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
ARCHITECTURAL Architectural Drawing of the 570 & 670 Rapid Roll Door Models.
ARCHITECTURAL Table of Contents STATEMENT OF WARRANTY RAPID ROLL® MODELS 670 .................................................................4 SAFETY PRACTICES ....................................................................................................................................5 PACKING LIST ...............................................................................................................................................6 RAPID ROLL® MODEL 570/670 INSTALLATION ...................
PACKING LIST STATEMENT OF WARRANTY RAPID ROLL® MODELS 670 EXCLUSIVE FIVE YEAR WARRANTY ON ROLLTEX FABRIC AND BALANCE/TENSIONING SPRINGS Albany International warrants to the original owner of the door that the ROLLTEX and TENSIONING SPRINGS will be free of defects in materials and workmanship for a period of FIVE (5) YEARS from the date of shipment.
INSTALLATION SAFETY PRACTICES WARNING THOROUGHLY READ THESE SAFETY PRACTICES PRIOR TO INSTALLING, OPERATING, OR SERVICING A HIGH-SPEED, RAPID ROLL® DOOR. FAILURE TO FOLLOW THESE SAFETY PRACTICES MAY RESULT IN PROPERTY DAMAGE, PERSONNEL BODILY INJURY, OR DEATH. 1. Do not operate a Rapid Roll® Door while you are under the influence of drugs or alcohol. 2. Do not use the door if any parts appear to be broken or damaged. 3. Stay clear of the door while it is operating. 4.
INSTALLATION PACKING LIST Before beginning the installation, thoroughly inspect the crate to ensure all necessary components are there. The following list applies to a standard Model 570/670 door (no optional parts are indicated).
INSTALLATION RAPID ROLL® MODEL 570/670 INSTALLATION FRAME AND GENERAL INSTALLATION Step 1. Unpack crate and inventory parts, comparing against 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.
INSTALLATION Step 3. Verify that the opening is plumb and that the floor slab is level. If they are not, shimming and adjustments to the side frames must be made to accomplish this during door installation. Refer to approval drawings for this door to confirm drive side mounting (left or right-hand). Step 4. Remove side frames from crate (one at a time) and erect them into position against the wall at the pre-marked locations on the floor. Step 5.
INSTALLATION FIGURE 3 FIGURE 4 FIGURE 5 Part Number 6410T0006 9 Release 10/15/2004
INSTALLATION Slide Motor onto Keyed Stub axle. Figure 5A Attach Limit sprocket to stub axle via bolt, bend tab up to secure.
INSTALLATION Step 8. Cut the plastic straps that are tied around the top roll assembly and bottom beam. Allow the door curtain to drape down a maximum of two feet. Step 9. Install the top pulley brackets on both side frames using the four remaining 3/8”-16 bolts and the 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).
INSTALLATION Correct Incorrect FIGURE 7 NOTE: the counter balance spring and cable installation section below is divided into two sections based on the bottom-beam 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 ¼ TO ½ OF A WRAP ON THE CABLE DRUM. IT SHOULD NEVER HANG STRAIGHT DOWN FROM THE CONNECTION POINT TO THE CABLE DRUM.
INSTALLATION A. Starting on one side, install a counter balance spring into one side frame by hooking the spring tang in the side frame bottom plate bracket and standing it upright inside the side frame. B. Each spring has a tag indicating the door serial number, spring size, number of pre-wraps on cable drums, and spring pre-stretch distance. Using a tape measure, determine and mark the inside of the side frame to indicate the pre-stretch point of the spring. C.
INSTALLATION NOTE:REFERENCE FIGURE 10 WHILE PERFORMING THE NEXT 4 STEPS. INSTALL CABLES AND SPRINGS ONE SIDE AT A TIME. FIGURE 10 F. Thread the cable through the intermediate pulley clamped to the side frame. Pull all of the cable slack through. G. Thread the cable over the top pulley 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.
INSTALLATION NOTE PRESTRETCH ON THE SPRING TAG IS A STARTING POINT AND MAY NEED TO BE EITHER INCREASED OR DECREASED TO ACHIEVE PROPER BALANCE. AFTER THIS IS ACHIEVED, USE A PERMANENT MARKER TO WRITE THE SPRING TAG INFORMATION ON THE INSIDE OF THE SIDE FRAME 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.
INSTALLATION BOTTOM BEAM EQUIPPED WITH SELF-REPAIRING DEVICE™ OPTION. A. Starting on one side, install a counter balance spring into one side frame by hooking the spring tang in the side frame bottom plate bracket and standing it upright inside the side frame. B. Each spring has a tag indicating the door serial number, spring size, number of pre-wraps on cable drums, and spring pre-stretch distance.
INSTALLATION NOTE: REFERENCE FIGURE 12 WHILE PERFORMING THE NEXT 7 STEPS. INSTALL CABLES AND SPRINGS ONE SIDE AT A TIME. FIGURE 12 F. Thread the cable through the intermediate pulley bracket clamped to the side frame. Pull all of the cable slack through. G. Thread the cable over the top pulley from back to front. 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.
INSTALLATION down 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.
INSTALLATION BOTTOM BEAM EQUIPPED WITH RAPID RESET™ OPTION. (Model 670 Only) For the model 670, the door size or wind load may cause the door design t exceed a practical limit to this technique. In this case, the Rapid Reset System (RRS) may be used. The mechanical installation is the same as the SRD. The Self Repair Device (SRD) option should be selected for interior doors or in exterior applications where there are no heavy winds.
INSTALLATION hole, and tighten the lock nut (Figure 14). Step 3. Remove come-a-long and perform steps 11 through 13 for the other side of the door. Step 4. When the counter balance system has been fully installed, disengage gearbox and manually move door over its entire range of motion. Larger size doors (i.e. 14’ wide x 14’ high) may require the assistance of a lifting device to manually move.
INSTALLATION FIGURE 16 FIGURE 17 FIGURE 18 Part Number 6410T0006 21 Release 10/15/2004
INSTALLATION MAINTENANCE AND INSPECTION WARNING REMOVE ALL POWER AT THE FUSED DISCONNECT DURING ALL ELECTRICAL OR MECHANICAL SERVICING. DISCONNECT MUST BE PROPERLY LOCKED OUT DURING MAINTENANCE OR SERVICE OF EQUIPMENT. DAILY INSPECTION 1. Run through a full door cycle (open/close) and ensure smooth operation. Verify that the door is not jammed or hanging up. 2. Check the door fabric and door frame for any visible damage or unusual wear. Refer to the maintenance checklist for more details. 3.
INSTALLATION RAPID ROLL DOOR 570/670 MAINTENANCE CHECKLIST MAINTAINENCE ITEM/ REFERENCE PERIOD ACTION / EM / EM /6.2 / EM D D C/A C/A D C Steel/Rope Cables /5.4.1 Cable Attachment Bolts /4.2 Cable Drum /5.4.3 Spring / Spring Attachment /4.2 Balance System /4.
INSTALLATION INSPECTIONS WIRE ROPE INSPECTION All wire ropes will wear out eventually and gradually lose work capability throughout their service life. That’s why periodic inspections are critical. Applicable industry standards such as ASME B30.2 for overhead and gantry cranes or federal regulations such as OSHA refer to specific inspection criteria for varied applications.
INSTALLATION A wire rope that has been subjected to repeated bending over sheaves under normal loads. This results in fatigue breaks in individual wires – these breaks are square and usually in the crown of the strands. An example of fatigue failure of a wire rope subjected to heavy loads over small sheaves. The breaks in the valleys of the strands are caused by “stand nicking.” There may be crown breaks, too. Here you see a single strand removed from a wire rope subjected to “strand nicking.
INSTALLATION Here’s a wire rope that has jumped a sheave. The rope “curled” as it went over the edge of the sheave. When you study the wires, you’ll see two types of breaks here: tensile “cup and cone” breaks and shear breaks that appear to have been cut on an angle. Drum crushing is caused by small drums, high loads and multiple winding conditions. PULLEY INSPECTION Check the cable pulleys for excessive wear on the inside of the groove. The cable should not be wearing of the insides of the pulleys.
INSTALLATION BRAKE ADJUSTMENT The motor brake is located inside the fan cover compartment of the motor. It can be accessed by removing the fan cover. Refer to Figure 28 while following this procedure. WARNING MAKE SURE THE DOOR IS POWERED DOWN AND LOCKD OUT BEFORE REMOVING THE FAN COVER. THIS IS TO 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.
INSTALLATION OPTION INSTALLATION AND OPERATION CHAIN DRIVE INSTALLATION 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.
INSTALLATION 1. Mount the chain drive bracket to the side frame using the (4) 3/8-16 nuts and existing studs on axle bearing bracket. 2. Attach the chain sprocket, 28mm diameter bore, to the stub axle and tighten set screw. 3. Mount the drive unit to the chain drive bracket using the (4) M16 x 30mm hex head bolts. Ensure chain tensioner bracket (“L” bracket) 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.
INSTALLATION CONTACTLESS SAFETY EDGE™ (C.S.E.) MECHANICAL INSTALLATION This patented 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.
INSTALLATION PACKING LIST • • Cable chain, (2 pieces, length dependent upon height of door) LH & RH C.S.E. guide bar assemblies NOTE REFERENCE FIGURE 30 WHILE PERFORMING THIS PROCEDURE. WARNING ENSURE THE DOOR COUNTER BALANCE SYSTEM HAS BEEN INSTALLED AND PROPERLY TENSIONED PRIOR TO PERFORMING THIS PROCEDURE. 1. Place the bottom beam of the door at an accessible height (i.e. four feet off the ground).
INSTALLATION ADJUSTMENTS Adjustments to the photo amplifier box will be required at installation of the C.S.E. and may also require periodic adjustments. (See Figure 31) 1. Activate door and stop it at a central location (i.e. 5 feet off the ground) using the EMERGENCY STOP button. 2. Ensure the range selector switch is in the up position (long range). 3. Ensure the operation selector switch is in the bottom position (light operated). 4. Ensure green power LED and the red relay activated LED are on.
INSTALLATION FRONT COVER INSTALLATION NOTE REFERENCE FIGURE 32 WHILE PERFORMING THIS PROCEDURE. FIGURE 32 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.
INSTALLATION FULL ROLL COVER & MOTOR COVER INSTALLATION NOTE REFERENCE FIGURE 33 WHILE PERFORMING THIS PROCEDURE. FIGURE 33 1. Attach full roll cover mounting brackets to the axle bearing brackets. 2. Lift the cover into place in front of the mounting brackets. 3. Align the pre-tapped holes in mounting brackets and secure cover using the six supplied #14 x ½” 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.
INSTALLATION FULL VISION PANEL™REPLACEMENT WARNING REMOVE ALL POWER AT THE FUSED DISCONNECT DURING ALL ELECTRICAL OR MECHANICAL SERVICING. DISCONNECT MUST BE PROPERLY LOCKED OUT DURING MAINTENANCE OR SERVICE OF EQUIPMENT. The Full Vision Panel™ consists of a 24” clear PVC panel the runs the entire width of the door. It is attached to the fabric approximately four to five feet off the floor. This option is not available on a 670 with a Self-Repairing Device™ or an Impact Release System™.
INSTALLATION FIGURE 35 Pull the bottom hinge pin out of the clips (Figure 35). In order to prevent damage to these parts, support the bottom door panel and bottom beam during this step. This will prevent them from dropping to the floor. Pull the top hinge pin out of 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).
INSTALLATION Before threading the hinge pin, ensure the Full Vision Panel™ is centered with respect to the door panel. Lubricate the clips and/or hinge pin with a small amount of light oil (or similar lubricant). This will help facilitate the threading procedure. Thread the hinge pin between the loops in the clips. The clips, from each panel, should be alternately spaced and threaded accordingly. d. Push the plastic hinge pin in as far as possible.
INSTALLATION Figure 37 Part Number 6410T0006 38 Release 10/15/2004
INSTALLATION Figure 38 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.
INSTALLATION When the hinge pin is completely threaded through the entire length of the clips, loop it back through the clips for six to eight inches, then back to the end again. Cut off excess on each end of the pin (Figure 37). Install a width support between the side frames. a. Measure the distance between the inside edge of rear windbar channel. Cut a wooden board (i.e. 2x4) length to the distance measured in the previous step plus 3/8”.
INSTALLATION MANUAL DISENGAGEMENT The manual disengagement lever assembly allows the drive unit brake to be released remotely. Two lever assemblies may be installed on the 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 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.
INSTALLATION Figure 39A Part Number 6410T0006 42 Release 10/15/2004
INSTALLATION MANUAL HOIST INSTALLATION This option eliminates the drive unit and allows the door to be operated manually via a manual hoist. NOTE REFERENCE FIGURE 40 WHILE PERFORMING THIS PROCEDURE. Mount manual hoist housing on wall a few inches below stub axle on drive side of door. 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.
INSTALLATION MANUAL HOIST WITH DISCONNECT INSTALLATION This option allows disengagement of the gearbox while allowing the door to be operated via a manual hoist. The manual hoist itself has a disconnect feature (mechanical and electrical) that allows it to spin freely when operating the door with a drive unit. NOTE REFERENCE FIGURE 41 WHILE FOLLOWING THIS PROCEDURE. Mount manual hoist housing on wall a few inches below stub axle on desired side of door.
INSTALLATION 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 the pocket wheel. Secure the chain by joining the end links together. Mount disengagement lever approximately five feet above the floor. Thread steel cable (supplied) through hole in engage coupling lever (located on hoist housing).
INSTALLATION WINDBAR INSTALLATION GENERAL A windbar is a hollow aluminum tube that runs the entire width of the door to provide additional wind resistance to the door fabric. It runs up and down in vertically mounted C-channels attached to both side frames. This tube is lifted by either straps (for strapped type) or rubber windbar hooks attached to the bottom beam (strapless type). For strapped type windbars, only one windbar per side (front or back) is permitted.
INSTALLATION Ensure the side frame covers are closed. Close the door fabric completely. Attach the two windbar strap attachment blocks to the top of each windbar strap bracket using the supplied #10-32 x ¾” cap screws (view A-A). Do not fully tighten the screws at this time. Measure from the top edge of the bottom beam assembly to the top edge of the windbar channel on each side frame cover. Mark the centerline of this dimension on the inside of each windbar channel.
INSTALLATION on the brake release lever (All★star™ with pulse encoder drive 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.
INSTALLATION STRAPLESS WINDBAR INSTALLATION NOTE REFERENCE FIGURES 44, 45, 46 WHILE PERFORMING THIS PROCEDURE. NOT AVIALIBLE WITH SRD OR RRS OPTIONS Ensure the side frame covers are closed. Close the door fabric completely. Insert the windbar from the top of the windbar channel and slowly 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.
INSTALLATION FIGURE 45 Figure 46 Part Number 6410T0006 50 Release 10/15/2004
INSTALLATION AIR CIRCULATION SYSTEM MECHANICAL INSTALLATION NOTE: REFERENCE FIGURE 47 WHILE PERFORMING THIS PROCEDURE. FIGURE 52 FIGURE 47 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 ¼ – 20 bolts (4 per ACS unit).
INSTALLATION ELECTRICAL INSTALLATION CAUTION ELECTRICAL SHOCK HAZARD. DISCONNECT POWER SOURCE WHENEVER SERVICING UNIT. WARNING TO REDUCE THE RISK OF FIRE OR ELECTRICAL 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.
INSTALLATION Connect the proper size cables (supplied by other) to the pigtail leads in the junction boxes. Run wires for switch controls back to the main control panel. AIR FLOW ADJUSTMENTS With the ACS operating and the door in its full open position, check to see that nothing is obstructing the airflow at the discharge nozzle. Find the air stream split location. Hold a handkerchief, by a corner, approximately 12” above the floor. Gently move the handkerchief back and forth in the doorway.
INSTALLATION on each end of the unit. Always disconnect the power source before removing the cover. MAINTENANCE AND CLEANING WARNING THE MOTOR HAS INTERNAL SELF-RESETTING 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.
PACKING LIST RAPID ROLL® MODEL 570/670 INSTALLATION CHECKLIST Door Serial No. __________ Date of Installation __________ Installer’s Name ________________________ Enduser________________________________ Company _____________________________ _______________________________________ City ___________________ State ______ City ____________ State______ Zip________ Phone No. ______________ MECHANICAL: Crate fully unpacked. Verified door parts against packing list. No parts are missing and they are undamaged.
INSTALLATION NOTES DOCUMENT TITLE 670 Owner’s Manual DOCUMENT NUMBER 6410T0005 ISSUE DATE 2004-06-01 DOOR MODEL(S) 570/670 ELECTRONIC FILE 670-570Owners Manual.
