Fast-Fold Installation Manual

Fast-Fold
®
Installation Manual
[Revision: May 16, 2008 0-115-565, ©Rytec Corporation, 2002]
TABLE OF CONTENTS
PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MATERIAL, TOOLS, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Floor-Loop Activator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fill-In Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL ARRANGEMENT OF DOOR COMPONENTS . . . . . . . . . . . . . . . . . . . . 3
ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LOCATING SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SIDE PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Panel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trimming Panels (Puralon Panels Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attaching Panels to Side Pipes (Side Pipe Doors) . . . . . . . . . . . . . . . . . . . 13
KNOB AND ROPE TIE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rope Tie Doors Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Center Seal – Hypalon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Side Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSULATED SIDE PANELS AND SEALED PURALON PANELS . . . . . . 16
STANDARD SIDE PANELS AND SEALED PURALON PANELS . . . . . . 16
FREEZER DOOR SIDE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PANEL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DOOR SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MANUAL BRAKE RELEASE (OPTIONAL ITEM) . . . . . . . . . . . . . . . . . . . . . . . . . 18
DEFROST SYSTEM (FREEZER DOOR OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . 18
Heat Lamp Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lamp Fixture Wiring and Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19
LAMP BULB AND RED SLEEVE INSTALLATION . . . . . . . . . . . . . . . . . 20
Lamp Fixture Adjustment (Warm-Side and Cold-Side Mounted Doors). . 20
Heat Lamp Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BLOWER SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BLOWER HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hard-Panel Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Door Close and Open Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CLOSE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPEN LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hard-Panel Door Remote Limit Switch
(Mandatory Item if Hard-Panel Door Is Installed) . . . . . . . . . . . . . . . . . . 24
FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INTRODUCTION—DOOR SERIAL NUMBER(S)
INTRODUCTION
Drive Motor
The installation of your Rytec Fast-Fold® Door is not difficult if you adhere to the procedures outlined in this
manual. Any unauthorized changes to these procedures, or failure to follow the steps as outlined, will automatically void our warranty. Any changes to the working
parts, assemblies, or specifications as written, that are
not authorized by Rytec Corporation, will also cancel
our warranty. The responsibility for the successful operation and performance of this door is yours.
DO NOT INSTALL, OPERATE, OR PERFORM MAINTENANCE ON THIS DOOR UNTIL YOU READ AND
UNDERSTAND ALL THE INSTRUCTIONS IN THIS
MANUAL.
If you have any questions, contact your Rytec representative or call the Rytec Customer Support Department
at 800-628-1909. Always refer to the serial number of
the door when calling the representative or Customer
Support. The serial number plate is located inside one
of the side panels.
Refer to the Rytec System 3 Drive & Control Installation
& Owner’s Manual for general information about wiring
connections. The actual schematic for your particular
door has been shipped with the door and is located
inside the control panel.
DOOR SERIAL NUMBER(S)
To obtain your DOOR SERIAL NUMBER, there are three
universal locations where this information can be found.
These are at the inside of either side column (approximately eye level), on the drive motor, and on the inside
door of the System 3 control panel. (See Figure 1.)
IMPORTANT: When installing multiple doors
of the same model but in different sizes, verify the serial number in the control panel with the
one in the side column.
Serial Number Plate
Located Inside One
of the Side Panels
System 3
Control Panel
A1500157
Figure 1
HOW TO USE MANUAL
Throughout this manual, the following key words are
used to alert the reader of potentially hazardous situations, or situations where additional information to successfully perform the procedure is presented:
WARNING is used to indicate the potential
for personal injury if the procedure is not
performed as described.
CAUTION is used to indicate the potential
for damage to the product or property
damage if the procedure is not followed as
described.
IMPORTANT: IMPORTANT is used to relay
information CRITICAL to the
successful completion of the
procedure.
NOTE: NOTE is used to provide additional information to aid in the performance of the
procedure or operation of the door, but not
necessarily safety related.
1
INSTALLATION—MATERIAL, TOOLS, AND EQUIPMENT
INSTALLATION
Floor-Loop Activator Requirements
MATERIAL, TOOLS, AND EQUIPMENT
If a floor-loop activator was ordered and shipped with
your Rytec Door, the following additional items will be
required to install the activator.
1. Threaded rod (¹₂-in. diameter) and other various
wall anchor hardware and material. Concrete
anchor bolts (¹₂-in. diameter).
(See “ANCHORING METHODS” on page 3.)
NOTE: For complete floor-loop installation instructions, refer to the manual that was shipped
with the activator.
2. Assorted shim stock.
3. Double-sided tape (for attaching shims to wall).
4. Carpenter’s level (4-ft. minimum length).
5. Carpenter’s square.
6. Hammer drill.
7. Masonry drill bit (for ¹₂-in. diameter anchors).
8. Hammer or mallet, and block of wood.
9. Crowbar or pry bar.
10. Assorted hand tools (pliers, tape measure, etc.).
11. Socket and wrench sets.
12. Water level, line level, or transit.
13. Two ladders (taller than height of door opening).
14. Forklift (see “Forklift Requirements” below).
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. Two installers.
2. An electrician is required for making all electrical
connections. (See the Rytec System 3 Drive & Control Installation & Owner’s Manual.)
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:
• 2,000-pound lift capacity
• minimum height ability — door height, plus 12 in.
• side-shift capability (desired)
Electrician’s Responsibilities
For complete details on the responsibilities of the electrician, refer to the Rytec System 3 Drive & Control
Installation & Owner’s Manual.
2
1. Concrete saw (with water cooling attachment).
2. Water supply and garden hose.
3. Wet/dry shop vacuum.
4. 200–500 feet of 16-gauge, 19-strand, type XLPE,
copper, crosslink polyethylene jacket wire (or equivalent). The size of the floor loop will determine the
length of wire required.
5. Bondo P606 Flexible Embedding Sealer (or equivalent) — required to fill saw cuts in floor after the activator is installed. For cold temperature applications,
Bondo P610 Speed Set must be added to the P606
to ensure the sealer cures properly.
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 ³₁₆-in. angle iron.
INSTALLATION—GENERAL ARRANGEMENT OF DOOR COMPONENTS
GENERAL ARRANGEMENT OF
DOOR COMPONENTS
ANCHORING METHODS
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.
Correct anchoring of the side panels 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.
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.
Figure 3 through Figure 6 show anchoring methods for
various types of walls. Use the method that is best
suited for your particular installation site.
Head Assembly
Serial Number Plate
Located Inside One
of the Side Panels
Rytec
Control
Panel
Turn
Arms
All necessary anchoring hardware and material required
for the installation of this door is the responsibility of the
door owner. If you have any questions, call your Rytec
representative or the Rytec Customer Support Department at 800-628-1909.
NOTE: Use ¹₂-in. diameter threaded through bolts
or ¹₂-in. diameter threaded rods to anchor
the door to all wall applications. Use ¹₂-in.
diameter concrete anchor bolts to anchor
the door to a concrete floor.
Concrete, Block, or Brick Walls
Fused
Disconnect
Concrete Wall
Side
Panel
Side
Panel
Expansion
Anchor
Side
Pipe
Puralon
Panels
Side
Pipe
A1500110
Side
Panel
A0500005
Figure 3
Figure 2
Wood, Block, Brick, or Insulated Walls
NOTE: The above illustration shows the front side
of the door. Left and right are determined
when viewing the front side of the door.
Wood
Wall
Side
Panel
Crush Plate
(¹₂-in. Thick,
6-in. x 8-in.
Steel)
Through Bolt
or Threaded Rod
A0500037
Figure 4
3
INSTALLATION—ANCHORING METHODS
Insulated Walls
Insulated Wall
Side
Panel
Through Bolt
or Threaded Rod
A0500039
Aluminum-Clad Lumber
(Front and Back Side — Full Length)
Figure 5
Insulated
Wall
Through Bolt
or Threaded Rod
A0500038
Side
Panel
Aluminum-Clad Lumber
(Back Side — Full Length)
Figure 6
4
INSTALLATION—UNCRATING
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 installation manual.
3. Remove the Puralon panels from the crate. The
panels have been stacked flat with the curve side of
each panel facing down, label side facing down.
Once the panels are removed from the crate, store
them flat with the curve side facing down. Also, protect the panels from damage. (See Figure 8.)
1. Remove the top of the crate.
NOTE: The material packed on the upper level of
the crate must be removed before the front
of the crate can be opened. Also, the front
of the head assembly faces the front of the
crate. (See Figure 7.)
Natural Curve
Side Panels and
Puralon Panels Packed
in Upper Level
Face Label Side
Down when Storing
Panels Flat
Crate
A1500044
Figure 8
Head Assembly, Control Panel,
and Small Parts Carton Packed
in Lower Level
A1500001
Figure 7
2. Remove the door’s side panels from the upper level
of the crate.
Storing the flexible, Puralon™1 panels incorrectly can cause problems in the way the panels will seal later on. To retain the natural
curvature of each panel, it is critical to store
the panels in a similar manner in which they
were found inside the shipping crate (curve
side down). If a panel is to be rolled, flip it over
and roll it with the label side of the panel facing up (curve side up). Rolling a panel against
the curve or storing it incorrectly could flatten
the natural curvature of the panel.
NOTE: If you find it necessary to roll the panels,
they must be rolled with the curve side of
the panel facing up. DO NOT allow the
Puralon panels to remain rolled for more
than a few hours. Allowing them to remain
rolled for too long, may effect the way the
panels seal the opening. (See Figure 9.)
To relax the panels before they are hung in
place, roll them out flat and flip them over
with the label facing down, curve side
down.
Face Curve Side of
Panel Up when
Rolling Up Panel
(Label Facing Up)
A1500045
Figure 9
4. Remove the front of the crate.
1. Puralon is a trademark of Rytec Corporation.
5
INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING
LOCATING CENTERLINE OF DOOR OPENING
NOTE: Accurate measurements are critical for the
proper installation and operation of your
Rytec Door. Verify all measurements.
2. Using the centerline as a reference point, lay out
and mark half of the door’s production width along
the floor. (See Figure 12.)
Half of Door
Production
Width
1. Measure the width of the door opening.
2. Divide the measurement in half to locate the centerline. Then mark the centerline along the floor.
(See Figure 10.)
Centerline of
Opening
Centerline of
Opening
Extend and Mark
Edges of Door Along Floor
A0500002
Figure 12
Overall Width
of Door Opening
A0500001
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.
Half Width of
Door Opening
Figure 10
LOCATING SIDE PANELS
1. The location of the side panels is determined by
measuring the production width (length) of the head
assembly. (See Figure 11.)
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 panel will be required.
Figure 13 and Figure 14 show two methods that
can be used to ensure level side panels.
NOTE: Contact the Rytec Customer Support
Department if the floor is more than 2 in.
out of level.
Production
Width
Line Level
Head
Assembly
A1500047
Figure 11
This Dimension Must Be
Equal on Both Sides of
Door Opening
Shim Plate
(As Required)
A0500003
Figure 13
6
INSTALLATION—SIDE PANELS
12 in.
Mounting
Holes
This Dimension
Must Be Equal
on Both Sides
of Door Opening
Center
Water Level
12 in.
Shim Plate
(If Required)
A0500004
Figure 14
SIDE PANELS
NOTE: Holes for floor anchors have been predrilled in the bottom of each side panel.
For standard panels, you must drill the
holes that are necessary to bolt the panels
to the wall. For insulated panels used on
freezer and cooler doors, the panels come
equipped with mounting lugs — for these
panels, drilling is not required.
1. Drill three mounting holes in the vertical rear edge
of each side panel. This is the thin sheet metal edge
of the panel. The holes should be located 12 in.
from the top and bottom, with one in the center.
(See Figure 15.)
In addition, the holes should be ¹₄ in. larger in
diameter than the anchors you are using to mount
the panels to the wall. This will allow room for
adjusting the panels later on, once the head
assembly is bolted in place.
A1500012
Figure 15
IMPORTANT: It is critical to mount the side
panels level and square to the
wall and floor, both vertically and
horizontally. A carpenter’s level
and square are recommended
for this procedure.
2. Locate the left and right side panels. The holes for
mounting a standard panel to the floor are located
along the bottom inside edge of the panel.
(See Figure 16.)
Threaded holes for mounting the head assembly to
the side panels are located along the top inside
edge of each panel.
Insulated side panels have mounting lugs fitted
along the inside edges for mounting the panels to
the wall and floor.
7
INSTALLATION—HEAD ASSEMBLY
Threaded Holes (Top)
Mounting Lugs
(Insulated Side
Panels Only)
4. Anchor the panel to the wall and floor as required.
(See “ANCHORING METHODS” on page 3.) DO
NOT tighten the mounting hardware at this time.
The panels may have to be repositioned once the
head assembly is in place.
5. Mount the left side panel following the same procedure used for mounting the right side panel.
HEAD ASSEMBLY
Insulated
Side Panel
Floor Mounting Holes
(Inside Edge)
A1500013, A1500015, A1500014
Figure 16
3. Place the right side panel perpendicular to the floor
as shown in Figure 17. Align the outside edge of the
panel with the line indicating the production width of
the door.
NOTE: Place shims under and behind each panel
as required. Use double-sided tape to
temporarily attach the shims to the wall or
side panel.
1. Remove the control panel, small parts carton, and
any other items from within the crate that might
block the head assembly during its removal.
2. Manually release the motor brake located on the
end of the drive motor. Then, to prevent the forklift
from damaging the head assembly, move the turn
arms to their fully open position to allow the forks to
clear the underside of the head assembly. (The turn
arms are the mechanical arms that the panels will
be hung from.)
The head assembly must be securely fastened to the forklift before it is lifted into
position on top of the side panels. Failure
to safely secure the head assembly can
result in damage to the assembly and
cause injury to personnel.
DO NOT remove the forklift out from under
the head assembly until the side panels
are securely fastened to the wall of the
building and the head assembly is
securely fastened to the side panels.
Carpenter’s Level
Handle the head assembly with care to
prevent damage to the turn arms.
Insulated Side Panel
Mounting Holes
Carpenter’s
Square
A1500048
Floor
Mounting
Holes
Figure 17
8
Production
Width Line
3. Remove the head assembly from the crate using a
forklift or other suitable means. Secure the head
assembly to the forks using clamps or other equivalent method. (See Figure 18.)
INSTALLATION—SIDE PIPES
Secure Head
Assembly to Forklift
NOTE: Spread Forks as
Wide as Possible
2. Insert a bushing into each pivot bracket. Then
attach each bracket to the side panels using the
pre-drilled holes in the lower corner of each panel.
DO NOT tighten the hardware at this time.
(See Figure 20.)
Bushing
Side Panel
Lock Washer
Place Turn Arms in
Fully Open Position
Lower Side
Pipe Bracket
Hex Head
Screw
A1500049
Figure 18
4. Place the head assembly on top of the side panels
with the holes in the head assembly aligned with the
holes in the side panels. Bolt the head assembly to
the side panels with the ⁵₈-11 x 1¹₂-in. serrated
flange hex head bolts located in the small parts carton. (See Figure 19.)
NOTE: On a head assembly configured for freezer
use, the insulation in the head must be
“notched out” to provide access to the
mounting holes. Later, once the head and
side panels are securely fastened, be sure
to replace the insulation.
Front Inside Edge
of Side Panel
A1500051
Figure 20
3. Slip the upper end of the side pipe over the side
pipe pivot post located on the end of the head
assembly. (See Figure 21.)
Side Pipe
Pivot Post
Head Assembly
Upper End of
Side Pipe
Serrated Flange
Hex Head Bolts
Hex Head Screws
(Two per Side)
Threaded Holes
A1500050
Lock Washers
(Two per Side)
Side Panel
Figure 19
5. Check that the side panels are plumb and square.
Clamp
Bracket
6. Tighten all mounting hardware on the head assembly and the side panels.
SIDE PIPES
A1500009
NOTE: Side pipes are required on a non-sealed
panel door only.
A1500008
1. Remove the two lower side pipe brackets, two bushings, four ⁷₁₆-14 x 1-in. screws, and four ⁷₁₆-in. lock
washers from the small parts carton.
4. Then align the lower side pipe pivot post with the
bushing in the pivot bracket and set the post in the
bushing. With the side pipe in place, tighten the
mounting hardware securing the pivot bracket to the
side panel. (See Figure 20.)
Figure 21
9
INSTALLATION—PANELS
5. Rotate the side pipe until the holes in the upper end
of the side pipe line up with the holes in the pivot
post. (See Figure 21 and Figure 22.)
Side Panel
Side Pipe
Pivot Post
Mount Clamp Bracket
on This Side of
Left Panel
Direction Panel Travels
Right
Side Pipe
Left
Side Pipe
Direction Panel Travels
A1500052
Turn Arm
Drill Hole
through Sleeve
and Pivot Post
to Fit Roll Pin
90°
Mount Clamp Bracket
on This Side of
Right Panel
Roll Pin
Figure 22
Side Pipe
Flange
6. Secure the side pipe to the pivot post using a clamp
bracket, two ⁷₁₆-in. lock washers, and two ⁷₁₆-14 x
1¹₄-in. screws located in the small parts carton.
7. Install the other side pipe in the manner as
described above.
8. With both side pipes in place, release the motor
brake and manually close the door.
IMPORTANT: The door must be in the fullyclosed position before proceeding with the next step.
9. Locate the two small roll pins packed in the small
parts carton. Then position the flange on both side
pipes at a 90° angle to their respective side panel.
10. Drill a hole through both turn arm sleeves and side
pipe pivot posts to fit the roll pins. Then drive the
pins into the holes to lock the arms to the posts.
(See Figure 23.)
A1500016
Figure 23
PANELS
The Puralon panels are mounted to the head assembly
by way of a specially designed mounting bracket system. Each panel comes from the factory with a series of
pre-drilled holes that run along the top edge of the
panel. A flat mounting strap, with matching holes, is
used to bolt each panel to its respective mounting
bracket. This design allows each panel to be adjusted
horizontally, side-to-side.
Designed into the two center-most mounting brackets is
a series of vertical slots to receive the bolts passing
through the strap and panel. These slots allow the vertical angle of the two center panels to be adjusted (tilted)
to the left or right. In addition, an oversized horizontal
slot has been added to the two center brackets to make
it easier to adjust the heavier and bulkier center panels.
IMPORTANT: Follow the instructions as outlined below in the order presented. Do not cut the Puralon
panels to finished length until
they have all been installed and
properly adjusted.
10
INSTALLATION—PANELS
Each panel has been tagged with an identification number to indicate its position as it should appear when
mounted on the door. The tag is located on the inside
face of the curve. When facing the front side of the door,
the panels (and their associated mounting brackets) are
numbered from left-to-right, with panel #1 on the far, lefthand side of the door. (See Figure 24.)
IMPORTANT: To ensure the door panels seal
properly, it is critical that the
panels be hung in their numbered order, with the natural
curve of each panel facing the
direction shown in Figure 24.
Metal Mounting
Strap
Remove All
Hex Nuts
Puralon
Panel
NOTE:
Leave Hex Bolts
and Strap in Place.
Only Remove Hex Nuts.
A1500119
2
1
3
4
Figure 25
6
5
Panel Numbers
Overlapping Panels
A1500035
1
Front Side
of Door
2
3
4
5
6
Panel Numbers
Front Side
of Door
A1500017
2. Working from the front side of the door, left-to-right,
lift each panel in place and attach it to its corresponding mounting bracket. (See Figure 26.)
Make sure the number on the panel matches up
with the correct mounting bracket and that the panels are hung with all mounting bolts pointing toward
the back side of the door.
Also, it is important that each mounting strap (and
panel) is centered on its respective mounting
bracket — later on, if it becomes necessary, the
panels can be repositioned.
Seamed Panels
Figure 24
1. The metal mounting strap used to attach each panel
to its respective mounting bracket has been
installed on the panel at the factory. Before a panel
can be installed, first remove the nuts that are
threaded onto the bolts that pass through the
mounting strap and panel. Leave the strap and bolts
in place once the nuts are removed.
(See Figure 25.)
Secure Mounting
Strap to Mounting
Bracket
Turn Arm
Panel with
Mounting Strap
Mounting
Bracket (Along
Bottom of Turn
Arm)
A1500120
Figure 26
11
INSTALLATION—PANELS
NOTE: The metal mounting straps used with the
two, center-most panels each have an extralong bolt located in the center hole. This
longer bolt allows you to hang these bulkier
door panels on their respective mounting
brackets without having to struggle with the
remaining (shorter) bolts. It will also allow
you to center the panel horizontally on the
bracket, before the remaining bolts are
installed. (See Figure 27.)
Thread Nut
on Extra-Long
Hex Bolt First
Two Center-Most
Panels
Uneven
Overlap
Uneven
Overlap
A1500056
Improper Panel Alignment
Figure 28
Extra-Long
Hex Bolt
Two Center-Most
Panels
Panel with
Mounting
Strap
Even Overlap
A1500121
Figure 27
3. After a panel is hung in place, work the remaining
bolts into the mounting bracket and then thread a
nut onto each bolt. Loosely tighten all nuts to temporarily secure the panel. (Later, the nuts will be
securely tightened once all the panels are adjusted
level and square.)
4. Continue the above procedure for each door panel.
Panel Alignment
With all the panels in place, the two center-most panels
can now be checked for level and square.
1. Stand far enough back from the door to visually
inspect the overlap and alignment of the two center
panels. They should both hang straight, with all
overlaps even along the entire length of the adjoining panels. (See Figure 28 and Figure 29.)
NOTE: Because the panels are shipped from the
factory slightly longer than necessary, it is
important that you lift (roll up) the bottom
edge of each panel just enough so that it
will not drag on the floor when the panels
are checked for level and square. Later on,
they will all be trimmed to finished length.
12
A1500057
Proper Panel Alignment
Figure 29
NOTE: If a panel requires any side-to-side adjustment, it is acceptable to index that panel
one hole in either direction. But repositioning a panel more than one hole could
cause the extended mounting strap to bind
and become damaged once the door is
activated.
Also, if you find it necessary to reposition
a panel, it may be necessary for you to
reposition the overhanging bolt to ensure
that the panel is fully supported from
behind by the mounting bracket. If a bolt is
to be moved, you will first need to drill a
new hole in the panel to fit the bolt.
2. Once the center panels are adjusted, check the
position of the remaining panels. After any necessary adjustments are made, tighten each nut on
every panel to secure all panels.
INSTALLATION—KNOB AND ROPE TIE INSTALLATION
Trimming Panels (Puralon Panels Only)
Side Pipe
Mounting Flange
If the panels on your particular door
include a Hypalon® sweep along the bottom edge, DO NOT trim the panels.
IMPORTANT: For Puralon panels only: Failure
to trim the panels to length will
cause them to drag across the
floor, which can result in the
door not sealing properly.
Using a utility knife, trim the bottom edge of each
Puralon panel to within ¹₄-in. of the floor. To make it easier to move your knife through the material when trimming the panels to length, pull the excess material away
from the blade as you make the cut. (See Figure 30.)
NOTE: Over time, the Puralon panels may stretch
and require retrimming.
Panel
NOTE:
Panel Must Be Seated All the
Way into Mounting Flange
A1500054
Figure 31
2. Using the pre-drilled holes along the edge of each
flange as a template, drill a series of holes along the
outside edge of each panel. Then fasten the panels
to the flanges using the ⁵₁₆-18 x 1¹₄-in. screws and
nuts located in the small parts carton.
KNOB AND ROPE TIE INSTALLATION
Rope Tie Doors Only
1. Move the door to the fully closed position.
2. Using Table 1 below, determine how many rows of
knobs and ties are required for your particular door.
Table 1
Distance from Floor (Inches)
Door Height
(Feet)
Row 1
Row 2
Row 3
Row 4
6
24
48
–
–
7
24
60
–
–
8
24
72
–
–
9
24
72
–
–
10
24
72
–
–
11
24
72
–
–
12
24
72
120
–
Attaching Panels to Side Pipes (Side Pipe Doors)
13
24
72
120
–
1. Insert the outside edge of the two outer panels into
the mounting flange of its adjoining side pipe. Make
sure each panel is seated all the way into the flange.
(See Figure 31.)
14
24
72
120
–
15
24
72
120
–
16
24
72
120
168
17
24
72
120
168
18
24
72
120
168
19
24
72
120
168
20
24
72
120
168
¹₄-in. Gap between
Panel and Floor
A1500095
Figure 30
13
INSTALLATION—KNOB AND ROPE TIE INSTALLATION
3. Once the number of rows is determined, the next
step is to lay out a column of holes along each overlapping pair of panels. For example, panels 1 and 2,
2 and 3, and so on. (See Figure 32.)
Drill Holes and Install
Knobs from This Side
Note that each panel has a straight, vertical edge
along one side and a 45° cut (or S-cut) near the top
of the opposite edge. When laying out a column of
holes, measure off the straight, vertical edge for all
the holes in that column. The two, 1-in.-diameter
holes used for each knob and rope tie are both
centered 2 in. from the same vertical edge.
(Refer to the Detail View in Figure 32.)
Turn-Arm Hinge
Panel
Numbers
1 2
23
45
56
Row 4
Row 3
Row 2
Row 1
Reference
Straight Edge
A1500036
A1500020
Figure 33
6. Locate the nylon rope shipped in the small parts
carton. To prevent fraying, wrap a short length of
tape around one end of the rope.
7. Locate the small wire crimps shipped in the small
parts carton. Place a crimp over the taped end of
the rope and lock it in place by crimping the ends
together with a side cutter or other suitable tool.
NOTE: Do Not Reference
Curved Edge
1-in.
Diameter
Hole
Drill Holes and Install
Knobs from This Side
A1500061
A1500060
2-in. 2-in.
Detail View
(Not to Scale)
8. Tie a knot next to the crimp.
9. Feed the other end of the rope through the wide
face of the first knob (the first knob is sandwiched
between the overlapping panels with the door
closed). Then feed the rope through the back of the
adjoining knob in the opposite panel and pull the
rope tight (with the panels closed). (See Figure 34.)
Figure 32
Turn-Arm
Hinge
4. Using a 1-in. hole saw or wood spade bit, drill the
holes for the knob and rope ties. Each hole should
be drilled from the same direction the knob will be
installed. Using the turn-arm hinge for reference,
drill the holes toward the turn-arm side of the panel,
as shown in Figure 33.
5. Insert the small end of each knob into the hole from
the side opposite the turn-arm hinge. Press each
knob firmly in place.
Knot
Second Knob
A1500021
Figure 34
14
Rope
First
Knob
INSTALLATION—KNOB AND ROPE TIE INSTALLATION
10. To secure the rope tie, tie a knot close to the wide
face of the second knob. The rope should be without slack with the door fully closed.
(See Figure 35 and Figure 36.)
Panel
12. Repeat the above steps for each pair of knobs. Figure 38 shows a complete set of knobs with a knot
and a crimp at each end of the tie. Figure 39 illustrates a complete rope tie on both sides of the door.
Crimp
Knot
Rope
Wide Face
of Knob
A1500005
Knob
Figure 35
A1500097
Figure 38
Rope Tie Must
Be Tight with
Door Closed
Side
Panel
Correct
Puralon
Panel
Rope
Knob
Incorrect
TurnArm Hinge
Knob
A1500062
A1500041
Figure 36
11. To prevent the other end of the rope tie from fraying
once it is cut to length, wrap a length of tape around
the rope, near the second knot. Then cut the rope
tie to length — cutting across the middle of the
taped section. Install a crimp over the taped end.
(See Figure 37.)
Left Side Shown — Top View
Figure 39
13. To prevent the Puralon panels from cutting into the
rope ties as the door is opened and closed, cut
(shave) a slight bevel, about 4 in. long, along the
edge of each panel where it makes contact with
each rope tie. (See Figure 40.)
Cut 4-in.-Long
Bevel along
Edge of Panel
Knot
Tape
Knob
Crimp
Rope Tie
A1500063
Figure 37
A1500096
Figure 40
15
INSTALLATION—SEAL
SEAL
Side Seal
Center Seal – Hypalon
NOTE: A Hypalon side seal is used to close off the
opening between the side panel and the
outside Puralon panel. A side seal is rectangular in shape.
NOTE: A center seal is used to close off the opening between two adjacent Puralon panels.
A center seal is wider at the top than it is
at the bottom.
1. Locate the Hypalon center seal(s). The wide end of
the seal is positioned at the top. (See Figure 41.)
Position Wide
End at Top
INSULATED SIDE PANELS AND SEALED
PURALON PANELS
A Hypalon side seal was factory installed on the two
insulated side panels. You must attach these seals to
the edge of the adjacent Puralon panel using the Velcro
strips provided on the seal and panel. (See Figure 43.)
Insulated
Side Panel
Sealed Puralon
Panel
Hypalon Side
Seal
Hypalon
Seal
Velcro Strips
Left Side Panel — Right Is Mirror Image
A1500002
A1500065
Figure 41
Figure 43
2. Attach a center seal to the edge of each adjoining
Puralon panel using the Velcro®1 strips provided on
the seal and panels. When attaching a center seal,
start at the bottom and work your way toward the
top. (See Figure 42.)
STANDARD SIDE PANELS AND SEALED
PURALON PANELS
The Hypalon side seals used on a door having standard
side panels and sealed Puralon panels are field
installed. The following steps illustrate the installation
procedure for the right side seal. The procedure used
for installing the left side seal is the same.
1. Remove the turn-arm stop from the side panel. It is
held in place by two hex head cap screws, flat washers, and serrated flange nuts. Save all hardware for
later use. (See Figure 44.)
NOTE: As you remove the turn-arm stops, note
that the right stop is along the back side of
the door and the left stop is along the front
side of the door. Also note that the cap
screws holding both stops in place are
installed from the front side of the door. It
will be critical, later on, to reinstall the
stops and hardware as originally found.
Hypalon
Seal
Puralon
Panel
Puralon
Panel
A1500006
A1500022
Velcro Strip
along Edge of
Seal and Panel
Hypalon
Seal
Figure 42
1. Velcro® is a registered trademark of Velcro Industries B.V.
16
INSTALLATION—SEAL
NOTE: Right Turn-Arm
Stop along Back Side
of Door. Left Turn-Arm
Stop along Front
Side of Door.
Serrated Flange
Nut
Hex Head
Cap Screw
Right Side
Panel
Standard
Side Panel
Sealed
Puralon
Panel
Face Velcro Strip on
Side Seal toward
Sealed Puralon Panel
Side
Seal
A1500042
Figure 46
Flat
Washer
Right TurnArm Stop
3. Drill two ³₈-in. holes in the side seal. The holes must
align with the holes in the side panel that are used
for mounting the turn-arm stop. (See Figure 47.)
A1500105
Figure 44
2. Locate the side seal and attach it to the side panel
using the bolting bar and the self-tapping screws
provided in the small parts carton. (See Figure 45.)
Make sure to position the seal so that the Velcro
strip along the back edge is facing the sealed
Puralon panel. (See Figure 46.)
Drill ³₈-in. Holes
in Side Seal to
Line Up with Holes
in Side Panel
Side
Panel
Side Seal
Side Seal
A1500109
Self-Tapping
Screw
Figure 47
Side
Panel
Bolting Bar
A1500108
Figure 45
4. Reattach the turn-arm stop as it was originally
found using the saved hardware. Face the rubber
bumper on the stop toward the center of the door.
(See Figure 44.)
5. Repeat the above procedure for the left side seal.
17
INSTALLATION—PANEL CLEANING
FREEZER DOOR SIDE SEAL
PANEL CLEANING
NOTE: A Hypalon side seal is used to close off the
opening between the side panel and the
outside Puralon panel.
Once the panels and seals are in place, clean the panels with a general household surface and glass cleaner.
Avoid scratching the panels by using a clean, soft cloth.
Locate the side seal and attach it to the side panel using
the clamp strip and self-tapping screws provided in the
small parts carton. (See Figure 48 and Figure 49.)
DOOR SEALING
Caulk the side panels and the head assembly where
they meet the wall of the building.
MANUAL BRAKE RELEASE (OPTIONAL ITEM)
Front of Door
If the door is equipped with a manual brake release kit,
there will be a cable attached to the brake release handle that is located on the end of the motor. Tie the cable
out of the way of traffic using a cable clamp or other
suitable method.
Hypalon
Side Seal
DEFROST SYSTEM (FREEZER DOOR OPTION)
Thermal
Break
Self-Tapping
Screw
Heat Lamp Fixture Installation
NOTE: On cold-side mounted doors, the heat
lamp fixtures were factory installed on the
door head assembly. For all other doors,
the fixtures are installed in the field.
1. Turn off power to the door.
Clamp Strip
Side
Panel
A1500100
The disconnect must be in the OFF position and properly locked and tagged before
performing the following procedure.
Figure 48
Hypalon
Side Seal
2. Bolt the left and right front-mount heat lamp support
brackets to the sides of the head assembly. Use the
⁷₁₆-in. x 1-in. hex head screws, lock washers, and
flat washers provided. (See Figure 50.)
Head
Assembly
Thermal
Break
Head
Assembly
Hex Head
Screws
Side
Panel
Self-Tapping
Screw
Side
Panel
Clamp
Strip
A1500025
A1500114
Figure 50
Figure 49
18
Front-Mount Heat
Lamp Support Bracket
INSTALLATION—DEFROST SYSTEM (FREEZER DOOR OPTION)
3. Install a triangular heat lamp fixture bracket on both
ends of each lamp fixture. Use the 10-24 x ³₄-in. hex
head screws, lock washers, and hex nuts provided.
(See Figure 51.)
5. Install the front-mount heat lamp angle (with fixtures) to the end of the support brackets that were
mounted earlier. Use the ³₈-in. x 1¹₄-in. hex head
screws and serrated flange nuts provided.
(See Figure 53.)
Hex Nut
Lock
Washer
Front-Mount
Heat Lamp
Angle
Heat Lamp
Fixture Bracket
Hex Head
Screw
Heat Lamp
Fixture
Serrated Flange
Nut
A1500111
Figure 51
4. Attach the heat lamp fixtures to the front-mount heat
lamp angle using the ³₈-16 x 1-in. hex head screws
and serrated flange nuts provided. DO NOT install
the lamp bulbs or red sleeves at this time.
(See Figure 52.)
Front-Mount
Heat Lamp Angle
Serrated Flange
Nut
Screw
Heat Lamp
Fixture
A1500026
Hex Head
Screw
Figure 53
Lamp Fixture Wiring and Bulb Installation
The disconnect must be in the OFF position and properly locked and tagged before
performing the following procedure.
Wire all heat lamp fixtures according to the schematic
that was shipped with the control panel, following all
state and local codes. The necessary conduit, junction
box, and wiring are to be supplied by the owner of the
door. Route the wiring from the lamp fixtures to the junction box as shown. (See Figure 54.)
Head
Assembly
A1500028
Figure 52
Junction
Box
Heat Lamp
Fixture
A1500027
Wiring
Figure 54
19
INSTALLATION—DEFROST SYSTEM (FREEZER DOOR OPTION)
LAMP BULB AND RED SLEEVE INSTALLATION
Never touch the glass surface of the lamp
bulb or the red sleeve with your bare fingers, and never handle them with a dirty or
oily rag. Any debris or oil on the surface of
the lamp will lead to a “hot spot,” which
will reduce the life of the lamp and even
cause it to immediately fail.
With the lamp fixture(s) mounted, a lamp bulb and red
sleeve can now be installed in each fixture.
1. Remove the end cover plates from the lamp fixture.
(See Figure 55.)
4. Connect the wire on the ends of the lamp to the
screw terminal located at each end of the fixture.
(See Figure 56.)
Leave a ¹₄-in. loop on the end of the wire
as shown in Figure 56. If the loops are not
made, the bulb can become damaged
when the fixture expands as a result of the
heat output from the lamp.
Lamp Fixture
(Cover Removed)
Wire on
End of Lamp
¼-in.
Loop
Lamp
Fixture
Screw
Terminal
Lamp
Bulb
Lamp Bulb with
Red Sleeve
A1500098
Figure 56
Red
Sleeve
5. After the lamp bulb is wired in place, cut off the
excess wire leading away from each screw terminal.
6. Reattach all end cover plates.
Screw
End
Cover Plate
A1500067
Lamp Fixture Adjustment (Warm-Side and ColdSide Mounted Doors)
Figure 55
2. Locate the lamp bulb and the red sleeve.
3. Slide the sleeve over the lamp and install the lamp
in the fixture. (The sleeve blocks most of the radiant
visible and ultra-violet light from the lamp, but it
does not affect the radiant heat output.)
The disconnect must be in the OFF position and properly locked and tagged
before making the following adjustments.
Excessive heat can severely damage the
Puralon panels.
1. Turn off power to the door.
2. To redirect a heat lamp, first loosen the nuts that
lock the lamp fixture in place.
20
INSTALLATION—DEFROST SYSTEM (FREEZER DOOR OPTION)
3. Direct the heat lamp fixture(s) to aim at the area of
the floor where the panels of the door meet the floor.
(See Figure 57 through Figure 60.)
Heat Lamp
Fixture
Figure 57 and Figure 59 show the correct method
for aiming a lamp fixture. Figure 58 and Figure 60
show the incorrect method.
Heat Lamp
Fixture
Aim fixture toward
area of floor where
Puralon panels meet
floor (allows warm
air to rise across
entire face of door).
Aim fixture toward
area of floor where
Puralon panels meet
floor (allows radiant
heat to rise across
entire face of door).
A1500029
Warm-Side Mounted Door
Correct Angle to Aim Lamp Fixture
Figure 57
A1500032
Cold-Side Mounted Door
Correct Angle to Aim Lamp Fixture
Figure 59
Damage to panel can
result if lamp fixture
is aimed directly at panel.
Damage to panel
can result if lamp
fixture is aimed
directly at panel.
Aiming lamp fixture
straight down will
have no affect on
defrosting the door.
Aiming lamp fixture straight
down will have no affect on
defrosting the door.
A1500030
Warm-Side Mounted Door
Incorrect Angle to Aim Lamp Fixture
A1500034
Cold-Side Mounted Door
Incorrect Angle to Aim Lamp Fixture
Figure 60
Figure 58
21
INSTALLATION—DEFROST SYSTEM (FREEZER DOOR OPTION)
Heat Lamp Controls
If your door is equipped with heat lamps, they are controlled by the control panel. Refer to the Rytec System 3
Drive & Control Installation & Owner’s Manual.
With the defrost system in the MANUAL mode, the heat
lamps will immediately power up. When in the AUTO
mode, the heat lamps are operated automatically by the
control system. An automatic timer function can be set
to periodically cycle the lamps on and off. Placing the
defrost system in the OFF mode turns off the lamps and
disables the automatic timer function.
Blower Controls
BLOWER SPEED
If your door is equipped with a blower (unheated or
heated), the blower fan speed has four modes of operation (OFF, LOW, HIGH, and AUTOMATIC). Refer to the
Rytec System 3 Drive & Control Installation & Owner’s
Manual.
With the blower switch in the AUTOMATIC position and
the door closed, the blower will run at low speed. When
the door is open, the blower will operate at high speed.
With the blower switch in the HIGH or LOW position, the
blower will run at high or low speed regardless of the
position of the door.
The blower speed you select (LOW, HIGH, or AUTOMATIC) will depend on the environmental conditions
(temperature, humidity, etc.) of the installation site.
Placing the switch in the OFF position will override the
control system and prevent the blower from turning on.
BLOWER HEATER
If the blower is equipped with an internal heater (heated
blower), the heat level is controlled by the control panel.
Refer to the Rytec System 3 Drive & Control Installation
& Owner’s Manual.
The standard heated blower has two heating levels. An
optional heated blower is available with three heating
levels.
The heat level you select will need to be set according
to the environmental conditions of the installation site.
Hard-Panel Door
If an optional, hard-panel door is installed with your
Rytec Door, the defrost system must be controlled by a
limit switch installed on the hard-panel door to prevent
heat build-up between the two doors. (“Hard-Panel Door
Remote Limit Switch (Mandatory Item if
Hard-Panel Door Is Installed)” on page 24.)
22
If an optional, hard-panel door is installed
with your Rytec Door, a limit switch to
override the defrost system must be
installed on the optional door.
When installed in accordance with the schematic that
was shipped with the door, the limit switch will allow the
defrost system to turn on only when the hard-panel door
is in the fully open position.
FIN ADJUSTMENT
All blowers are equipped with air deflection fins in the
heat vent that runs along the bottom of the blower unit.
To redirect the airflow, loosen the nuts that lock the fins
in place and reposition the fins as necessary. Tighten
the nuts to lock in the adjustment. (See Figure 61.)
Blower
Unit
Air
Deflection Fins
Adjustment
Nut
A1500007
Figure 61
Figure 62 shows the correct angle to direct the airflow
for a standard blower. Figure 63 shows the correct angle
to direct the airflow for a Rytec bottom intake (RBI)
blower.
INSTALLATION—ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
Standard
Blower
NOTE: Refer to the Rytec System 3 Drive & Control Installation & Owner’s Manual for electrical system wiring.
Door Close and Open Limit Position
The door should open and close completely, without
traveling beyond the limits in either direction.
Improperly adjusted open and close limits
can result in damage to the drive system.
Aim heat vent fins
toward area of floor
where Puralon panels
meet floor.
NOTE: To set the close and open limits, refer to
the Rytec System 3 Drive & Control Installation & Owner’s Manual.
CLOSE LIMIT
1. Turn on the power and close the door.
Cold-Side Mounted Door
Correct Angle to Aim Standard Blower
A1500154
2. Check the spacing between each door panel. If the
door is not closed completely, the leading panels
will have a gap between them. If the door is closed
too tightly, the rubber bumpers on the turn arms will
be compressed. (See Figure 64.)
Figure 62
Rytec Bottom
Intake Blower
(RBI)
Turn Arm
Turn Arm
Direct heat vent
fins straight down
to ensure air
intake pulls return
air across entire
face of panel.
A1500004
Puralon
Panel
Bumper
Hypalon Seal
Puralon
Panel
Figure 64
NOTE: To check if the door has closed too far, perform the following procedure.
A1500153
Cold-Side Mounted Door
Correct Angle to Aim RBI Blower
3. With the door closed, turn off the power and manually release the brake. If the door springs back
toward the open direction as the brake is released,
the door is closing too far and the close limit should
be readjusted. Refer to the Rytec System 3 Drive &
Control Installation & Owner’s Manual.
Figure 63
23
INSTALLATION—ELECTRICAL SYSTEM
OPEN LIMIT
1. Turn on the power and open the door.
2. Check that the door is in the fully open position. If
the door is not open all the way, the leading panels
will be inside the door opening. If the door is open
too far, the rubber bumpers between the turn arms
will be compressed. (See Figure 65.)
Hard-Panel Door Remote Limit Switch
(Mandatory Item if Hard-Panel Door Is Installed)
The disconnect must be in the OFF position and properly locked and tagged
before installing the remote limit switch.
Turn Arm
Excessive heat can severely damage the
Puralon panels. If a hard-panel door is
installed with your Rytec Door and the
defrost system (heat lamps or blower) is
located between the two doors, the defrost
system must be turned off any time the
hard-panel door is not in the fully open
position to prevent heat from building up
between the two doors. To automatically
control the defrost system, a remote limit
switch must be installed and located as
shown in Figure 66.
Bumper
Puralon
Panel
A1500003
Figure 65
NOTE: To check if the door has opened too far,
perform the following procedure.
3. With the door open, turn off the power and manually
release the brake. If the door springs back toward
the close direction as the brake is released, the
door is opening too far and the open limit should be
readjusted. Refer to the Rytec System 3 Drive &
Control Installation & Owner’s Manual.
1. Locate the remote limit switch in the small parts carton. If a remote limit switch (Rytec part number
0-114-031) was not included with your door, contact
the Rytec Customer Support Department.
2. Mount the remote limit switch so that the hard-panel
door will actuate the limit-switch only when the
hard-panel door is in the fully open position. Install
the limit switch using the track provided or other
suitable mounting method. The installation of this
switch may vary from one application to another.
Consult the factory if you have any questions.
Figure 66 shows the general layout of the remote
limit switch.
Fast-Fold Door
Wall
Remote
Limit Switch
A1500112
CAUTION: Locate remote limit
switch so that defrost system will
power up only when hard-panel
door is in fully open position.
Figure 66
24
Hard-Panel
Door (Shown in
Fully Open Position)
INSTALLATION
FINAL CHECKS
NOTE: Check all of the following door components and systems once the door panel
has been cycled at least 20 times.
Side Panels: Check that side panels 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.
Door Panels: Check that all door panels are installed
properly, hanging straight, and travel smoothly as
described in “PANELS” on page 10. Make sure all hardware is in place and tight.
The panels should be kept trimmed to within ¹₄-in. of the
floor as described in “Trimming Panels (Puralon Panels
Only)” on page 13. Because the panels can stretch over
time, failure to keep them trimmed to length could result
in a door that seals poorly.
Knobs and Rope Ties: All knobs and rope ties should
be installed correctly as described in “Knob and Rope
Tie Installation” on page 13.
Seals: All seals should be installed correctly, as
described in “SEAL” on page 16.
Side Pipes (Non-Sealed Panel Doors Only): Both
side pipes should be installed with a roll pin as shown in
Figure 23. The outer Puralon panels should be bolted to
the side pipes.
Close and Open Limits: Adjusted properly. Side-toside travel of the door should be as described in “Door
Close and Open Limit Position” on page 23.
Motor: Check that the door travels in the proper direction when the button is pressed.
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: Be sure that the side panels and head assembly
are caulked where they meet the wall of the building.
Freezer Doors: Check the defrost system for normal
operation and adjust as required. If an optional hardpanel door is used, verify that the remote limit switch
allows the defrost system to power up only when the
hard-panel door is in the fully open position. Check all
controls for proper operation.
25
NOTES
26