R
Y
T
E
Turbo-Seal
Insulated
Installation Manual
P.O. Box 403, One Cedar Parkway, Jackson, WI 53037
Phone: 262-677-9046
Fax: 262-677-2058
Rytec Website: www.rytecdoors.com, Rytec On-line store: www.rytecparts.com
Rytec E mail: helpdesk@rytecdoors.com, Parts E mail: Parts@rytecdoors.com
[Revision: December 2nd, 2014, R11701100, ©Rytec Corporation 2010]
C
TABLE OF CONTENTS
PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MATERIAL, TOOLS, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fill-In Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL ARRANGEMENT OF
DOOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COUNTERWEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DOOR SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 13
DOOR OPEN- AND CLOSE-LIMIT POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT . . . . . . . . . . . . 14
Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 15
KILL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RESETTING BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PATHWATCH LED™ WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR CURTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SIDE COLUMN HEATED BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Insulated Panel Travel - Shimming Panel……………………...……………………21
INTRODUCTION
INTRODUCTION
The information contained in this manual will allow you
to install your Rytec Turbo-Seal Insulated® Door in a
manner that will ensure maximum life and trouble-free
operation.
Any unauthorized changes in procedure, or failure to follow the steps as outlined in this manual, will automatically 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 operation 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 UNDERSTAND THE INSTRUCTIONS CONTAINED IN THIS
MANUAL.
If you have any questions, contact your Rytec representative or call the Rytec Technical Support Department at
800-628-1909. Always refer to the serial number of the
door when calling the representative or Technical Support. The serial number plate is located inside one of the
side columns.
NOTE: NOTE is used to provide additional information to aid in the performance of the
procedure or operation of the door, but not
necessarily safety related.
DOOR SERIAL NUMBER(S)
To obtain your DOOR SERIAL NUMBER, there are
three universal locations where this information can be
found. These are on the door of the System 4 control
panel, the left side column (remove lower side column
cover) at approximately eye level and the drive motor.
(See Figure 1.)
IMPORTANT: When installing multiple doors
of the same model but in different sizes, verify the serial number in the control panel with the
one in the side column.
System 4
Control
Panel
Drive Motor
Gearbox Assembly
Lifting
Pockets
A wiring schematic is provided with each individual
door, specifically covering the control and electrical
components of that door.
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader to potentially hazardous situations, or situations where additional information to successfully perform the procedure is presented:
Air Curtains
Left Side Column
With Heated Blower
WARNING is used to indicate the potential
for personal injury, if the procedure is not
performed as described.
Right Side Column
With Heated Blower
A8700065
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.
Figure 1
NOTE: The lifting pockets mounted to the top of
the head assembly are there for forklift
operation only. It’s not necessary to
remove
the
lifting
pockets
after
installation.
1
INSTALLATION—MATERIAL, TOOLS, AND EQUIPMENT
INSTALLATION
Electrician’s Responsibilities
MATERIAL, TOOLS, AND EQUIPMENT
For complete details on the responsibilities of the electrician, refer to the Rytec System 4 Drive & Control
Installation & Owner’s Manual.
1. Threaded rod (¹/₂-in. diameter) and other various
wall anchor hardware and material. Concrete
anchor bolts (¹/₂-in. diameter).
(See “ANCHORING METHODS” on page 3.)
2. Assorted shim stock.
3. Double-sided tape (to temporarily hold shims).
1. Install fused disconnect and Rytec control panel.
(See Figure 2 for typical installation.)
2. Install all necessary conduit tubing.
NOTE: Separate high and low voltage conduit.
4. Carpenter’s or spirit level (4-ft. minimum length).
3. Run electrical power lines to disconnect.
5. Carpenter’s square.
4. Run power lines from disconnect to control panel.
6. Fish tape.
5. Run power lines from control panel to upper junction box.
7. Hammer drill.
8. Masonry drill bit (for ¹/₂-in. diameter anchors).
9. Three or four bar clamps (48-in. long).
10. Hammer or mallet, and block of wood.
11. Crowbar or pry bar.
12. Assorted hand tools (pliers, tape measure, etc.).
13. Socket and wrench sets.
14. Water level, line level, or transit.
15. Two ladders (taller than height of door opening).
16. Forklift (see “Forklift Requirements”).
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. Two installers.
2. An electrician is required for making all electrical
connections. (See “Electrician’s Responsibilities”.)
NOTE: All electrical work must be performed in
accordance with local and state building
codes.
3. 100% accessibility to the door opening during the
entire installation process. No traffic should be
allowed to pass through the opening while the door
is being installed.
Forklift Requirements
A forklift supplied by the customer, dealer, or installer is
mandatory for the safe and proper installation of this
door. The forklift should have:
• 4,000-pound lift capacity.
• minimum height ability — door height plus 42 in.;
39 in. if lifting pockets are removed.
• side-shift capability (desired).
2
6. Run power lines from control panel to door motor.
7. Run low-voltage cables from door to control panel.
8. Mount rear photo eyes.
9. Wire low-voltage safety devices and activators (if
used).
High and low voltage wires/cables in separate metal
conduit run to the bottom of the System 4 control panel.
All wires/cables cut to length DO NOT leave excess
wire/cable loops on the door or in the control panel.
Fill-In Material Requirements
Some applications may require the use of a door pullout
(extension) to gain clearance of an existing obstruction
between the door and the door opening. The following
materials can be used to fill the space or gap between
the door and the door opening.
1. 16-gauge hot-rolled sheet steel.
2. 2-in. x 2-in. x ³/₁₆-in. angle iron.
3. Insulated panels.
NOTE: If any pullout or buildout is used in the
installation it must be insulated to prevent
frost and ice buildup on or in the door. Failure to properly insulate the pullout can
affect the operation of the Turbo-Seal
Insulated door.
It is very important to seal and caulk
around the pullouts to prevent frost and ice
buildup.
INSTALLATION—GENERAL ARRANGEMENT OF DOOR COMPONENTS
GENERAL ARRANGEMENT OF
DOOR COMPONENTS
Figure 2 shows the location of the major components of
the door and the general placement of the associated
sub-assemblies for a typical installation.
This illustration is provided to you for informational purposes only. It should not be relied upon solely during the
installation of your door and its sub-assemblies.
Head Assembly (Includes
Drive Motor Gearbox Assembly,
Fabric Roll)
Fused
Disconnect
A8700042
Lifting
Pockets
Figure 3
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.
System 4
Control
Panel
Air curtains
Bottom Bar
Assembly
Left Side Column with
Heated Blower (Includes Serial
Number Plate, Counterweight,
and Patchwatch LED)
Right Side Column with
Heated Blower (Includes
Counterweight and Patchwatch LED)
Figure 2
NOTE: Figure 2 shows the front side of the door.
Left and right are determined when viewing the front side of the door.
Figure 4 through Figure 7 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 are the responsibility of
the door owner. If you have any questions, call your
Rytec representative or the Rytec Technical Support
Department 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.
If expansion anchors are used, a quarterly
inspection should be implemented for safe
and secure door operation.
Concrete, Block, or Brick Walls
UNCRATING
Your Rytec door has been crated to allow for minimal
handling of assemblies during the installation process.
NOTE: Remove parts and sub-assemblies from
the shipping crate in the order directed
throughout this manual.
Concrete Wall
Side
Column
Expansion
Anchor
1. Remove the top of the crate.
2. Remove the front of the crate. (See Figure 3.)
A0500005
Figure 4
Patchwatch LED™ is owned by Rytec High Performance Doors.
3
INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING
LOCATING CENTERLINE OF DOOR OPENING
Wood, Block, Brick, or Insulated Walls
Wood
Wall
Side
Column
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.
Crush Plate
(¹/₂-in. Thick,
6-in. x 8-in.
Steel)
2. Divide the measurement in half to locate the centerline. Then mark the centerline along the floor.
(See Figure 8.)
Through Bolt
or Threaded Rod
A0500037
Figure 5
Centerline of
Opening
Insulated Wall
Insulated Wall
Side
Column
Through Bolt
or Threaded Rod
Overall Width
of Door Opening
A0500001
Half Width of
Door Opening
Figure 8
LOCATING SIDE COLUMNS
Aluminum-Clad Lumber
(Front and Back Sides — Full Length)
A0500039
Figure 6
2. Using the centerline as a reference point, lay out
and mark half of the door’s production width along
the floor. (See Figure 9.)
Insulated
Wall
Through Bolt
or Threaded Rod
Side
Column
Aluminum-Clad Lumber
(Back Side — Full Length)
A0500038
Figure 7
4
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 production width of your door. Verify the dimension provided by measuring the width (length) of the head
assembly.
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 representative or the Rytec Technical Support
Department at 800-628-1909.
INSTALLATION—SIDE COLUMNS
Half of Door
Production
Width
Centerline of
Opening
This Dimension
Must Be Equal
on Both Sides
of Door Opening
Extend and Mark
Edges of Door Along Floor
Water Level
A0500002
Shim Plate
(If Required)
Figure 9
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-toside. If one side of the opening is higher than the
other, a shim under the side column will be required.
Figure 10 and Figure 11 show two methods that
can be used to ensure level side columns.
A0500004
Figure 11
SIDE COLUMNS
The following procedure details the installation of the
side columns in standard and freezer door applications.
They are virtually the same except that the freezer door
will come with insulated channels.
NOTE: Contact the Rytec Technical Department if
the floor is more than 1 in. out of level.
Side columns are extremely heavy; use
proper lifting and support equipment
when removing from crate. Personal injury
may result from using improper handling
procedures.
Line Level
1. Remove the right side column from the shipping
crate.
2.
Remove the covers from the side column by removing the screws that hold the covers in place. Save all
hardware for later use.
3. Stand the right side column on the floor. Place it
against the wall, just outside the line indicating the
production width of the door. Use bar clamps as
needed. (See Figure 12.)
This Dimension Must Be
Equal on Both Sides of
Door Opening
Shim Plate
(If Required)
A0500003
Figure 10
5
INSTALLATION—SIDE COLUMNS
IMPORTANT: It is critical that the side columns
are mounted square and plumb
with the wall, and level across
the door opening. Using a 4-foot
level and carpenter’s square will
help ensure the columns are correctly set. Place shims where
necessary.
In addition, the use of bar clamps
will allow you to temporarily
secure the columns to the wall,
while allowing you to make slight
adjustments during the installation process.
Anchor Point
Carpenter’s
Level
Right Side
Column
Before drilling any holes, ensure there are
no electrical wires, water pipes, or gas
lines, etc., buried in the floor or hidden in
the wall.
4. Once the side column is set plumb and square,
anchor it to the wall and floor. Predrilled anchor
points have been provided in the side column. DO
NOT securely tighten the anchors at this time —
they will be tightened later on after the head assembly is installed. (See Figure 12 and Figure 13.)
NOTE: Use ¹/₂-in. expansion shell or stud-type
anchors for concrete walls. Use through
bolts or threaded rods for brick walls and
other applications where expansion
anchors are not appropriate.
If a stud-type anchor is used for the bottom
anchor, the anchor must not extend more
that 1¹/₂ in. above the base plate of the side
column.
A8700004
Production Width Line
Figure 12
5. Mount the left side column to the wall and floor in
the same manner that was used for installing the
right side column.
6. With both columns set and snugly bolted in place,
check the overall squareness of each column.
(See Figure 13.)
Compare the diagonal measurements and the
upper and lower horizontal measurements across
the columns. The columns are square and parallel
when the diagonal measurements are equal and
the horizontal measurements are equal.
If either column requires a slight repositioning
(when the difference of either comparison is
greater than ¹/₄ in.), use a block of wood and a mallet to nudge the column into position.
6
INSTALLATION—HEAD ASSEMBLY
The head assembly is extremely heavy;
use proper lifting and support equipment
when removing from crate. Personal injury
may result from using improper handling
procedures.
Horizontal Measurements
Must Be Equidistant.
Secure the head assembly to the forklift
prior to lifting it to the top of the side columns.
Diagonal
Measurements
Must Be
Equidistant
2. Lift head assembly into position by using one of two
methods:
a. Use the fork pockets on top of the head assembly. The lifting pockets are provided to prevent
damage to the foam panel. (See Figure 15.)
NOTE: Personal injury or equipment damage may
result from the head assembly not being
secured.
A8700037
Figure 13
HEAD ASSEMBLY
1. Remove head assembly from crate.
(See Figure 14.)
Fork
Pockets
Head
Assembly
A8700044
Figure 15
A8700043
Figure 14
b. For overhead clearance problems, secure head
assembly with C-clamps and a strap from the
rear spreader to the forks of the forklift or
mechanical lift before lifting it into position. (See
Figure 16 and Figure 17.)
NOTE: Personal injury or equipment damage may
result from the head assembly not being
secured.
To prevent damage to door components,
use cloth or packing material between the
forks and the head assembly. Pay close
attention to the foam door panel.
7
INSTALLATION—HEAD ASSEMBLY
Forks
4. Attach head assembly to each side column. Hardware is located in the small parts carton.
Strap
a. Install two ³/₈-16 x 1¹/₄-in. hex flange machine
screws and ³/₈-16 serrated flange hex lock nuts.
Install machine screws from the bottom of the
side column. (See Figure 19.)
NOTE: Items have been removed for clarity.
A8700045
Figure 16
Forks
C-Clamps
Hex Flange Machine Screws
and Serrated Flange Lock Nuts
A8700051
Figure 19
b. Install five ³/₈-16 x 1¹/₄-in. hex flange machine
screws. (See Figure 20.)
A8700046
Figure 17
3.
With the head assembly safely secured to the forklift, place it on top of the side columns. Line up the
alignment pin on the head assembly with the alignment hole in the side column. (See Figure 18.)
NOTE: Items have been removed for clarity.
Hex Flange Machine Screws
Alignment Pin Inserted
in Alignment Hole
Hex Flange Machine Screws
(Two Installed from Bottom)
Head
Assembly
A8700051
Figure 20
5. Once the head assembly is set plumb and square,
anchor it to the wall.
A8700015
Figure 18
8
INSTALLATION—COUNTERWEIGHTS
NOTE: Anchor points in the head assembly are
predrilled at the factory for the load bearing cross-sectional area. Do not add additional points for mounting. Please consult
your Rytec representative or call the
Rytec Technical Support Department at
800-628-1909 with questions.
6. After the head assembly is secured to both side columns, securely tighten all floor and wall anchors.
7. Unclamp the head assembly from the forklift and
then remove the forklift.
8. Remove the bar clamps that were used to secure
the side columns to the wall.
COUNTERWEIGHTS
A counterweight can weigh in excess of
100 pounds. Make sure that safe handling
procedures are followed and that each
counterweight is securely supported during its installation. If not handled properly,
a counterweight can damage door components and cause serious personal injury.
6 to 8 in.
A8700012
Figure 21
3. Install counterweight guide plate toward the rear of
the column. (See Figure 22.)
1. Place a counterweight in the bottom of each side
column.
2. Securely block each counterweight 6 to 8 in. above
the bottom of the side column. (See Figure 21.)
Guide
Plate
At this point the counterweight is free
standing. Secure counterweight from falling over while installing the guide plate
assembly. Personal injury can result.
NOTE: For photo purpose, the guide plate is shown
and should NOT be installed at this time.
A8700007
Figure 22
4. Swing guide plate up for installation.
(See Figure 23.)
9
INSTALLATION—COUNTERWEIGHTS
Counterweight
Strap
Guide
Plate
Plastic
Tie
Swing Up
A8700008
A8700047
Figure 23
Figure 25
5. Set mounting plate on top of the guide plate.
6. Secure mounting plate and guide plate to the counterweight with two ³/₈-16 UNC x 1³/₄ hex head cap
screws and ³/₈ in. split lock washers.
(See Figure 24.)
8.
Route counterweight strap over idler pulley and
feed through access hole in the head assembly.
(See Figure 26.)
NOTE: The counterweight strap is installed at the
factory. The factory standard is three prewraps around the counterweight spool.
Mounting
Plate
Guide
Plate
Hex Head Cap Screws
with Split Lock Washers
NOTE: Items have been removed for clarity.
Counterweight
Strap Spool
Counterweight
Idler
Pulley
Counterweight
Strap
Guide
Roller
A8700055
Figure 26
A8700006
Figure 24
7. Remove the plastic tie from each counterweight
strap. (See Figure 25.)
NOTE: Door must be in the fully open position.
10
9.
With the straps hanging straight, attach them to the
counterweights using two ³/₈-16 UNC x 1³/₄ hex head
cap screws, ³/₈ in. split lock washers, and clamp bars
provided in the small parts carton. Route the straps
through the clamp bars as shown in Figure 27.
INSTALLATION—ANTENNA
IMPORTANT: The 6 to 8 in. mounting height for
each counterweight, as indicated in Figure 21, is adequate
for most Turbo-Seal Insulated
Doors. However, for extra-wide
or -short doors, the counterweights may have to be adjusted
closer to the bottom of the side
column.
To check the position of each
counterweight, first release the
motor brake by pulling on the
brake release cable. Then manually move the door to its fully
closed position. The clearance
between the top of each counterweight and the top of its associated side column must be at
least 2 in.
If an adjustment is necessary,
move the door to the fully open
position. After placing a support
block under the counterweight,
readjust the strap, as required,
until the 2-in. clearance is
achieved.
Counterweight
Strap
Hex Head
Cap Screws
10. Tighten the clamp bars to secure each strap. Then
carefully remove the support block from under each
counterweight to allow the weights to hang free. If
necessary, readjust the straps.
11. After all adjustments are complete, cut off any
excess strap to within 6 in. of the upper clamp bar.
Use tape or a tie strap to attach the loose end of
each strap to the main length of strap.
12. Secure bottom guide plate to the counterweight
with two ³/₈-16 UNC x 1³/₄ hex head cap screws and
³/₈ in. split lock washers.
13. Attach the side column covers using the saved
hardware.
ANTENNA
IMPORTANT: The antenna is a fragile and highly
sensitive instrument. Extreme care
should be used in handling this
piece of equipment.
1. Remove antenna from small parts carton.
2. Carefully remove packing material from antenna.
Inspect for damage.
NOTE: Do not install antenna if it is found to be
damaged. Call your local Rytec representative or the Technical Support Department at
800-628-1909 for a replacement.
3. Remove machine screw from the bottom of the side
column. (See Figure 28.)
Split Lock
Washer
Clamp
Bars
Machine
Screw
Counterweight
A8700052
Figure 28
A8700009
Figure 27
11
INSTALLATION—ENCODER
4. Install antenna mounting bracket to side column
along with machine screw previously removed.
Socket Head
Cap Screw
5. Install antenna onto mounting angle and secure
with two M4 x 12 mm Phillips flathead machine
screws, M4 flat washers, and M4 hex head nuts.
Hardware is located in the small parts carton.
6. Route antenna cable over side column to the
encoder. (See Figure 29.)
NOTE: To secure antenna cable, use plastic ties
as required.
Split Lock
Washer
Encoder
Feig
Encoder
Hub Shaft
Encoder
Coupling
Shaft
Mounting
Bracket
Machine
Screw
To Wireless
Antenna
Encoder
Mounting
Plate
Eurodrive
Washer
Antenna
A9800016
Figure 30
DOOR SEALING
ENCODER
Foam insulation is built into the side column. The insulation is a technical and important item in the proper
operation of the Turbo-Seal Insulated Door. From the
moment the door is uncrated until the door is installed,
strict care should be taken not to damage the insulation
on the back side of the side column. (See Figure 31.)
1. Install the Feig encoder hub shaft end to the end of
the encoder coupling shaft and tighten set screw.
The Feig encoder hub can be found in the small
parts carton.
In addition to the insulation, a thermal break foam core
is constructed into the components of the door assembly. This gives the door an extra barrier to combat
against temperature differential. (See Figure 32.)
NOTE: The Eurodrive washer, split lock washer,
and encoder coupling shaft are factory
installed on the gearbox. Use a mild
thread locker on set screw.
For a tight and air-proof seal, a bead of caulk should be
applied at the inside perimeter of the door assembly.
Use a construction grade of caulk to seal the door.
Nut, Washer, and
Machine Screw
A8700020
Figure 29
2. Install encoder mounting plate with encoder using
four M8 x 1.25 x 18 mm socket head cap screws.
3. Connect encoder cable to encoder.
4. Install plastic zip tie into socket head screw and
secure the encoder cable. (See Figure 30.)
NOTE: The zip tie that is used to secure the
encoder cable is of special design. The
ribbed end inserts into the valley of the
socket head cap screw.
All hardware is located in the small parts
carton.
12
IMPORTANT: Use caulk as directed per manufacturer’s instructions. Improper
wall preparation may result in
poor adhesion. The door may
not be altered in any form to
apply caulk.
INSTALLATION—CONTROL PANEL AND ELECTRICAL CONNECTIONS
NOTE: Foam insulation is shaded in gray.
Wall
Foam
Insulation
Foam
Insulation
NOTE: If a floor loop is used, all wiring from the
fused disconnect to the control box and
from the control box to the motor mount
side column, as well as conduit running
from the control box to the floor, is provided by the door owner/installer or the
electrician. All wiring and conduit must
meet all local and state codes. Wires provided with the door are labeled with terminal or contact numbers.
DOOR OPEN- AND CLOSE-LIMIT POSITIONS
See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The close- and open-limit
door positions are detailed below.
Close-Limit Position
Foam
Insulation
The close-limit position should be adjusted so that the
door travel allows the black vinyl loop on the bottom bar
to gently seal against the floor. (See Figure 33.)
DO NOT allow the rubber reversing edge, enclosed in
the black vinyl loop, to come in contact with the floor.
A8700032
Figure 31
Foam Core
Damage to the rubber reversing edge or
other bottom bar parts can occur if the
door seal is allowed to seal too tightly
against the floor.
Foam Panel
A8700038
Figure 32
Foam End Tab
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec System 4 Drive & Control Installation & Owner’s Manual for
information on control panel installation, electrical connections, door limit settings, and initial door start-up procedure.
Black Vinyl
Loop
A8700079
Figure 33
13
INSTALLATION—REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT
Open-Limit Position
Reversing Edge Switch Air Bleed Check
When the door is knocked out of position, the System 4
Drive & Control takes over and will raise the tabs high
enough to be reinserted into the side columns. The
open-limit switch should be adjusted so that the door
travel allows a minimum of half the foam breakaway
tab into the yellow channel guides of each side column.
(See Figure 34.)
The disconnect must be in the OFF position and properly locked and tagged before
performing the following procedure.
1. The reversing edge switch is located inside the bottom bar assembly, on the end opposite the drive
motor. To inspect and adjust the switch, remove the
access cover from the face of the bottom bar
assembly. (See Figure 35.)
Access Cover
Foam End Tab
Yellow Channel
Guide
Bottom Bar
Assembly
A8700080
Figure 34
REVERSING EDGE SWITCH INSPECTION AND
ADJUSTMENT
A8700080
Figure 35
Do not stand under the door panel when
testing the reversing edge. If the reversing
edge switch is not working properly, the
panel could strike personnel and cause
injury.
To check the reversing edge switch, run the door
through the down cycle. As the door is lowered, tap the
bottom of the reversing edge. The door is set up from
the factory for 3 impacts of the reversing edge before
remaining open. If the reversing edge is tripped 3 times
consecutively the door will remain open and code F:361
will appear on the display. Push and hold the STOP/
RESET button 3 to 5 seconds and the control will reset.
Push the down arrow to close the door.
If the door does not reverse direction, check the air
bleed and sensitivity of the reversing edge switch.
14
2. Make sure the clear PVC hose is in tight contact
with the air input post so that air leakage cannot
occur and that vibration will not cause the hose to
fall off. Also make sure the hose is not kinked.
(See Figure 36.)
INSTALLATION—KILL SWITCH INSPECTION
Reversing
Edge Switch
(On Side
Opposite
Door Motor)
Air Bleed
Adjustment
Screw
2. Turn the sensitivity adjustment screw clockwise until
continuity is achieved. Then turn the sensitivity
screw 2 full turns counterclockwise for a standard
setting. Some doors may require a further adjustment counterclockwise. (See Figure 37.)
NOTE: Testing the reversing edge is the best way
to determine sensitivity.
3. Reattach the wires and resistor; then replace the
access cover.
NOTE: If the reversing edge is too sensitive, the
door may reverse direction during the closing cycle without coming in contact with an
object. If this occurs, readjust the reversing edge switch.
PVC Hose — Must Be Tight
on Lower Input Hose
A7500227
Figure 36
3.
The air bleed has been set at the factory and should
not require adjustment. If adjustment is necessary,
turn the air bleed adjustment screws located on the
front and back of the switch fully clockwise — but do
not overtighten. Then turn each screw back (counterclockwise) one full turn.
KILL SWITCH INSPECTION
Kill switches have been mounted at each end of the bottom bar assembly. The purpose of these switches is to
prevent the door from being operated if the breakaway
bottom bar becomes separated from one or both of the
side columns.
Reversing Edge Switch Sensitivity Adjustment
The disconnect must be in the OFF position and properly locked and tagged before
performing the following procedure.
1. The reversing edge switch is a normally open contact. The PVC hose is on the lower air input post. To
adjust the switch, first remove the resistor from the
contact terminals and attach an ohmmeter across
the two terminals. (See Figure 37.)
Reversing
Edge Switch
Resistor
Remove Resistor
to Test and
Adjust Switch
Sensitivity
Adjustment Screw
Take precautions to prevent the door from
being opened or closed while performing
the following procedure.
1. Move the door so that the bottom bar assembly is
approximately head or chest height.
2. Push the breakaway bottom bar out of the side column. It should not be possible to restart the door.
If the kill switch operated properly: Reinstall the
bottom bar into the side column. (See “RESETTING BOTTOM BAR” on page 16)
If the kill switch did not operate properly: Check
wiring. If wiring is OK, repair or replace the switch.
Performing this adjustment without the
door in the JOG MODE may cause personal injury or death.
A7500227
Figure 37
15
INSTALLATION—RESETTING BOTTOM BAR
Whisker Switch
Bottom Bar
Assembly
NOTE: Should the door panel have been damaged during the impact, remove the door
from service and repair. If you have any
questions, contact your Rytec representative or call the Rytec Technical Support
Department at 800-628-1909.
Foam Breakaway Tab
Foam Tabs Out
of Side Column
A8700003
Figure 38
Side Column
Channel
A8700081
Foam Breakaway Tab
Figure 40
2. The door panel will momentarily pause and then
execute the reset procedure.
3. The door panel’s foam breakaway tabs will roll
upward above the side column’s channel. (See
Figure 41.)
Bottom Bar
Assembly
Foam Breakaway Tab
A8700081
Figure 39
RESETTING BOTTOM BAR
The Turbo-Seal Insulated Door is a fully automated selfresetting door. After a strike and a clear sensor path, the
door will automatically reset the bottom bar. The process goes as follows:
1. The foam breakaway tabs have popped out of the
side column’s channel due to impact. (See Figure
40.)
Side Column
Channel
A8700071
Figure 41
16
INSTALLATION—PATHWATCH LED™ WARNING LIGHTS
4. The photo eye senses if the path is clear of any
obstructions.
5. Then the door panel will guide itself into the channel
and resume its normal operation.
(See Figure 42.)
NOTE: The Pathwatch LED’s are already preinstalled in the side columns at the factory.
Be sure to route cables away from all moving parts. Use cable ties as required.
Door Panel Has Been Reset
and Is Shown in Normal
Operating Position
Amber and Red Pathwatch
LED Warning Lights
RY-WI Cover
A8700017
Figure 43
Front
A8700080
Figure 42
NOTE: The door function is fully automatic; it will
reset, rise to the open position, and reinsert the bottom bar according to factoryinstalled parameters. Cycling the door and
checking for proper door operation is not
required unless prescribed, but an occasional test of the self-repair system would
ensure its proper operation. Should slight
adjustments of the door be needed,
please contact your Rytec Technical Support at 800-628-1909.
PATHWATCH LED™ WARNING LIGHTS
The standard setting for the warning lights is: 3 seconds
prior to the door closing, the lights will flash yellow and
then change to a steady red while closing. Adjustments
to the closing time can be made through the System 4
Control Panel. Please contact your Rytec Technical
Support department at 800-628-1909 for assistance.
(See Figure 43.)
IMPORTANT: Photo eyes are used as a safety
feature and not as a door opener.
Never try to interrupt either set
of photo eyes as the door is closing. Wait for the door to perform
its normal cycle before entering
or exiting doorway.
1. Connect cable to front warning light.
2. Route front cable:
a. Down the side column.
b. Through the angle iron bracket at the bottom of
the side column.
c. Up the rear of the side column through the back
angle corner pieces.
d. Through the top access hole in the head assembly and to the rear junction box.
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable
across to the junction box.
3. Secure cable with plastic ties to the rear angle corner pieces.
4. Connect cable to junction box per schematic.
Rear
1. Connect cable to rear warning light.
2. Route rear cable:
a. Up the rear of the side column through the back
angle corner pieces.
b. Through the top access hole in the head assembly and to the rear junction box.
Patchwatch LED™ is owned by Rytec High Performance Doors.
17
INSTALLATION—PHOTO EYES
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable to
the junction box.
3. Secure cable with plastic ties to the rear angle corner pieces.
4. Connect cable to junction box per schematic.
PHOTO EYES
The photo eyes are provided as a safety feature. If the
photo eyes are correctly installed, interrupting either set
of eyes as the door is closing will reverse the direction
of the door and hold it in the fully open position until the
interruption is removed.
Your Turbo-Seal Insulated Door is equipped with two
sets of photo eyes. The front set of eyes monitors the
front side of the door — they are mounted in holes 18
inches from the bottom. The rear set of eyes monitors
the back side of the door — they are mounted in holes
28 inches from the bottom.
The transmitter and receiver can be identified in two
ways. The transmitter is designated SMT 3000 on the
white label or by a single green light that comes on at the
clear end of the transmitter. (See Figure 44.) The receiver
is designated SMR 3215 on the white label or by a yellow
light that illuminates only when it is in proper alignment
with the transmitter. (See Figure 45.)
NOTE: When the cable is connected to the photo
eye, there is only a ¹/₄-inch window to see
the green or yellow LED light.
Receiver
Module
Designation
Alignment Light
(Yellow)
A2500259
Figure 45
Front
1. Connect cable to front photo eye.
2. Route front cable:
a. Down the side column.
b. Through the angle iron bracket at the bottom of
the side column.
c. Up the rear of the side column through the back
angle corner pieces.
d. Through the top access hole in the head assembly and to the rear junction box.
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable
across to the junction box.
3. Secure cable with plastic ties to the rear angle corner pieces.
4. Connect cable to junction box per schematic.
Transmitter
Module
Designation
Rear
1. Connect cable to rear photo eye.
Power Light
(Green)
2. Route rear cable:
a. Up the rear of the side column through the back
angle corner pieces.
b. Through the top access hole in the head assembly and to the rear junction box.
A2500258
Figure 44
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable to
the junction box.
3. Secure cable with plastic ties to the rear angle corner pieces.
4. Connect cable to junction box per schematic.
18
INSTALLATION—AIR CURTAIN
Testing Photo Eyes
With the power on, the green light on the transmitter
indicates the photo eye module is powered up. When
the yellow light on the receiver module is also lit, the
transmitter and receiver modules are properly aligned.
3. Install right side of air curtain to mounting bracket
using two 10-24 x ³/₄-in. cap screws and ¹/₄-in. lockwashers. (See Figure 48.)
Placing your hand in front of the receiver breaks the light
path and causes the yellow light to go out. Removing
your hand causes the yellow light to go back on.
Hardware
Air Curtain
NOTE: Hardware is located in the small parts carton.
1.
Right Air Curtain
Mounting Bracket
Install left air curtain mounting bracket using two
¹/₄-20 x ³/₄-in. hex flange serrated machine screws and
¹/₄-in. hex serrated flange lock nuts. (See Figure 46.)
Air Curtain
A8700076
Figure 48
4. Repeat procedure for left side of air curtain.
(See Figure 49.)
Hardware
Left Air Curtain
Mounting Bracket
Hardware
Left Air Curtain
Mounting Bracket
Hardware
A8700074
Air Curtain
Figure 46
2. Repeat procedure for right mounting bracket.
(See Figure 47.)
A8700077
Hardware
Figure 49
5. Repeat procedure for opposite air curtain assembly.
6. Route electrical wiring to the junction box through
the angle brackets located behind the front panel of
the head assembly.
Hardware
Right Air Curtain
Mounting Bracket
A8700075
Figure 47
19
INSTALLATION—SIDE COLUMN HEATED BLOWER
Side Column Heated Blower
There are two holes are in the bottom of the side column.
These holes expose the interior of the yellow fiberglass
triangular extrusions. Warm air blows into these holes up
the triangular extrusions and exit two holes at the top of
the side column. (See Figure 50 and Figure 51.)
NOTE: Heated blowers are shipped loose and
holes are pre-cut in side columns.
NOTE: Use the wire chase in the side column to
route the cable to the power source. The
cable can be routed through a hole in the
head assembly. Leave excess cable in the
bottom of the side column to allow for
removal of bottom cover in the future.
3. Be sure that the cable doesn't interfere with the
travel of the counterweight.
4. Using the supplied Tek® screws, mount the heated
blower to the side column cover pre-drilled holes.
5. Plug supplied cord into end of heated blower.
6. Turn the thermostat control fully clockwise to set
blower heat to high.
Warm Air Top Exit Holes
Thermostat Control
A8700086
Figure 50
A8700088
Figure 52
7. Install side column covers and turn on the electrical
supply.
Warm Air Bottom Supply Holes
After 30 minutes the surface of the heater
housing should be warm to the touch and
frost should begin to dissipate. Please
contact Rytec Technical Support at 1-800628-1909 with any questions.
A8700087
Figure 51
1. Remove side column covers.
2.
20
NOTE: The fan for the side column heaters must
be rotating for the defrost system to work
properly. During shipment the fan may
bind against the casing. If the fan is not
turning, rotate the fan on the shaft and the
fan should begin to turn. If not, check for
proper voltage to the fan and contact
Rytec Technical Support for assistance at
1-800-628-1909.
Starting from the bottom, route the supplied cord up
the side column through the head assembly and to
the junction box.
FINAL CHECKS
FINAL CHECKS
NOTE: Check all of the following door components and systems once the door panel has
been cycled at least 20 times.
Side Columns: Check that side columns are plumb and
square and that all anchor bolts are secure and tight.
Head Assembly: Check that all mounting hardware is
in place and tight.
Bottom Bar: Smoothly travels up and down within the
side columns.
Limit Positions: Adjusted properly. Up and down travel
of the door should be as described in “DOOR OPENAND CLOSE-LIMIT POSITIONS” on page 13.
Motor: Check that the door travels in the proper direction when the button is pressed.
Reversing Edge: Works properly. As the door is closing, if the reversing edge makes contact with an object,
the door should immediately return to the fully open
position as described in “REVERSING EDGE SWITCH
INSPECTION AND ADJUSTMENT” on page 14.
Timers: Automatic timers must be set to ensure that the
door closes properly, as described in the Rytec System
3 Drive & Control Installation & Owner’s Manual.
Activators: Operate as specified by manufacturer.
Caulk: Ensure that the side columns and head assembly are caulked where they meet the wall of the building.
Counterweight Straps: Check the routing of all counterweight straps as indicated in Figure 26. Ensure that
the straps are in full contact with all rollers.
Counterweights: Counterweights should be adjusted
as shown in Figure 21. Adjust if necessary.
Kill Switch: When the bottom bar assembly is knocked
out of the side column(s), the kill switch must operate as
described in “KILL SWITCH INSPECTION” on page 15.
Insulated Panel Travel: The foam of the insulated
panel of the door varies in thickness and compression.
Therefore, the panel may require shimming. A 20”X20”
section of Rilon™ material shipped with the door to
use as shim material. This material can be cut to use
as shim material. (See Figure 53)
Operate the door several times and watch the yellow
plastic bottom bar travel as the door opens and closes.
The yellow plastic bottom bar should remain centered
in the opening throughout the travel of the door. You
may notice the bottom bar shifting left and right but
again it should remain in the center of the opening.
If the yellow bottom bar is traveling too far in one
direction it will be necessary to shim the panel to
correct the travel.
To shim the panel place a piece of the Rilon™ material
between the panel and the drum; when the door is in
the closed position.(See Figure 54)
Lock out and tag out the electrical supply
before placing the shim material between
the drum and insulated panel.
DO NOT attempt to perform this procedure
with the power on or serious injury could
result.
When the shim has been installed repeat testing of the
panel travel to ensure the shimming is correct.
It is possible that both sides may require shimming.
NOTE: Shim opposite the direction the bottom bar is
traveling. For example, if the bottom bar is
traveling to the right too far, shim on the left
between the drum and panel. Service Bulletin
#196 contains more detail. Can be found on
Rytec Knowledge Center website.
Photo Eyes: Make sure the photo eyes are working as
described in “DAILY INSPECTION” on page 6 in the
Turbo-Seal Insulated Owner’s Manual.
Defrost System: Make sure the blowers are adjusted
and operating properly.
Figure 53
Figure 54
21
NOTES
22