure that the floor is level using a carpenter’s level or hydro-level (water level). If the floor is not level to within 1/8", shimming of the sideframe assemblies will be required, Figure 1. Carefully lift the sideframes by hooking a chain to the sideframe. Caution should be used to insure chain is secure. 5. Install sideframe that does not require shimming at the marks made on the wall. Using a 6’ carpenter’s level make sure that sideframe is plumb and square to the wall. NOTE: For one directional breakaway the s/f’s are mounted at O.D.W. plus 14 3/4”: +1/4” -0”. 6. Mark the mounting holes in the back of the sideframe and remove sideframe. Drill holes through the wall, reposition sideframe and fasten to wall using thru the wall bolts and a backing plate for each bolt. For two way-directional breakaway the sideframes are mounted at O.D.W: +1/4” -0”. Electrical prints included in the parts or control box, supersede any prints included in this owners manual on Pages 20-23. Always check parts or control box for prints. NOTE: Anchors, wall fasteners and shims are not supplied. If welding, the sideframe should only be tack welded in at this time. It is not recommended to weld sideframes securely in place until door has been tested to ensure proper operation. PREPARING THE JAMB 1. When laying out the sideframe locations, make all measurements from the centerline of the door opening. Measure between the jamb at the top of the opening and at the floor, divide this measurement in half, mark the centerline on the wall and on the floor, Figures 1. Drop a plumb bob from the mark at the top of the jamb and place a mark on the floor. The distance should be within 1/8”, if not place a mark half way between these two marks. ONE-WAY BREAKAWAY: OR 2. From this centerline, measure 1/2 O.D.W. plus 7 3/8" and place a mark on the floor on each side. This will offset the location of the V-Flex™ Curtain straps, Figure 2. Fork Lift Support Block Roller Tube 7. Repeat procedure for the opposite sideframe. 8. Plumb the sideframe and double-check the overall width measurements at the bottom of the sideframes. There should not be more than +1/4” / -0”. 9. The sideframe should be square to the header, if the sideframes twists when fastening to the wall, shim as required. DRIVE ASSEMBLY INSTALLATION 1. Place the header in front of the opening. Place support blocks on the lift forks and clamp header to lift. The blocks are needed since the roller tube is lower than the header. Failure to do this may bend the roller tube, Figure 2. 2. Remove drive or non-drive shrouds. 3. Locate the gearmotor assembly, limit switch chain, connector link, and 30 tooth sprocket. 4. For ease of gearbox installation and maintenance, apply a grease lubricant or anti-seize (not supplied) to the drive shaft, bumper block and motor bumpers. 5. Turn roller tube to align the shaft and gear keyway. 6. Place 1 1/2 pre-wraps of the lifting straps around the roller tube, Figure 5. The roller tube will be between the lifting straps and the curtain. 7. Install gearmotor assembly onto the drive shaft, some force may be required to get the bumpers over the bumper blocks, Figures 3 & 4. Header Tube Clamp FIGURE 2-HEADER LIFTING 4 Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL DRIVE ASSEMBLY INSTALLATION 8. Route the limit switch cable through the hole in the back of the motor mount bracket and run down the length of the sideframe, Figure 30, Page 19. I M P O R TA N T ! ! ! Be sure retaining ring is fully seated in the groove. Failure to do this, may cause the motor to move on the shaft during operation. I M P O R TA N T ! ! ! An anti-seize lubricant MUST BE applied to the shaft prior to motor installation. Failure to do this may result in a difficult time removing the motor for maintenance. Rear Header Brace 9. 10. Gearbox case should be flush with the end of the retaining ring groove. 11. Install retaining ring into shaft groove, Figure 6. 12. Install 30 tooth sprocket onto the drive shaft until it hits the shoulder. Sprocket needs to line up with the 10 tooth sprocket on the limit switch shaft, if not loosen and move the 10 tooth sprocket and use a short straight edge to align. When aligned, tighten the 1/4” set screws onto the flat spot of the shaft with an 1/8” allen wrench to 75 in/lbs and lock-tight. 13. Install #35 chain onto sprockets, by lining up the chain so the connector falls onto the large sprocket, Figure 7. 14. Place connector link onto chain and lock in place, Figure 7. Adjust the chain so it does not slip over the teeth. Loosen the limit switch mounting bolts and adjust Bumper Brackets Front Header Brace Sideframe Shaft Lubricate and install 1/4”x3/16”x 4 1/2” key into the keyway. DO NOT force the key. The key should slide freely, forcing the key may cause distortion. Tap key into keyway slot until it is past the retaining ring slot. Anti-Rotation Bracket FIGURE 3-MOTOR ASSEMBLY Anti-Rotation Bracket Bumper Block Bumpers Roller Tube Retaining Ring Drive Shaft FIGURE 4-MOTOR ASSEMBLY FIGURE 6 Motor Assembly Straps MUST Roll off the Roller Tube on the Opposite Side that the Curtain is Hanging Non-Drive Shaft Lifting Straps 1 1/2 Pre-Wraps Roller Tube FIGURE 5-LIFTING STRAP INSTALLATION Pub. No. 8920PLG JANUARY 2007 Center Lifting Straps for Doors > 21’ O.D.W. 5 TRAKLINE™ FOLD Model 8920PL HEADER INSTALLATION 15. so the chain deflects approximately 1/4” when pressure is applied. A chain that is too tight may cause wear on the limit switch shaft bearing. 2. Fasten the header to the sideframe using the 8 sets of 3/8” x 1 1/4” carriage bolts, washers and nuts provided, Figure 8. The limit switch assembly should be adjusted down in the slots to achieve proper chain tension. 3. The shroud may need to be removed to ease curtain and lifting strap installation, Figure 16. NOTE: DO NOT place the limit switch assembly at the top of the slots. This may cause interference with the covers and make switch adjustment difficult. 16. The limit switch plate Grade 2 bolts must be retightened to 66 in/lbs, if too loose, the plate may slip. NOTE: ! DANGER !!! Use extreme caution when lifting the header unit. Be sure to secure header to the lifting device. It may be required to lift 600lbs or more and lift as high as 28’ in the air. The motor and brake cables are pre-wired into the motor junction box, but need to be terminated to the control panel later in the installation process. The control box option will have a short cable coming out of the motor and limit switch with plugs on. A door mounted on the exterior of a building or on the interior of the building, but not on the outside wall will have the curtain attached to the front header brace. A door mounted internally on an outside wall of the building will have the curtain attached to the rear header brace. See Figures 12 & 13 for proper mounting. The lifting straps on the curtain will always be on the inside of the building. HEADER INSTALLATION Header Sideframe to Header Attachment Bolts NOTE: If overhead clearance is available, the preferred method is to place cargo straps around the header tubes and lift. Make sure to place clamps on the forks to prevent the straps from sliding off the forks. Use Caution not to bend the roller tube. 1. Sideframe Washers and Nuts This Side Carefully raise the header and set onto the sideframes. FIGURE 8-HEADER TO SIDEFRAME MOUNTING Large Limit Sprocket Bumper Bumper Block Bumper Limit Chain Link Connector 6 Small Limit Sprocket FIGURE 7-MOTOR/LIMIT SWITCH ASSEMBLY Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL V-FLEX STRAP INSTALLATION I M P O R TA N T ! ! ! The V-Flex straps Must not be installed until after the header has been installed, due to interference constraints. V-Flex straps with not enough tension may result in premature breakaway and curtain wear. ! WA R N I N G ! ! ! Use Caution when winding up tension pins, as substantial force is being applied to the pins and the belting. 4. Using a 1 1/4” and 1 1/2” wrench, turn the left hand tensioning pins clockwise to put tension on the V-FLEX straps and counter-clockwise for the right hand tension pins. 5. Turn tensioning pin until the strap is very tight or to a total of approximately 170 ft/lb. For taller doors, the tension will need to be increased. 6. When the correct tension is applied to the V-Flex strap tighten down the locking nut using a 1 1/2” wrench. The use of a cheater bar may be required. NOTE: When standing in the opening between the sideframes and looking at the sideframe, the left hand threaded pin goes on the left hand side. Likewise, the right hand threaded pin goes on the right hand side. The left hand pins will have a narrow groove machined into the hex shape near the end of the pins, Figure 9 & 11. NOTE: DO NOT INSTALL FRONT V-FLEX STRAPS, UNTIL AFTER INSTALLATION OF THE CURTAIN AND OPTIONAL RETENTION BAR. 1. Using a 1 1/4” and 1 1/2” wrench, loosen the nuts on the tension pins in the sideframe until they spin freely, Figure 9. Header Sideframe FIGURE 10 Bolt Nut V-Flex Strap w/Plate V-Flex Strap Tensioning Pin Sideframe Washer V-Flex Strap Cover w/ Flap Away From Curtain Locking Nut FIGURE 9-TENSION PINS HARDWARE 2. 3. Place Screw Thru Seal Flap Approximately 2” Above Guards To Prevent Sliding Locate two of the four V-Flex straps, pressure plates and hardware in the parts box and attach to the rear header braces with the sewing seam to the outside and the head of the bolts to the inside, Figures 10 & 11 then lower the straps to floor. Wrap the straps around the tension pins, so that the straps are being wound up when the pin is turned clockwise for the left hand threaded pins and counterclockwise for the right hand threaded pins. The straps will always be on the inside of the pins, Figure 11. Pub. No. 8920PLG JANUARY 2007 Right Hand Tension Pin Left Hand Tension Pin Tensioning Pin Guard FIGURE 11-TENSION PINS 7 TRAKLINE™ FOLD Model 8920PL CURTAIN RETENTION INSTALLATION Curtain Retention Plate and Hardware Adjustment Bar Holding Bolt Adjustment Bar Tabs 2”x6” Header Tube Adjustment Bar Lock Down Bolt Header Dim “X” Dim “X” Curtain Retention Bracket and Hardware Dim “X” Dim “X” Curtain Retention Bar Curtain Retention Strap V-Flex Straps Curtain Adjustment Bar Curtain Slots Curtain Sideframe FIGURE 12 When the Curtain Retention Assembly is used it should be installed prior to curtain installation, Figure 12. 1. Slide retention straps onto the retention bar, space equally, per DIM “X” across the width. 2. Slide retention brackets into the ends of the retention bar. 3. Lift assembly to the top of the sideframes and attach to each sideframe with the hardware provided. 4. Attach retention straps to the header using the retention plates and hardware provided, access may be limited. Straps should be fairly tight and not allow curtain to flex into roller tube. 5. 1. 8 Place curtain on a fork lift so the curtain will unroll toward the wall with approximately 2’ to 3’ of loose curtain off the roll. Clamp the forks of the lift so the curtain will not fall off the lift. 2. Lift the curtain in place and insert the adjustment bar into the brackets on the header and fasten with the 3/8” holding bolts and nuts, Figures 12 & 13. 3. To roll the curtain up, loosen the 3/8” holding bolts and the 5/16” locking screws on the adjustment bar, Figure 13. Lifting Straps 4. Using a 1 1/4” wrench turn the nut on the end of the bar so the curtain is turned against the header brace. It may be required to have two people, one on each side of the header to turn the adjustment bar. 5. The curtain is properly rolled up when the slots are not visible under the front brace. 6. Tighten the 3/8” hex head bolt and the 5/16” locking screws on each end of the adjustment bar with a socket wrench, Figure 13. I M P O R TA N T ! ! ! The retention bar is designed to properly fit between the sideframes, if the bar is too long, check for proper sideframe spacing. Cutting of the bar can be done to achieve the desired fit. CURTAIN INSTALLATION Curtain Care should be taken so as the curtain unrolls it does not tear. Failure to roll curtain on adjustment bar may result in curtain damage or failure of curtain 7. Slowly lower the curtain to the floor to prevent damage to the curtain or injury to personnel. The curtain should be pushed against the rear V-Flex straps, so it will not roll off the forks. 8. If the curtain has slack or is not sealed on the floor, loosen the 3/8” hex head bolt and the 5/16” locking screws on each end of the adjustment bar, and raise or lower the curtain, Figures 12 & 13. After the curtain is properly adjusted, tighten the bolts. 9. Install the front V-Flex straps, per rear strap instructions. Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL LIFTING STRAP & SHROUD INSTALLATION Lock Down Bolt Hold Down Bolt Curtain Adjustment Bar 2”x6” Header Brace V-Flex Mounting Bracket Lifting Straps Are Opposite the Curtain Adjustment Bar Retention Strap Curtain I M P O R TA N T ! ! ! FIGURE 13-ADJUSTMENT BAR FASTENING If one side is tighter than the other, the curtain may fold up at an angle and cause undue friction on the end of the curtain and sideframe. LIFTING STRAP INSTALLATION 1. Remove the lifting strap pressure plates and hardware from the parts box. 2. The lifting straps are fastened to the roller tube, Figures 5 & 12. The lifting straps need 1 1/2 pre-wraps on the roller tube before attaching to the curtain. 3. Insert the lifting straps through all the 2” strap rings, making sure they are not twisted, Figure 14. 4. Route the straps through the bottom short lifting strap ring and attach the pressure plates and clamp the straps, Figure 15. 5. Attach pressure plates to the strap, just above the strap rings, such that the rounded curve and the head of the bolt are toward the curtain, Figure 15. 6. The straps should be snug with little or no tension applied. The curtain should not raise off the floor. 7. Repeat procedure on all the remaining straps. Retention Bar 2” Strap Rings Curtain Lifting Strap FIGURE 14-LIFTING STRAP ROUTING Pub. No. 8920PLG JANUARY 2007 9 TRAKLINE™ FOLD Model 8920PL PHOTOEYE ADJUSTMENT Pressure Plates w/Hardware Rounded Side Toward Curtain PHOTOEYE SPECIFICATIONS: 1. Locate the photoeye assemblies in the sideframe(s) and make sure they are plugged in, Figures 17 & 18. Nondrive photoeye cable is located in the 2”x6” header tube. 2. Plug in the cable from the non-drive sideframe to the header cable. Plug in the header cable and the the drive side cable into the control box cable, Figure 18. NOTE: Steps 4 and 5 will be completed during the start-up procedure. Short Straps Bottom Bar FIGURE 15-PRESSURE PLATE FASTENING SHROUD INSTALLATION 1. The header shroud is pre-installed and may need to be removed for curtain installation. 2. The shroud may include several pieces depending on door width, Figure 16. 3. After the shroud has been installed to the header, caulk the back end of the shroud to the wall to prevent rain seepage. 4. The yellow LED should be on when the thru-beam photoeye (emitter) is powered up, if not check connections, and proper terminal connections, Figure 19. 5. If the red and green LED’s on the receiver are OFF, either the beam is blocked or the photoeye is out of alignment. If necessary re-aim the photoeye by using the adjustment screws on the sideframe assembly around the photoeye, Figure 17. The bottom screw allows for vertical adjustment and the two side screws adjust horizontal alignment. Rotate the screw until the red and green LED’s turns ON. Adjust photoeye beam so it is centered on the reflector to prevent false trips. NOTE: Make sure to secure electrical cables away from counter weight, belting and pulley. Reversing photoeye must be set to “Light Mode”. This photoeye is for reversing only, not remote activation. Disconnect power before wiring photoeyes. CONTROL BOX Header Shroud Hardware For thru-beam installation with a control box, all photoeyes will have plugs that attach to the plugs on the cables that run back to the control box, Figure 18. Header Shroud Top Photoeye Header Shroud Brace Bottom Photoeye Photoeye Adjustment Screws Header Front Cover FIGURE 16-HEADER SHROUD 10 Sideframe FIGURE 17-PHOTOEYE ADJUSTMENT Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL LIMIT SWITCH ADJUSTMENT Header Grommet Header Grommet Photoeye Cable Runs Through The 2x6 Tube Thru-Beam Photoeye Cable w/2 Plugs For Integral Control Station Thru-Beam Photoeye Cable w/3 Plugs For Control Box Drive Side Thru-Beam Photoeye w/Cable and Plug For Control Box Integral Control Panel, Located in Drive Sideframe Drive Side Thru-Beam Photoeye w/Cable For Integral Control Station Non-Drive Thru-Beam Photoeye’s w/Plugs For Control Box or Integral Control Station Control Box FIGURE 18-PHOTOEYE CABLE ROUTING Yellow LEDPower Red and Green LEDAlignment 3. Measure from the floor to the bottom of the curtain with the door in the full open position, adjust the curtain to manufactured opening size. 4. Making sure everyone is clear of the door, press both the open/reset and black jog button to raise the door to the full open position. 5. Adjust open limit switch by turning the cam screw labeled #2 until the contact is in line with the cam lobe, input X0 LED will also be off, Figure 20. 6. The limit switches are normally closed, the input LED’s will be on all the time, unless the limit cam lobe is made. Light/Dark Switch Sensitivity Adjustment FIGURE 19-PHOTOEYE DETAIL INTEGRAL CONTROL STATION For thru-beam installation with a integral control panel, the non-drive sideframe photoeyes will have plugs that attach to the plugs on the cable that runs back to the control station, the driveside photoeyes, will be wired directly to the control panel, Figure 18. NOTE: Determine which drive and mount your door is to figure out which direction to turn the limits: Right Hand Drive Internal door or a Left Hand Drive External Mounted door. LIMIT SWITCH ADJUSTMENT Turn the #1 close/photoeye limit switch screw clockwise to raise the door and counter-clockwise to lower the door. NOTE: Setting the limits are based on drive location and interior or exterior mount, see following instructions. Turn the #2 open limit switch screw clockwise to raise the door and counter-clockwise to lower the door. 1. Loosen the two phillips screws and remove cover. 2. Adjust the closed limit switch, by loosening the center screw and turning the cam screw labeled #1, past the first lobe and onto the second, until you hear the contact click. Input X1 LED will also be off, Figure 20. Right Hand Drive External door or a Left Hand Drive Internal Mounted door. Turn the #1 close/photoeye limit switch screw counterclockwise to raise the door and clockwise to lower the door. Turn the #2 open limit switch screw counter-clockwise to raise the door and clockwise to lower the door. Pub. No. 8920PLG JANUARY 2007 11 TRAKLINE™ FOLD Model 8920PL SHROUD / COVER INSTALLATION 7. Fine tuning of the limits may be necessary. This will be determined by running the door up and down. 8. If the door has an optional alternate open, adjust to the desired alternate height using the same procedures as with the open and close limits, Figure 21. 9. For any reason if the limit switch plate adjustment bolts need to be loosened or replaced they should be Grade 8 bolts and torqued to 19ft/lbs. Not Used Partial Open L/S Sideframe Open L/S Close L/S FIGURE 21 Cover INSTALLATION OF SHROUD / COVERS 1. Locate drive shroud and hardware. 2. Fasten drive shroud to drive sideframe by using the 6 tek screws provided, Figure 22. 3. Install brake release lever and cord. 4. Fasten front cover by lining up holes to header brace brackets holes with the hardware provided. FIGURE 23 SIDEFRAME COVER INSTRUCTION STAND CLEAR INSTRUCTION LABEL 1. Clean wall surface where label is to be placed. 1. Install the sideframe covers that were previously removed during sideframe installation, Figure 23. 2. Peel backing away from label. 2. Repeat procedure to the opposite sideframe. 3. Apply label in proper position, Figure 23A. Sloped Shroud Conduit Holder for Control Box Cable 12” Drive Shroud 5’-0” Fasten Front Cover To Header Braces Mounting Holes Label Both Sides View of back Side Of Door Sideframe FIGURE 23A FIGURE 22-DRIVE SHROUD INSTALLATION Center Adjustment Screw Open Limit Switch Cam #2 Open Limit Switch Screw #1 Close Limit Switch Screw Contact Blocks #3 Close/Photoeye Limit Switch #1 Close/Photoeye Limit Switch 12 FIGURE 20 Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL ELECTRICAL INSTALLATION the electrical wire from the header down to the control panel or control box. Make sure to route all conduit through the bottom of the control box, Figure 21. ! WA R N I N G ! ! ! 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. 1. I M P O R TA N T ! ! ! A qualified electrician should install the wiring in accordance with local and national electrical codes. Use lockout and tagout procedures to avoid injury. I M P O R TA N T ! ! ! To reduce risk of injury or death, an earth ground connection MUST BE made to the green/yellow control box ground terminal. If metal conduit is used as the ground connector, an N.E.C. approved ground bushing and green/yellow wire MUST BE properly attached to the conduit for connection to the ground terminal. 2. 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. 3. The control box is provided with class CC protective fusing for the incoming power. 4. The incoming power terminals in the control box will not accommodate wires larger than 10AWG. 5. If possible, all control boxes should be mounted on the inside of the building regardless of door mount side on a wall adjacent to the door at approximately 54" above the floor level. All holes drilled through the control box must be through the bottom of the box, Figure 21. 6. Cables with connectors on one end are provided for the motor, brake, limit switches and photoeye’s and will need to be terminated to the control panel. The cables will be enclosed in flexible liquid tight conduit and can be attached to the conduit bracket at the top, Figure 24. 7. The motor ground cable must be grounded to the sideframe at the conduit holder using the tek screw and star washer provided, Figure 24. 8. Connect wiring as indicated by the device field wiring diagram on Pages 20-23. Incoming 3-phase power must connect into terminals L1, L2, and L3. Ground must attach to the green/yellow terminal, Figure 26. 9. For an Integral control panel, run the power supply cable (by others) into the sideframe at the control panel height. The control panel is covered with a PVC material for protection, Figure 25. 10. Turn power on and pull the E-Stop button out and press the jog (black) and open (green) button to get the door in the full open position. I M P O R TA N T ! ! ! 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. ! CAUTION !!! When drilling holes in the box, DO NOT turn control box upside down or go too deeply into the box. Damage or debris may fall into electrical components causing failure or severe equipment damage. Motor/Brake Cables Control Box Ground Cable Connector Limit Switch Cable Route all field installed wires inside the control box so that separation is maintained between line voltage wires and low voltage class II wiring. It is the responsibility of the installing electrician to be sure all local, state, and national electrical codes are met. Integral Control Box Station TM i-COMM Drive Side Photoeyes The Leading Edge in Door Safety. Milwaukee, WI (800) 456-0600 Non-Drive Side Photoeyes OPERATING PROCEDURES The OPEN/RESET Button activates the door to the full open position. Door will close automatically. RESET PROCEDURE Press the OPEN/RESET button to activate the door to the full open position and to reset the controls. The door must be reset whenever power is restored. Sideframe JOG/REFEED PROCEDURES Hold the JOG button in while pressing the OPEN/RESET button to run the door through the open and close cycles. The door must be reset whenever the jog button is pressed. Control Box Cable FIGURE 24 NOTE: The Integral control panel is standard on interior doors and is located in the drive sideframe . The control box is standard on externally mounted doors. It may be required by local electrical codes that a junction box and rigid conduit be used when running Pub. No. 8920PLG JANUARY 2007 Push Button Controls E-Stop Open Button Jog Button Example of Mounting Electrical Box Plate to Sideframe for Conduit Holder (not supplied) FIGURE 25 13 TRAKLINE™ FOLD Model 8920PL Illuminated Output LED’s Serial # Label Here INPUT/OUTPUT CHART Programming Receptacle Illuminated Input LED’s Incoming Power Terminals L1, L2, L3, Ground FIGURE 26 Before start-up of the door, the following must be completed. 1. All mounting hardware must be tightened. 2. The correct motor phase of the door has been verified. Door must open when the green open button is pressed. 3. Open and close limit switches have been adjusted. 4. Counterbalance system has been properly installed. Test door to see that it functions properly, if the weight bottoms out or hits pulley at the top, re-adjust belting. 5. 14 Curtain is placed between the V-Flex straps. 6. The lifting straps should be routed correctly and hardware tightened. 7. All photoeye’s must be adjusted with the yellow, red, and green LED’s on. 8. Make sure all activation is not wired until the door is operated to ensure that a faulty activation device is not causing the door to be inoperable. 9. With the E-Stop button pulled out, press the open/reset button to allow the door to time out and close. 10. Check that photoeye’s reverse the door. Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL COUNTER BALANCE SYSTEM The TRAKLINE PL door by RITE-HITE DOORS, INC. is equipped with a counter-balance system that is used to assist the door open in the case of a power outage. It is also used to help balance the door to reduce motor load. The Counter-Balance weight system operates in the non-drive sideframe. The system is driven by a pulley on the non-drive roller tube shaft. The weight attaches to the belting by using pressure plates and hardware. To partially raise the door in case of a power outage, simply pull on the brake release cord. Some assistance may be required on large doors. ! WA R N I N G ! ! ! 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. 1. The counter weight pulley is installed onto the shaft at the factory. 2. With the door in the open position, fasten the belting to the pulley with hardware provided. 3. Place 1 1/2 pre-wraps around the idle pulley making sure it comes off the pulley the opposite the direction that the lifting straps come off the roller tube. 4. Install the weight on blocks approximately 12” off the floor. 5. Route belting into a loop and tighten the pressure straps with the hardware provided, Figure 27. 6. Install the loop between the weight brackets and install pin and cotter pin. 7. Jog the door closed so the weight lifts up in the air. Make sure the weight is not interfering with the pulley. 8. Install the longer pvc tube over the weight, place the shorter piece on the floor and attach the two pieces. 9. Make sure the thru-beam photoeye cable is clear of the counter weight belting. ! WA R N I N G ! ! ! 10. Use caution when working with the counter weight. Make sure the belting is properly fastened to prevent it from slipping. Lifting Straps Would Be On the Front Side of the Roller Tube In This Detail Belting Pulley THRU-WALL BRAKE RELEASE The TRAKLINE can be equipped with an optional opposite Thru-Wall Brake Release system that in the case of a power outage, can be used to partially open the door. 1. Using the pulley as a guide, mark the location on the wall in line with the route of the rope, Figure 28. 2. Check the other side of the wall for clearance, if clear, drill a 1” Ø hole through the wall. If not clear, move the conduit left or right. For additional clearance while drilling, remove the shroud. 3. Insert the conduit through the wall. It may be necessary to cut the conduit to length to achieve desired end results. Insert plugs into each end of the conduit. 4. Thread rope from the handle, through the shroud, around the pulley and through the conduit. Re-install the shroud. Idler Pulley Belting Pre-Wraps (1 1/2) Roll Off Opposite Side of Pulley As The Curtain Lifting Straps Proceed to adjust limit switches as required after operating the door. The counterweight must be installed before operating the door. Failure to do this may result in the overload relay tripping out. Pressure Plates Counter Weight PVC Tube FIGURE 27-COUNTER WEIGHT DETAIL Pub. No. 8920PLG JANUARY 2007 FIGURE 28-THRU-WALL BRAKE RELEASE 15 TRAKLINE™ FOLD Model 8920PL MAINTENANCE PROCEDURES TORQUE: The brake is supplied from the factory with the nominal torque setting. BRAKE REPLACEMENT 1. Run the door to the full open position, tie the curtain in place so it will not unwind and disconnect power to the door. Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. Also barricade the work area on both sides of the door to prevent unauthorized access while servicing. 2. Loosen and remove the brake handle and the four screws holding the cover to the brake, with a short phillips screwdriver, Figure 29. 3. Remove the snap ring and the fan. 4. Disconnect the blue and brown brake wires from terminals 5 and 6 on the rectifier. 5. To remove the brake from the motor housing, loosen the 4mm allen head screws holding it in place. 6. Take note of the orientation of the brake before removing. Pull the brake straight off the motor. 7. If the hex hub needs replacing, remove the snap ring. 8. Install the new brake. 9. Insert the 4mm allen head screws and tighten. 10. 11. Replace the brake cover and tighten the four phillips screws that hold it in place and the brake handle. 12. Reconnect power and check for proper operation. NOTE: Planned maintenance programs are available for the TRAKLINE PL door. Contact your local Rite-HitE DOORS, INC. representative for details. Misc: To remove open, jog or E-stop buttons, turn the latch to the left at the top of the button with a small screwdriver. The unit will pop off. Reconnect the blue and brown brake wires to the #5 and #6 terminals on the rectifier. Polarity is not important. FIGURE 29-BRAKE WIRING CUSTOMER: RITE-HITE® DOORS PLANNED MAINTENANCE Model 8910/20/PL TRAKLINE™ TRAKLINE™ PL SO# SERIAL# Periodic Cycle Check: Planned Maintenance 1 Brake Recommended P.M. Intervals (Time Shown In Months) 4 8 12 18 24 30 • • • Chain • • Controls Covers Curtain • • • • • • Gearbox Header • • • • • • • Limit Switch Motor Photoeyes • • • • • Seals • • • • • • • • • • • Sideframe Stabilizer Bars Straps Strap Clamps (Fold Door Only) 16 • DATE: Inspect and Perform the Following (See Manual) 36 • Perform manual test by releasing brake and making sure door stops in the desired position. • Inspect for wear, tighten or replace as required. Lubricate. • Clean and check all connections. • Make sure sideframe and header covers are installed. • Clean with Isopropyl alcohol or warm soapy water. DO NOT use abrasive cleaner on vision. Make sure curtain is tracking straight. • Check for unusual noise. Check fluid level. • Check mounting hardware connections. Blow dust and debris from the header. • Check open and close positions, and chain is tight. • Check for normal operation, check connections. • Check alignment, adjust as required. Check all connections. Wipe lens or reflectors clean. • Check for wear and tear. Make sure seals are sealing at the header and sideframe locations. • Inspect for damage. Check all mounting hardware. • Inspect bars for damage, straighten or replace as required. • Inspect for wear and tear, replace as required. Make sure straps are tight, and tension pin nuts are tight. • Make sure lifting straps and clamps are tight and curtain is sealing at the floor. Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL TROUBLESHOOTING, REPAIR AND ADJUSTMENTS ITEM Activation Devices Brake Contactor MC1 Open Contactor MC2 Closed Control Box Counter-Weight Option Curtain D.O.H./D.O.W. Door Operation and Controls E-Stop Button i-COMM Controller™ Fold Door F1 Fuse F2 Fuse F3 and F4 Fuses Integral Interlock Jog Push Button Limit Switch Chain Limit Switches 208-230V Motor 460V Motor 400V Motor 575V Motor FUNCTION Operate the door system with all activation devices. Make sure that the door fully opens and closes after the time set on the re-close timer has expired. If you have wired the devices in toggle mode, operate the device twice to verify that the door will open with an activation and close with an activation. All activation devices use a set of normally open contacts. For activation questions, refer to the Activation Manual or on Page 23. If the brake is not functioning properly, check the following: a) Check F1 fuse-replace. b) Brake wiring at terminals B1 & B2 and plug in connections. c) The brake rectifier should put out 90-110VDC. d) 120V brake will have 290 ohms on normal readings. (must be checked after the rectifier). (Previous generation brakes will have 350 ohms) MC1 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. MC2 contactor is the closed contactor, and when an closed command is given the contactor pulls in and closes 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 control box is a fuse protected NEMA 4X. Standard controls include open/reset button, curtain jog button, a mushroom E-stop and auto-reclose are standard. Voltages can be 208V, 230V, 400V, 460V, and 575V 3-phase. The door can be equipped with a Counter-Weight option and in the event of a power outage the door can be opened. The material is a one-piece heat sealed vinyl curtain. Oval Vision is optional on the Fold door. The curtain consists of fiberglass stabilizer bars that maintain the door in the guide straps under normal operation. The door comes standard with an 8 1/2” tall vision located 63” off the floor. Door Opening Height or Door Opening Width The door operations are controlled by an i-COMM Universal Controller. The i-COMM is set-up and programmed during testing at the factory. Unless you are a RITE-HITE DOORS, INC. authorized service technician, you should not attempt to change the factory set program. A quick way of determining that the door is ready to operate normally is to open the control box and look for the green LED lights to be ON (Illuminated) at the X INPUTS and the Y OUTPUTS. Refer to the Input/Output logic table located on Page 14 of this manual. If the door fails to function, contact your local RITE-HITE DOORS, INC. representative or Technical Support at 563-589-2722. 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. The i-COMM controller is a circuit board that controls the actions of the door. There is a digital display that shows the cycles, status and position of the door at any time during its travel. For input and output function signals, refer to chart on Page 14. Settings can be changed for re-close or preannounce timers, interlocks, special activation commands, among many others, refer to instructional manual included. The Fold door is for exterior or interior use. A Fold door that is mounted on the exterior of a building or any interior wall except the outside wall will have the curtain attached pre-attached to the header front brace. A Fold door that is mounted internally on an outside wall of the building will have the curtain pre-attached to the header rear brace. A Fold door is standard with s/f integral controls unless it is an external mounted Fold door, which a control box is standard. The option for a control box is available on internally mounted doors. The Fold door can be equipped with either One-Way Breakaway, Two-Way breakaway or High Wind package. F1 Fuse is for 120VAC devices and receives power from the X1& X3 transformer taps. The F1 fuse protects the brake and 120VAC pre-announce devices at terminals B1, S2, and S4. The fuse is a 1amp 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 and all 24VAC activation devices. The fuse is a 2amp 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 mechanical interlock prevents both the MC1 & the MC2 contactor from being pulled in at the same time, thereby shorting out the motor. The jog push button is a constant pressure button and the door will move only when the button is pressed. It must be pressed in conjunction with the open button. When the both buttons are pressed the door will always move in the closed direction. The limit switch chain length is determined at the factory, it should be 16” long for a RHD and 18” long for a LHD door. If there is concern, check the following: a) If the chain is not aligned properly, move the smaller sprocket to align. b) If the chain makes noise, lubricate as needed. c) Chain should deflect approx. 1/4”, less may cause wear on the bearings, chain wear or slipping. The Open, Closed, Photoeye, and Alternate open limit switches are a normally closed device and should only be open when the limit switch lobe is in-line with the contact. If the switch is open when it is not in-line with the lobe, check wiring or replace the switch. 208-230V 2 HP motor will have 2.4 ohms on normal readings. 460V 2 HP motor will have 9.2 ohms on normal readings. 400V 2 HP motor will have 6.6 ohms on normal readings. 575V 2 HP motor will have 13.4 ohms on normal readings. Pub. No. 8920PLG JANUARY 2007 17 TRAKLINE™ FOLD Model 8920PL TROUBLESHOOTING, REPAIR AND ADJUSTMENTS ITEM Motor Phasing FUNCTION 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, U and W Motor will not run If door will run will given an activation, check the following: a) Faulty or tripped O/L1 overload relay. b) Faulty MC1 or MC2 contactors. c) Check voltage and for loose wires at terminals, U, V, and W and wires on the contactors and overload relay. d) Check limit switch, if the 2 screws holding the contacts in place are too tight, it may cause the contact to stick, thereby causing the door not to run. O.D.H./O.D.W. Ordered Door Height or Ordered Door Width One-Way Breakaway A door built with the One-Way Breakaway can only be broken away from the wall. A door that is impacted toward the wall can be damaged. The inside edge of the sideframes are mounted at 1/2 O.D.W. plus 7 3/8” from the centerline of the door jamb. The length of the header braces will be O.D.W. plus 14 3/4”. The opening is clear of any door components. Open Push Button When the open push button is pressed, a command to open the door is given. Overload Relay O/L1 The O/L1 overload relay supply's 24VAC to the CR1 relay and the open/reset button. If the overload trips, 24VAC to 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 O/L1 overload relay before it reaches the MC1, MC2 contactor's, if the contactor's are not receiving the correct voltage, check the O/L1 overload for proper voltage. Fuses may blow if pins are not clipped. The O/L1 overload should be set to the following settings: a) 208V 4.2 Amps (Size > 144) b) 208V 3.8 Amps (Size =< 144) c) 230V-240V-3.7 Amps d) 380V-415V-2.1 Amps e) 460V-480V-1.8 Amps f) 575V-1.5 Amps Relay CR2 CR2-24VAC single pole relay is optional and is required when pre-announce to close is chosen. Reversing Photoeyes The door is equipped with 2 sets of thru-beam photoeyes that monitor each side of the door. When the beam is broken or blocked, the door will reverse and stay open until the object blocking the photoeye beam is removed or the photoeyes are lined up to send a signal to the i-COMM to allow the door to close. 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 three lights on the photoeyes. Yellow is for power. Red and green should be on for proper alignment, if the eyes are not aligned properly, turn the adjustment screws. The receiver photoeye is 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 autoreclose. Thru-Wall Brake Release Option The door can be equipped with a Thru-Wall Brake Release option in conjunction with the counterweight option. In the event of a power outage, opening of the door can be completed from the opposite side of the wall. Transformer The standard transformer is a tri-volt transformer that takes an incoming voltage of 208, 230, 460V and converts it to 110VAC & 24VAC. An optional transformer is available for 380V, 415V, 575V doors. a) 208V(Taps H1-H2) 6.8 Ohms b) 230V(Taps H1-H3) 7.5 Ohms c) 380V(Taps H1-H2) 18.4 Ohms d) 460V(Taps H1-H4) 27 Ohms e) 415V(Taps H1-H3) 20.5 Ohms f) 575V(Taps H1-H4) 29 Ohms g) 120V(Taps X1-X3) 4.4-4.8 Ohms h) 24V(Taps X1-X2) .4 to .6 Ohms Two-Way Breakaway A door built for Two-Way Breakaway can be impacted in either direction. The inside edge of the sideframes are mounted at 1/2 O.D.W. from the centerline of the door jamb. The opening will be infringed upon by 7” the full height of the door by the “V”-Flex strap guides and 7 3/8” at the bottom by the guide brackets on each side of the door. The length of the header braces will be O.D.W. V-Flex™ Curtain Release System The door is equipped with the V-Flex curtain release system. The system of straps run vertically along the sideframe and guide the curtain. When impacted the V-Flex straps will flex allowing the curtain to be released with little or no damage to the door or customer product. These straps MUST BE kept taut to prevent damage to the curtain. Verify Door Operation It is recommended that the operation of all controls on the TRAKLINE door be verified monthly. Wind Pressure If the curtain is blowing out because of high wind or negative pressures, check the following: a) The V-Flex belting straps should have a minimum of 70ft/lbs on doors 10’ D.O.H. and 170ft/lbs on doors 24’ D.O.H. b) Check to make sure the curtain has all the stabilizer bars in place and not bent. c) If wind or pressure exceeds 35 thru 45 mph, the door may blow out. OPERATING PROCEDURE 1. 2. 18 To operate the door, simply press the green open button on the front of the control box, the door should go to the full open position. Normal settings are set to auto-reclose, and once the open button is pressed the door will open, time out per the setting of the re-close timer on the i-COMM and close. 3. The door can be equipped with several types of activation devices that can open or close the door and can be setup to either auto-reclose or toggle mode. 4. For toggle mode, the door can be setup such that if a device is used to open the door, it or another device needs to be reactivated to close the door. Pub. No. 8920PLG JANUARY 2007 TRAKLINE™ FOLD Model 8920PL DRIVE SYSTEM INFORMATION 1. Rewire motor per, Figure 30. 2. Replace overload per voltage change. 1. Wire activation devices after door is operational. 3. Change transformer taps per electrical diagram and according to the power supply available. 2. Verify operation of all activation devices. 4. Change fuse sizes per control box drawing. ACTIVATION DEVICE INSTALLATION Route Limit Switch Cable Through the Back of the Plate Spot Ground Flat on Limit Shaft for Set Screw Jumper Wires .31 Ref. Must be Aligned with the 30 Tooth Sprocket n/a Alt Open L/S Open L/S Closed L/S Black Wire Red Wire Green Wire White Wire OPTIONAL ALTERNATE OPEN LIMIT SWITCH WIRING Jumper Wire Green Wire Black Wire White Wire STANDARD LIMIT SWITCH WIRING 208V-230V 460V 400V/575V FIGURE 30-MOTOR VOLTAGE WIRING Pub. No. 8920PLG JANUARY 2007 19 20 PRIOR 2006 7818-E-009 REV. K 16 GA. / 7 CONDUCTOR CABLE 18 GA. / 3 CONDUCTOR CABLE 22 GA. / 5 CONDUCTOR CABLE 1/9/2006 4994 2/20/2006 RPB 7818E034 9"=1' 7818E034 i-COMM CONTROLS EXTERNAL FIELD WIRING DIAGRAM TRAKLINE - ROLL & FOLD-ENCLOSURE N EUROPEAN ONLY 18 GA. / 2 CONDUCTOR CABLE TRAKLINE™ FOLD Model 8920PL FIELD WIRING DIAGRAM-CONTROL BOX Pub. No. 8920PLG JANUARY 2007 Pub. No. 8920PLG JANUARY 2007 PRIOR 2006 7818-E-007 REV. K 16 GA. / 6 CONDUCTOR CABLE 18 GA. / 3 CONDUCTOR CABLE 1/9/2006 4994 2/20/2006 RPB 6"=1' 7818E033 TRAKLINE - ROLL & FOLD-SIDEFRAME CONTROLS EXTERNAL FIELD WIRING DIAGRAM, i-COMM N EUROPEAN ONLY TRAKLINE™ FOLD Model 8920PL FIELD WIRING DIAGRAM-CONTROL PANEL 21 22 CONNECTOR TABLE J5 J4 J3 LOOP INPUT (X13) 6 LOOP INPUT 1 2 DC POWER OUT LOOP INPUT 2 DC POWER OUT 1 3 5 OPEN OUTPUT (K0) 8 DC COMMON OUT CLOSE OUTPUT (K1) 4 24V AC COMMON (N) OPEN/CLOSE COMMON 7 24V AC INPUT 4 6 DC POWER INPUT 2 5 UNUSED DC COMMON INPUT 1 RESET INPUT (X12) 4 3 DC POWER OUT UNUSED OUTPUT I-ZONE ALARM OUT 2 3 1 24 VDC 24 VDC 24 VDC 24 VDC 24 VAC 24 VAC N 24 VAC 24 VAC 24 VDC 0 VDC 24 VDC 24 VDC 0 VDC 0 VDC THIS TABLE SHOWS THE FUNCTION OF EACH OF THE CONNECTORS ON THE UNIVERSAL CONTROLLER. THE VOLTAGES LISTED FOR EACH PIN ASSUME THAT EITHER THE INPUT OR OUTPUT IS ACTIVATED. CONN. PIN # FUNCTION VOLTAGE PRIOR 2005 7818-E-010 REV. K 10/13/2005 4994 2/20/2006 RPB 7818E030 A A 9"=1' i-COMM 5065 SEE ABOVE 7818E030 WIRING DIAGRAM TRAKLINE - ROLL & FOLD CORRECT J3 ER. DEPICTION 1 of 1 1 of 1 7/21/2006 NCN A TRAKLINE™ FOLD Model 8920PL WIRING DIAGRAM-CONTROL BOX & PANEL Pub. No. 8920PLG JANUARY 2007 2006 7804E035 Pub. No. 8920PLG JANUARY 2007 2/3/2006 5009 4/18/2006 8"=1' 7804E035 PROTECDOR/TRAKLINE SERIES ACTIVATION WIRING i-COMM I-ZONE & INTERLOCK CORRECTIONS 4994 2/20/2006 A A RPB A TRAKLINE™ FOLD Model 8920PL ACTIVATION WIRING DIAGRAM 23 TRAKLINE™ FOLD Model 8920PL ARCHITECTURAL DRAWING 24 Pub. No. 8920PLG JANUARY 2007