Albany RAPID-ROLL 570, Owner'S Manual

Page 1: ...USER MANUAL RAPID ROLL DOOR OWNER S MANUAL Model 670 Model 570 975 A OLD NORCROSS ROAD LAWRENCEVILLE GA 30045 770 338 5000 TEL 770 338 5034 FAX 877 925 2468 TOLL FREE ...

Page 2: ...Part Number 6410T0006 Version 4 22 2010 2 Architectural Drawing of the 570 670 Rapid Roll Door Models ...

Page 3: ...INTENANCE CHECKLIST 23 INSPECTIONS 24 PULLEY INSPECTION 26 CABLE DRUM INSPECTION 26 SELF REPAIRING DEVICE BOTTOM BEAM TYPE 26 BRAKE ADJUSTMENT 27 OPTION INSTALLATION AND OPERATION 28 CHAIN DRIVE INSTALLATION 28 CONTACTLESS SAFETY EDGE C S E 30 MECHANICAL INSTALLATION 30 ELECTRICAL INSTALLATION 31 ADJUSTMENTS 32 FULL ROLL COVER MOTOR COVER INSTALLATION 34 FULL VISION PANEL REPLACEMENT 35 MANUAL DIS...

Page 4: ...ision or other abuse of the product Adjustments made to the control panel or to the mechanical operation of the door without the authorization of Albany Door Systems will void this warranty Any changes made to product configuration without the express written approval from Albany Door Systems may null and void this warranty Albany Door Systems obligations under this warranty are limited to repairi...

Page 5: ... all times Keep the door opening free of any obstructions 7 Remove power at the fused disconnect during all electrical or mechanical service OSHA requires a disconnect to be properly tagged and locked out during all maintenance or service of equipment 8 All electrical troubleshooting or service must be performed by a qualified electrician or service person and must meet all applicable local state ...

Page 6: ... optional parts are indicated Left Hand and Right Hand Side Frames with attached Covers 2 sets Top Roll Assembly with attached Drive Unit 1 Electrical Control Panel 1 Reversing Photocells 1 set Pressure Switch Enclosure w attached Retractile Cord 1 set Counter Balance Springs 2 Cables 2 Assembly Hardware 2 Top pulley brackets 2 Intermediate pulley brackets 8 Bolts axle bearing brackets 3 8 16 4 Lo...

Page 7: ...nst the packing list in the front of this manual to verify all parts are on site Step 2 Using a tape measure determine the actual door width by measuring the width gauge on the top roll assembly Figure 1 Apply this measurement to the actual door opening Mark the floor on each side of the opening to indicate the inside position of the side frame assemblies FIGURE 1 ...

Page 8: ...to the top roll assembly with the supplied hardware Or it can be added after the top roll assembly is bolted to the side frames Raise the top roll assembly into position and lower it slowly onto the top of both side frames Using the supplied 3 8 16 bolts fasten the side frame top plates to axle bearing plates using the three corner bolt holes Figure 4 NOTE POSITION THE LIFTING DEVICE AND STRAPS AC...

Page 9: ...Part Number 6410T0006 Version 4 23 2010 9 FIGURE 3 FIGURE 4 FIGURE 5 ...

Page 10: ...umber 6410T0006 Version 4 23 2010 10 Slide Motor onto Keyed Stub axle Figure 5A Figure 5B Attach Limit sprocket to stub axle via bolt bend tab up to secure Attach L bracket mounted on motor to header assembly ...

Page 11: ... two center bolt holes in the side frame top clamping plates Figure 4 Step 10 Release the brake by pulling down on the brake release lever Figure 6 Rotate the top roll assembly until the slots in both cable drums are accessible through the openings in the axle bearing brackets Figure 7 Reengage the brake by releasing the brake disengagement lever Both cable drum slot should have the same orientati...

Page 12: ...type Reference the section that is applicable to your installation NOTE WITH 0 WRAPS THE CABLE DOES NOT HANGS STRAIGHT DOWN FROM THE CABLE DRUM IT STILL HAS TO OF A WRAP ON THE CABLE DRUM IT SHOULD NEVER HANG STRAIGHT DOWN FROM THE CONNECTION POINT TO THE CABLE DRUM COUNTER BALANCE SPRING INSTALLATION AND CABLE ROUTING STANDARD BOTTOM BEAM FIGURE 7 Correct Incorrect ...

Page 13: ...t the pre stretch point Figure 8 D Unroll cables and lay out to full length Ensure that they are not twisted and there are no kinks in the cable itself Starting on one side left hand or right hand attach the looped end of the cable to the cable drum at the attachment point Figure 7 E Starting at the cable drum feed the other end of cable from front to back going underneath the cable drum and aroun...

Page 14: ...from back to front Pull all of the cable slack through H Thread the cable under the bottom pulley from front to back Pull all of the cable slack through I Thread the end of the cable up through both U bolt wire rope clips on the appropriate end on the bottom beam Figure 10 Detail A Pull cable taught and tighten down bolts on both clips See notes below NOTE DO NOT TRIM EXCESS CABLE AT THIS TIME CAB...

Page 15: ...E FOR FUTURE REFERENCE NOTE IGUS CHAIN ADJUSTMENT FIGURE 11 THE IGUS CHAIN SHOULD BE ADJUSTED WITH THE DOOR IN THE CLOSED POSITION THIS IS TO PREVENT IT FROM BECOMING ENTANGLED AND CAUSING BREAKAGE TO THE CHAIN THE IGUS CHAIN SHOULD BE ADJUSTED SO THAT THE LOOP IS APPROXIAMTELY 2 3 INCHES ABOVE THE GROUND WITH THE DOOR IN THE CLOSED POSITION RUN THE DOOR TO FULL OPEN POSITION AND BACK TO THE FULL ...

Page 16: ...RITE THE SPRING TAG INFORMATION ON THE INSIDE OF THE SIDE FRAME FOR FUTURE REFERENCE C Clamp the intermediate pulley bracket in an upright position with center hole placed at the pre stretch point Figure 8 D Unroll cables and lay out to full length Ensure that they are not twisted and there are no kinks in the cable itself Starting on one side left hand or right hand attach the looped end of the c...

Page 17: ... Pull all of the cable slack through H Thread the cable under the bottom pulley from back to front Pull all of the cable slack through I Pull the cable taught up to the cable clamp block on the appropriate side of the bottom beam Mark the cable at this point where it matches up with the cable clamp block Figure 13 J Remove the 10 24 bolt holding the cable clamp in the block Thread the cable up thr...

Page 18: ...through the outside hole Pull all slack out cable at this time K Tighten both set screws 10 24 on cable clamp L Install the cable clamp back in the block and tighten the bolt Ensure that clamp is able to swivel freely in the block FIGURE 13 FIGURE 14 ...

Page 19: ...abric completely into the side frame guide Either moving the bottom beam manually back and forth to allow the curtain to slide back into the side frames or open the side frame covers and re insert the curtain to accomplish this task B Push and hold the reset button for 3 5 seconds until the reset light goes out The door has been reset and is ready for operation Refer to the electrical manual for w...

Page 20: ...side frames are plumb and door is level at this time by placing a level on the top roll assembly Shim either side frame as required to accomplish this Step 7 Using proper anchoring hardware for this application weld or through bolt the side frames in position If welding a 2 inch weld every 12 inches is recommended If bolting in place there are anchor holes located on the backside at the top and th...

Page 21: ...Part Number 6410T0006 Version 4 23 2010 21 FIGURE 17 FIGURE 16 FIGURE 18 ...

Page 22: ...dge QUARTERLY INSPECTION 1 Inspect all hardware for proper tightness Any loose hardware should be tightened It is recommended to apply a thread locker compound to any bolts that are consistently coming loose I e Loctite 242 blue Refer to the maintenance checklist for more details 2 Observe both open and close door limits Ensure that a proper floor seal is intact when door is fully closed There sho...

Page 23: ...ons EM Q C A Interlock EM Q C Timers EM Q C A Warning Lights Horns EM D C R ACTUATORS Pushbuttons EM D C Pull Switches EM D C Radio Controls EM D C A Motion Detectors EM D C A Floor Loop Detector EM D C A DOOR FABRIC SIDEFRAMES Door Fabric D C Fabric Tracking D C A Bottom Beam End Brackets 4 2 Q C Mounting Fasteners Q C A Bearings Locking Collars Q C A Windbar System 6 9 D C A Vision Panels 6 5 D ...

Page 24: ...ce or the more severe the service the more thoroughly and frequently it should be inspected Be sure to maintain records of each inspection Appoint a qualified person to inspect Inspections should be carried out by a person who has learned through special training or practical experience what to look for and who knows how to judge the importance of any abnormal conditions the may discover It is the...

Page 25: ... will not be returned to their original positions The rope should be replaced immediately A typical failure of a rotary drill line with a poor cutoff practice These wires have been subjected to continuous peening causing fatigue type failures A predetermined regularly scheduled cutoff practice can help eliminate this type of problem This is localized wear over an equalized sheave The danger here i...

Page 26: ...rrected and the pulleys replaced CABLE DRUM INSPECTION Check the cable drums for excessive wear The grooves on the cable drums should be well defined and deep enough so the cable tracks in the grooves and does not overlap on itself If the grooves are worn to the extent they do not retain the cable then the cable drums should be replaced SELF REPAIRING DEVICE BOTTOM BEAM TYPE Optional a steel cable...

Page 27: ...ASSURE THAT THE MOVING MOTOR PARTS ARE NOT EXPOSED WHILE THIS PROCEDURE IS BEING PERFORMED Steps 1 Remove the fan cover 2 Loosen nut referred to in Figure 28 as item 6 3 Set the air gap T referred to Figure 28 to 0 3mm by adjusting the screw referred to in Figure 28 as item 5 4 Tighten nut referred to in Figure 28 as item 6 to lock in the gap setting 5 Verify that the gap X referred to Figure 28 i...

Page 28: ...This option adds a bracket and chain drive sprockets to remote the standard drive unit out in front of the door top roll It is used in applications with limited side room clearance This option is not available with an All Star drive unit NOTE REFERENCE FIGURE 29 WHILE PERFORMING THIS PROCEDURE FIGURE 29 ...

Page 29: ...acket is in between gear reducer and chain drive bracket 4 Attach the other chain sprocket to the output shaft of the gearbox and tighten setscrew 5 Attach the chain around both chain sprockets and connect the two ends of the chain together using the chain connection link 6 Loosen slightly M16 x 30mm bolts Apply tension to the chain by turning the center bolt on the chain tensioner 3 8 16 x 2 5 he...

Page 30: ...ed reversing feature utilizes through beam photocells that are mounted on retractable stainless steel tubes located on each end of the bottom beam The photocells travel 6 below the leading edge during door travel and reverse the door immediately when an object is detected before edge strikes object FIGURE 30 ...

Page 31: ...tion 4 Re install rubber stops to the top ends of both guide bars 5 Feed the photocell cables through the pre installed female cable chain clips inside the side frames 6 Manually move the C S E guide bars up and down to verify smooth operation 7 Disengage the gearbox or release brake if equipped with an All Star pulse encoder drive unit and lower the door slowly until it is fully closed The cable ...

Page 32: ...ise until it turns on At this point turn the knob slightly more to ensure a stable operation 5 Place an object i e tool underneath the door reversing edge to break the photocell beam The red relay activated LED should turn off If it does not then rotate gain knob counter clockwise until LED turns off Rotate the gain knob back clockwise until it turns on At this point rotate the knob slightly more ...

Page 33: ...ROCEDURE 1 Attach front cover mounting brackets to both axle bearing brackets utilizing pre tapped holes in bearing brackets 2 Lift the cover into place in front of both mounting brackets 3 Align all pre tapped holes in cover and mounting brackets and secure cover using the four supplied 5 16 18 cap screws FIGURE 32 ...

Page 34: ... front of the mounting brackets 3 Align the pre tapped holes in mounting brackets and secure cover using the six supplied 14 x screws 4 Attach and secure the end plates to the full roll cover using the ten supplied 8 x 5 8 hex head screws 5 Attach motor cover to full roll cover open side up The flap on the motor cover will attach to the backside of the full roll cover 6 Secure bottom of motor cove...

Page 35: ...ol panel at the disconnect switch 2 Open both side frame covers 3 Remove cable tension from the bottom beam 4 There are two suggested methods available to accomplish this a Using a chain pull and starting on one side pull the spring up to remove tension from the cables Remove the bolt that supports the spring tang inside the intermediate pulley bracket Remove tension from the spring until it is fu...

Page 36: ...clips This will allow the removal of the old existing Full Vision Panel INSTALL REPLACEMENT FULL VISION PANEL Thread the hinge pin between the clips on the bottom door panel and the Full Vision Panel Figure 35 Lay both pieces on a clean level surface and align the clips NOTE ENSURE TO INSTALL THE VELCRO STRIPS ON THE FULL VISION PANEL ON THE SAME SIDE AS THE VELCRO FOR THE BOTTOM DOOR PANEL WHEN I...

Page 37: ...ter grip on the hinge pin use a pair of pliers to push the hinge pin in short increments Be careful not to bend the hinge pin which could weaken it 2 If the hinge pin becomes jammed on one of the clips pull it back a short distance twist it slightly and resume pushing Once it becomes extremely difficult to continue pushing the hinge pin using a pair of needle nose pliers pull it out and away from ...

Page 38: ...Part Number 6410T0006 Version 4 23 2010 38 Figure 37 ...

Page 39: ...T0006 Version 4 23 2010 39 NOTE ENSURE THE HINGE PIN DOES NOT BECOME TWISTED AS THE SLACK IS PULLED OUT DEPENDING ON THE DOOR PANEL WIDTH SEVERAL LOOPS MAY BE REQUIRED TO HELP FACILITATE THREADING OF THE PIN Figure 38 ...

Page 40: ...he installer to the clips on both top and Full Vision Panel Ensure the velcro strips are facing the front of the door panel Clamp the Full Vision Panel to the board in several places to assist in supporting the weight and to keep the clips aligned Figure 38 NOTE WHILE SUPPORTING THE FULL VISION PANEL AND BOTTOM BEAM IT IS IMPERATIVE THAT THEY ARE KEPT AS SMOOTH AND STRAIGHT AS POSSIBLE WRINKLES IN...

Page 41: ...he motor The flexible cables of the assemblies allow them to be mounted at various positions on the same side of the wall as the drive unit or can be mounted remotely on the opposite side of a wall KEY TO FIGURE 39 Note Assembly part number 8220050 does not include items 3 or 4 1 Disengagement Handle 2 Cable flexible with sheath 3 Motor brake disengagement lever 4 Washer 5 Mounting Bolt Figure 39 ...

Page 42: ...Part Number 6410T0006 Version 4 23 2010 42 Figure 39A ...

Page 43: ... stub axle and attach the 41B54 sprocket onto stub axle While ensuring it is in line with the 41B12 sprocket tighten set screw on sprocket Thread the 41 roller chain around both sprockets Adjust size of chain to enable it to ride securely on both sprockets by removing links as necessary Secure the chain by joining the end links together Thread the hand chain through the chain guide holes and over ...

Page 44: ...ROCEDURE Mount manual hoist housing on wall a few inches below stub axle on desired side of door Note this will be on the opposite side from the door operator if supplied Place supplied small key in keyway and attach the 41B12 sprocket to shaft on manual hoist housing Tighten set screw to secure sprocket in place Place supplied larger key in keyway on stub axle and attach the 41B54 sprocket onto s...

Page 45: ...ole in engage coupling lever located on hoist housing Run cable through end of spring attachment on disengagement lever and secure using cable clamp supplied To engage the manual hoist the lever should be in the down position Wire electrical interlock switch as indicated by the electrical schematics provided with the door This switch will wire in place where a crank switch is indicated on the draw...

Page 46: ...r strapped type windbars only one windbar per side front or back is permitted The strapless option allows for up to three windbars per side When using multiple windbars on one side of a door rubber spacers are installed on the ends of the tubes for noise reduction Each windbar per side will reduce the door full open position by 4 inches WARNING REMOVE ALL POWER AT THE FUSED DISCONNECT DURING ALL E...

Page 47: ... rear windbar mount simply run the straps over the top to the backside of the door NOTE WHEN INSTALLING THE WINDBAR STRAPS REMOVE ANY TWISTS AND ENSURE THAT NO FRAYING OCCURS IN THE WINDBAR STRAPS DO NOT CUT WINDBAR STRAPS UNTIL WINDBARS ARE COMPLETELY INSTALLED Working with one strap at a time loop the outside right hand strap around the bottom of the windbar and bring it up to the strap bracket ...

Page 48: ...ive unit Manually move the door to the fully open position Ensure the windbar is lifted by the straps and remains inside the windbar channel Check the windbar level again and adjust the straps again if necessary Cut the excess strap at least 3 to 6 inches from the clamps Re engage the drive unit brake ...

Page 49: ...wly lower it onto the windbar stops located inside the C channel view A A For a rear windbar install the windbar into the C channel at the cut out provided at the tops of the side frames If more than one windbar per side install remaining windbars stacking them one on top of another spacers placed on the ends of each windbar will prevent them from knocking together when the door is opened There ar...

Page 50: ...Part Number 6410T0006 Version 4 23 2010 50 FIGURE 45 Figure 46 ...

Page 51: ... INSTALLATION NOTE REFERENCE FIGURE 47 WHILE PERFORMING THIS PROCEDURE Locate the pre drilled mounting holes on the top roll assembly Lift ACS unit into place in front the door top troll assembly Attach ACS unit to door using supplied 20 bolts 4 per ACS unit FIGURE 52 FIGURE 47 ...

Page 52: ...AL SHOCK DO NOT USE THIS FAN WITH ANY SOLID STATE SPEED CONTROL DEVICE Ensure the correct voltage as marked on the unit is used Provide electrical disconnect and wire according to ACS wiring diagram Figure 48 Size disconnect according to actual ACS wiring diagrams supplied with door Note A separate fused 3 phase circuits must be provided for ACS unit to provide for proper protection FIGURE 48 ...

Page 53: ...cal with minimal or no fluttering FOR INTERIOR MOUNTING the split location should be approximately 3 outside the doorway and 12 above the floor See Figure 50 FOR EXTERIOR MOUNTING the split location should be approximately 6 outside the doorway and 12 above the floor See Figure 51 If the split location does not conform to the above the specifications the air directional vanes in the outlet nozzle ...

Page 54: ...NG OVERLOAD PROTECTION ALWAYS DISCONNECT THE POWER SOURCE BEFORE SERVICING To keep your ACS operating at peak efficiency semi annual cleaning of the blower wheels and housings is recommended Remove dust and dirt build up from the blower wheels and housings The motor is totally enclosed and permanently lubricated ...

Page 55: ...of motion ELECTRICAL Fused disconnect installed and properly wired to control panel Three phase power available at control panel Control panel mounted at serviceable height Drive unit door limit switches gearbox disconnect switch and brake motor kill switch properly wired to control panel Door actuators installed and properly wired to control panel i e pushbuttons pullswitches floor loops etc Door...

Page 56: ...NOTES DOCUMENT TITLE 670 Owner s Manual DOCUMENT NUMBER 6410T0005 VERSION DATE 4 23 2010 DOOR MODEL S 570 670 ELECTRONIC FILE 670 570Owners Manual DOC ASSEMBLY Owners Manual REPLACES N A ORIGINATOR Rick Walton Andrew Wojcik MANAGER APPROVAL DATE ...