R Y T E C

Turbo-Seal
Insulated
Installation Manual

P.O. Box 403, One Cedar Parkway, Jackson, WI 53037

Phone: 262-677-9046 Fax: 262-677-2058
Rytec Website: www.rytecdoors.com, Rytec On-line store: www.rytecparts.com
Rytec E mail: helpdesk@rytecdoors.com, Parts E mail: Parts@rytecdoors.com
[Revision: December 2nd, 2014, R11701100, ©Rytec Corporation 2010]
 TABLE OF CONTENTS
PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DOOR SERIAL NUMBER(S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MATERIAL, TOOLS, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADDITIONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Labor and Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fill-In Material Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL ARRANGEMENT OF
DOOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ANCHORING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Concrete, Block, or Brick Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Insulated Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LOCATING SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SIDE COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

COUNTERWEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DOOR SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 13

DOOR OPEN- AND CLOSE-LIMIT POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT . . . . . . . . . . . . 14

Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 15
KILL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RESETTING BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

PATHWATCH LED™ WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR CURTAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SIDE COLUMN HEATED BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Insulated Panel Travel - Shimming Panel……………………...……………………21

 INTRODUCTION

INTRODUCTION NOTE: NOTE is used to provide additional infor-

mation to aid in the performance of the
The information contained in this manual will allow you procedure or operation of the door, but not
to install your Rytec Turbo-Seal Insulated® Door in a necessarily safety related.
manner that will ensure maximum life and trouble-free
operation. DOOR SERIAL NUMBER(S)
Any unauthorized changes in procedure, or failure to fol- To obtain your DOOR SERIAL NUMBER, there are
low the steps as outlined in this manual, will automati- three universal locations where this information can be
cally void the warranty. Any changes in the working found. These are on the door of the System 4 control
parts, assemblies, or specifications as written that are panel, the left side column (remove lower side column
not authorized by Rytec Corporation, will also cancel cover) at approximately eye level and the drive motor.
the warranty. The responsibility for the successful oper- (See Figure 1.)
ation and performance of this door lies with the owner of
the door. IMPORTANT: When installing multiple doors
of the same model but in differ-
DO NOT OPERATE OR PERFORM MAINTENANCE
ent sizes, verify the serial num-
ON THIS DOOR UNTIL YOU READ AND UNDER-
ber in the control panel with the
STAND THE INSTRUCTIONS CONTAINED IN THIS
one in the side column.
MANUAL.
If you have any questions, contact your Rytec represen-
tative or call the Rytec Technical Support Department at Drive Motor
800-628-1909. Always refer to the serial number of the System 4 Gearbox Assembly
door when calling the representative or Technical Sup- Control
Panel Lifting
port. The serial number plate is located inside one of the Pockets
side columns.
A wiring schematic is provided with each individual
door, specifically covering the control and electrical
components of that door.
HOW TO USE MANUAL
Throughout this manual, the following key words are Air Curtains
used to alert the reader to potentially hazardous situa-
tions, or situations where additional information to suc-
cessfully perform the procedure is presented:

Left Side Column

WARNING is used to indicate the potential With Heated Blower
for personal injury, if the procedure is not
performed as described.
Right Side Column
With Heated Blower
A8700065

Figure 1
CAUTION is used to indicate the potential
for damage to the product or property NOTE: The lifting pockets mounted to the top of
damage, if the procedure is not followed the head assembly are there for forklift
as described. operation only. It’s not necessary to
remove the lifting pockets after
IMPORTANT: IMPORTANT is used to relay installation.
information CRITICAL to the
successful completion of the
procedure.

1
INSTALLATION—MATERIAL, TOOLS, AND EQUIPMENT
INSTALLATION
MATERIAL, TOOLS, AND EQUIPMENT
1. Threaded rod (¹/₂-in. diameter) and other various
wall anchor hardware and material. Concrete
anchor bolts (¹/₂-in. diameter).
(See “ANCHORING METHODS” on page 3.)
2. Assorted shim stock.
3. Double-sided tape (to temporarily hold shims).
4. Carpenter’s or spirit level (4-ft. minimum length).
5. Carpenter’s square.
6. Fish tape.
7. Hammer drill.
8. Masonry drill bit (for ¹/₂-in. diameter anchors).
9. Three or four bar clamps (48-in. long).
10. Hammer or mallet, and block of wood.
11. Crowbar or pry bar.
12. Assorted hand tools (pliers, tape measure, etc.).
13. Socket and wrench sets.
14. Water level, line level, or transit.
15. Two ladders (taller than height of door opening).
16. Forklift (see “Forklift Requirements”).
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. Two installers.
2. An electrician is required for making all electrical
connections. (See “Electrician’s Responsibilities”.)
NOTE: All electrical work must be performed in
accordance with local and state building
codes.
3. 100% accessibility to the door opening during the
entire installation process. No traffic should be
allowed to pass through the opening while the door
is being installed.
Forklift Requirements
A forklift supplied by the customer, dealer, or installer is
mandatory for the safe and proper installation of this
door. The forklift should have:
• 4,000-pound lift capacity.
• minimum height ability — door height plus 42 in.;
39 in. if lifting pockets are removed.
• side-shift capability (desired).
2
Electrician’s Responsibilities
For complete details on the responsibilities of the elec-
trician, refer to the Rytec System 4 Drive & Control
Installation & Owner’s Manual.
1. Install fused disconnect and Rytec control panel.
(See Figure 2 for typical installation.)
2. Install all necessary conduit tubing.
NOTE: Separate high and low voltage conduit.
3. Run electrical power lines to disconnect.
4. Run power lines from disconnect to control panel.
5. Run power lines from control panel to upper junc-
tion box.
6. Run power lines from control panel to door motor.
7. Run low-voltage cables from door to control panel.
8. Mount rear photo eyes.
9. Wire low-voltage safety devices and activators (if
used).
High and low voltage wires/cables in separate metal
conduit run to the bottom of the System 4 control panel.
All wires/cables cut to length DO NOT leave excess
wire/cable loops on the door or in the control panel.
Fill-In Material Requirements
Some applications may require the use of a door pullout
(extension) to gain clearance of an existing obstruction
between the door and the door opening. The following
materials can be used to fill the space or gap between
the door and the door opening.
1. 16-gauge hot-rolled sheet steel.
2. 2-in. x 2-in. x ³/₁₆-in. angle iron.
3. Insulated panels.
NOTE: If any pullout or buildout is used in the
installation it must be insulated to prevent
frost and ice buildup on or in the door. Fail-
ure to properly insulate the pullout can
affect the operation of the Turbo-Seal
Insulated door.
It is very important to seal and caulk
around the pullouts to prevent frost and ice
buildup.
 INSTALLATION—GENERAL ARRANGEMENT OF DOOR COMPONENTS

GENERAL ARRANGEMENT OF
DOOR COMPONENTS
Figure 2 shows the location of the major components of
the door and the general placement of the associated
sub-assemblies for a typical installation.
This illustration is provided to you for informational pur-
poses only. It should not be relied upon solely during the
installation of your door and its sub-assemblies.

Head Assembly (Includes

Drive Motor Gearbox Assembly,
Fabric Roll)
Fused A8700042
Disconnect
Lifting Figure 3
Pockets
ANCHORING METHODS
Correct anchoring of the side columns to the wall and
the floor is important for the smooth and safe operation
of the door. The wall material should be strong enough
to support the weight of the door and all wall anchors.
System 4 Air curtains Figure 4 through Figure 7 show anchoring methods for
Control various types of walls. Use the method that is best
Panel suited for your particular installation site.
Bottom Bar
Assembly All necessary anchoring hardware and material required
for the installation of this door are the responsibility of
the door owner. If you have any questions, call your
Rytec representative or the Rytec Technical Support
Left Side Column with
Heated Blower (Includes Serial Department at 800-628-1909.
Number Plate, Counterweight, NOTE: Use ¹/₂-in. diameter threaded through bolts
and Patchwatch LED) or ¹/₂-in. diameter threaded rods to anchor
Right Side Column with the door to all wall applications. Use ¹/₂-in.
Heated Blower (Includes diameter concrete anchor bolts to anchor
Counterweight and Patchwatch LED) the door to a concrete floor.

Figure 2 If expansion anchors are used, a quarterly

inspection should be implemented for safe
NOTE: Figure 2 shows the front side of the door. and secure door operation.
Left and right are determined when view-
ing the front side of the door. Concrete, Block, or Brick Walls

UNCRATING
Your Rytec door has been crated to allow for minimal Concrete Wall
Side
handling of assemblies during the installation process. Column
NOTE: Remove parts and sub-assemblies from
the shipping crate in the order directed Expansion
throughout this manual. Anchor

1. Remove the top of the crate.

2. Remove the front of the crate. (See Figure 3.)
A0500005

Figure 4

Patchwatch LED™ is owned by Rytec High Performance Doors.

3
INSTALLATION—LOCATING CENTERLINE OF DOOR OPENING

Wood, Block, Brick, or Insulated Walls LOCATING CENTERLINE OF DOOR OPENING

NOTE: Accurate measurements are critical for the
Wood proper installation and operation of your
Wall Side Rytec door. Verify all measurements.
Column
1. Measure the width of the door opening.
Crush Plate 2. Divide the measurement in half to locate the center-
(¹/₂-in. Thick, line. Then mark the centerline along the floor.
6-in. x 8-in.
(See Figure 8.)
Steel)

Through Bolt
or Threaded Rod
A0500037

Figure 5 Centerline of
Opening
Insulated Wall

Insulated Wall

Side Overall Width

Through Bolt Column
or Threaded Rod of Door Opening
Half Width of
A0500001 Door Opening

Figure 8

LOCATING SIDE COLUMNS

1. Locate the layout drawing of the door. It should be
Aluminum-Clad Lumber attached to the small parts carton packed inside the
(Front and Back Sides — Full Length) shipping crate. This drawing identifies the produc-
A0500039 tion width of your door. Verify the dimension pro-
Figure 6 vided by measuring the width (length) of the head
assembly.
2. Using the centerline as a reference point, lay out
Insulated
and mark half of the door’s production width along
Wall
the floor. (See Figure 9.)
Through Bolt
or Threaded Rod Side
Column

This door is equipped with a breakaway

bottom bar assembly. To ensure that it
works properly, the width of the door
opening must not be smaller (narrower)
Aluminum-Clad Lumber than the production width of the door. If
(Back Side — Full Length) the width of the opening is narrower than
A0500038
the width of the door, do not proceed with
Figure 7 the installation. Contact your Rytec repre-
sentative or the Rytec Technical Support
Department at 800-628-1909.

4
 INSTALLATION—SIDE COLUMNS

Half of Door
Production Centerline of
Width Opening

This Dimension
Must Be Equal
on Both Sides
of Door Opening

Extend and Mark

Edges of Door Along Floor Water Level
A0500002

Figure 9 Shim Plate

3. With a carpenter’s square placed against the wall,
mark both sides of the door along the floor. Extend
the line along each edge.
4. Check the floor for level across the door opening.
The floor must be level within 0.12 in. from side-to-
side. If one side of the opening is higher than the
other, a shim under the side column will be required.
Figure 10 and Figure 11 show two methods that
can be used to ensure level side columns.
NOTE: Contact the Rytec Technical Department if
the floor is more than 1 in. out of level.
Line Level
(If Required)
A0500004
Figure 11
SIDE COLUMNS
The following procedure details the installation of the
side columns in standard and freezer door applications.
They are virtually the same except that the freezer door
will come with insulated channels.
Side columns are extremely heavy; use
proper lifting and support equipment
when removing from crate. Personal injury
may result from using improper handling
procedures.

1. Remove the right side column from the shipping

crate.
2. Remove the covers from the side column by remov-
ing the screws that hold the covers in place. Save all
hardware for later use.
3. Stand the right side column on the floor. Place it
against the wall, just outside the line indicating the
This Dimension Must Be production width of the door. Use bar clamps as
Equal on Both Sides of needed. (See Figure 12.)
Door Opening
Shim Plate
A0500003
(If Required)

Figure 10

5
INSTALLATION—SIDE COLUMNS

IMPORTANT: It is critical that the side columns

are mounted square and plumb
with the wall, and level across
the door opening. Using a 4-foot
level and carpenter’s square will
help ensure the columns are cor-
rectly set. Place shims where
necessary.

In addition, the use of bar clamps

will allow you to temporarily
secure the columns to the wall, Anchor Point
while allowing you to make slight
adjustments during the installa- Carpenter’s
tion process. Level
Right Side
Column

Before drilling any holes, ensure there are

no electrical wires, water pipes, or gas
lines, etc., buried in the floor or hidden in
the wall.

4. Once the side column is set plumb and square,
anchor it to the wall and floor. Predrilled anchor
points have been provided in the side column. DO
NOT securely tighten the anchors at this time —
they will be tightened later on after the head assem-
bly is installed. (See Figure 12 and Figure 13.)
NOTE: Use ¹/₂-in. expansion shell or stud-type
anchors for concrete walls. Use through
bolts or threaded rods for brick walls and
other applications where expansion
anchors are not appropriate.
If a stud-type anchor is used for the bottom
anchor, the anchor must not extend more
that 1¹/₂ in. above the base plate of the side
column.
Production Width Line
A8700004
Figure 12
5. Mount the left side column to the wall and floor in
the same manner that was used for installing the
right side column.
6. With both columns set and snugly bolted in place,
check the overall squareness of each column.
(See Figure 13.)
Compare the diagonal measurements and the
upper and lower horizontal measurements across
the columns. The columns are square and parallel
when the diagonal measurements are equal and
the horizontal measurements are equal.
If either column requires a slight repositioning
(when the difference of either comparison is
greater than ¹/₄ in.), use a block of wood and a mal-
let to nudge the column into position.

6
 INSTALLATION—HEAD ASSEMBLY

Horizontal Measurements The head assembly is extremely heavy;

Must Be Equidistant. use proper lifting and support equipment
when removing from crate. Personal injury
may result from using improper handling
procedures.

Secure the head assembly to the forklift

Diagonal prior to lifting it to the top of the side col-
Measurements umns.
Must Be
Equidistant 2. Lift head assembly into position by using one of two
methods:
a. Use the fork pockets on top of the head assem-
bly. The lifting pockets are provided to prevent
damage to the foam panel. (See Figure 15.)
NOTE: Personal injury or equipment damage may
result from the head assembly not being
secured.
A8700037

Figure 13

HEAD ASSEMBLY
1. Remove head assembly from crate.
(See Figure 14.)

Fork
Head Pockets
Assembly

A8700044

Figure 15

b. For overhead clearance problems, secure head

assembly with C-clamps and a strap from the
A8700043
rear spreader to the forks of the forklift or
Figure 14 mechanical lift before lifting it into position. (See
Figure 16 and Figure 17.)
NOTE: Personal injury or equipment damage may
result from the head assembly not being
secured.

To prevent damage to door components,

use cloth or packing material between the
forks and the head assembly. Pay close
attention to the foam door panel.

7
INSTALLATION—HEAD ASSEMBLY

4. Attach head assembly to each side column. Hard-

Forks ware is located in the small parts carton.
Strap
a. Install two ³/₈-16 x 1¹/₄-in. hex flange machine
screws and ³/₈-16 serrated flange hex lock nuts.
Install machine screws from the bottom of the
side column. (See Figure 19.)

NOTE: Items have been removed for clarity.

A8700045

Figure 16

Forks

C-Clamps Hex Flange Machine Screws

and Serrated Flange Lock Nuts

A8700051

Figure 19
A8700046
b. Install five ³/₈-16 x 1¹/₄-in. hex flange machine
Figure 17 screws. (See Figure 20.)
3. With the head assembly safely secured to the fork-
lift, place it on top of the side columns. Line up the NOTE: Items have been removed for clarity.
alignment pin on the head assembly with the align-
ment hole in the side column. (See Figure 18.)

Hex Flange Machine Screws

Alignment Pin Inserted Hex Flange Machine Screws

in Alignment Hole Head (Two Installed from Bottom)
Assembly
A8700051

Figure 20

5. Once the head assembly is set plumb and square,

A8700015
anchor it to the wall.
Figure 18

8
 INSTALLATION—COUNTERWEIGHTS

NOTE: Anchor points in the head assembly are

predrilled at the factory for the load bear-
ing cross-sectional area. Do not add addi-
tional points for mounting. Please consult
your Rytec representative or call the
Rytec Technical Support Department at
800-628-1909 with questions.

6. After the head assembly is secured to both side col-

umns, securely tighten all floor and wall anchors.
7. Unclamp the head assembly from the forklift and
then remove the forklift.
8. Remove the bar clamps that were used to secure
the side columns to the wall.
COUNTERWEIGHTS 6 to 8 in.

A counterweight can weigh in excess of

100 pounds. Make sure that safe handling
procedures are followed and that each A8700012
counterweight is securely supported dur-
ing its installation. If not handled properly, Figure 21
a counterweight can damage door compo- 3. Install counterweight guide plate toward the rear of
nents and cause serious personal injury. the column. (See Figure 22.)
1. Place a counterweight in the bottom of each side
column.
2. Securely block each counterweight 6 to 8 in. above
the bottom of the side column. (See Figure 21.)
Guide
Plate

At this point the counterweight is free

standing. Secure counterweight from fall-
ing over while installing the guide plate
assembly. Personal injury can result.

NOTE: For photo purpose, the guide plate is shown

and should NOT be installed at this time.

A8700007

Figure 22

4. Swing guide plate up for installation.

(See Figure 23.)

9
INSTALLATION—COUNTERWEIGHTS

Counterweight
Guide Strap
Plate
Plastic
Tie

Swing Up

A8700008 A8700047

Figure 23 Figure 25
5. Set mounting plate on top of the guide plate. 8. Route counterweight strap over idler pulley and
feed through access hole in the head assembly.
6. Secure mounting plate and guide plate to the coun- (See Figure 26.)
terweight with two ³/₈-16 UNC x 1³/₄ hex head cap
screws and ³/₈ in. split lock washers. NOTE: The counterweight strap is installed at the
(See Figure 24.) factory. The factory standard is three pre-
wraps around the counterweight spool.
Mounting
Plate
Guide NOTE: Items have been removed for clarity.
Hex Head Cap Screws
Plate
with Split Lock Washers

Counterweight
Strap Spool
Counterweight

Idler
Pulley

Counterweight
Strap

Guide
Roller
A8700055

A8700006 Figure 26

Figure 24 9. With the straps hanging straight, attach them to the

7. Remove the plastic tie from each counterweight counterweights using two ³/₈-16 UNC x 1³/₄ hex head
strap. (See Figure 25.) cap screws, ³/₈ in. split lock washers, and clamp bars
provided in the small parts carton. Route the straps
NOTE: Door must be in the fully open position. through the clamp bars as shown in Figure 27.

10

IMPORTANT: The 6 to 8 in. mounting height for
each counterweight, as indi-
cated in Figure 21, is adequate
for most Turbo-Seal Insulated
Doors. However, for extra-wide
or -short doors, the counter-
weights may have to be adjusted
closer to the bottom of the side
column.
To check the position of each
counterweight, first release the
motor brake by pulling on the
brake release cable. Then manu-
ally move the door to its fully
closed position. The clearance
between the top of each counter-
weight and the top of its associ-
ated side column must be at
least 2 in.
If an adjustment is necessary,
move the door to the fully open
position. After placing a support
block under the counterweight,
readjust the strap, as required,
until the 2-in. clearance is
achieved.
Hex Head Counterweight
Cap Screws Strap
Split Lock
Washer
Clamp
Bars
Counterweight
A8700009
Figure 27
INSTALLATION—ANTENNA
10. Tighten the clamp bars to secure each strap. Then
carefully remove the support block from under each
counterweight to allow the weights to hang free. If
necessary, readjust the straps.
11. After all adjustments are complete, cut off any
excess strap to within 6 in. of the upper clamp bar.
Use tape or a tie strap to attach the loose end of
each strap to the main length of strap.
12. Secure bottom guide plate to the counterweight
with two ³/₈-16 UNC x 1³/₄ hex head cap screws and
³/₈ in. split lock washers.
13. Attach the side column covers using the saved
hardware.
ANTENNA
IMPORTANT: The antenna is a fragile and highly
sensitive instrument. Extreme care
should be used in handling this
piece of equipment.
1. Remove antenna from small parts carton.
2. Carefully remove packing material from antenna.
Inspect for damage.
NOTE: Do not install antenna if it is found to be
damaged. Call your local Rytec representa-
tive or the Technical Support Department at
800-628-1909 for a replacement.
3. Remove machine screw from the bottom of the side
column. (See Figure 28.)
Machine
Screw
A8700052
Figure 28
11
INSTALLATION—ENCODER

4. Install antenna mounting bracket to side column

along with machine screw previously removed. Socket Head
Cap Screw
5. Install antenna onto mounting angle and secure To Wireless
with two M4 x 12 mm Phillips flathead machine Encoder Antenna
screws, M4 flat washers, and M4 hex head nuts. Mounting
Plate
Hardware is located in the small parts carton.
Split Lock
6. Route antenna cable over side column to the Washer
encoder. (See Figure 29.)
Encoder
NOTE: To secure antenna cable, use plastic ties
Feig
as required. Encoder
Hub Shaft
Encoder
Coupling
Shaft Eurodrive
Mounting Washer
Bracket

Machine Antenna
Screw
A9800016

Figure 30

DOOR SEALING
Nut, Washer, and Foam insulation is built into the side column. The insu-
Machine Screw lation is a technical and important item in the proper
A8700020 operation of the Turbo-Seal Insulated Door. From the
moment the door is uncrated until the door is installed,
Figure 29
strict care should be taken not to damage the insulation
ENCODER on the back side of the side column. (See Figure 31.)

1. Install the Feig encoder hub shaft end to the end of In addition to the insulation, a thermal break foam core
the encoder coupling shaft and tighten set screw. is constructed into the components of the door assem-
The Feig encoder hub can be found in the small bly. This gives the door an extra barrier to combat
parts carton. against temperature differential. (See Figure 32.)

NOTE: The Eurodrive washer, split lock washer,
and encoder coupling shaft are factory
installed on the gearbox. Use a mild
thread locker on set screw.
2. Install encoder mounting plate with encoder using
four M8 x 1.25 x 18 mm socket head cap screws.
3. Connect encoder cable to encoder.
4. Install plastic zip tie into socket head screw and
secure the encoder cable. (See Figure 30.)
NOTE: The zip tie that is used to secure the
encoder cable is of special design. The
ribbed end inserts into the valley of the
socket head cap screw.
For a tight and air-proof seal, a bead of caulk should be
applied at the inside perimeter of the door assembly.
Use a construction grade of caulk to seal the door.
IMPORTANT: Use caulk as directed per manu-
facturer’s instructions. Improper
wall preparation may result in
poor adhesion. The door may
not be altered in any form to
apply caulk.

All hardware is located in the small parts

carton.

12
 INSTALLATION—CONTROL PANEL AND ELECTRICAL CONNECTIONS

NOTE: If a floor loop is used, all wiring from the

NOTE: Foam insulation is shaded in gray. fused disconnect to the control box and
from the control box to the motor mount
side column, as well as conduit running
Wall from the control box to the floor, is pro-
vided by the door owner/installer or the
Foam Foam electrician. All wiring and conduit must
Insulation Insulation meet all local and state codes. Wires pro-
vided with the door are labeled with termi-
nal or contact numbers.

DOOR OPEN- AND CLOSE-LIMIT POSITIONS

See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The close- and open-limit
door positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that the
door travel allows the black vinyl loop on the bottom bar
to gently seal against the floor. (See Figure 33.)
Foam
Insulation DO NOT allow the rubber reversing edge, enclosed in
the black vinyl loop, to come in contact with the floor.
A8700032

Figure 31

Damage to the rubber reversing edge or

other bottom bar parts can occur if the
door seal is allowed to seal too tightly
Foam Core
against the floor.

Foam Panel

A8700038

Figure 32
Foam End Tab
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec Sys-
tem 4 Drive & Control Installation & Owner’s Manual for
information on control panel installation, electrical con-
nections, door limit settings, and initial door start-up pro-
cedure. Black Vinyl
Loop

A8700079

Figure 33

13
INSTALLATION—REVERSING EDGE SWITCH INSPECTION AND ADJUSTMENT

Open-Limit Position Reversing Edge Switch Air Bleed Check

When the door is knocked out of position, the System 4
Drive & Control takes over and will raise the tabs high
enough to be reinserted into the side columns. The
open-limit switch should be adjusted so that the door
travel allows a minimum of half the foam breakaway The disconnect must be in the OFF posi-
tab into the yellow channel guides of each side column. tion and properly locked and tagged before
(See Figure 34.) performing the following procedure.

1. The reversing edge switch is located inside the bot-

tom bar assembly, on the end opposite the drive
motor. To inspect and adjust the switch, remove the
access cover from the face of the bottom bar
assembly. (See Figure 35.)

Access Cover
Foam End Tab

Yellow Channel
Guide

A8700080 Bottom Bar

Assembly
Figure 34

REVERSING EDGE SWITCH INSPECTION AND

ADJUSTMENT
A8700080

Figure 35

2. Make sure the clear PVC hose is in tight contact

Do not stand under the door panel when
testing the reversing edge. If the reversing
edge switch is not working properly, the
panel could strike personnel and cause
injury.
with the air input post so that air leakage cannot
occur and that vibration will not cause the hose to
fall off. Also make sure the hose is not kinked.
(See Figure 36.)

To check the reversing edge switch, run the door

through the down cycle. As the door is lowered, tap the
bottom of the reversing edge. The door is set up from
the factory for 3 impacts of the reversing edge before
remaining open. If the reversing edge is tripped 3 times
consecutively the door will remain open and code F:361
will appear on the display. Push and hold the STOP/
RESET button 3 to 5 seconds and the control will reset.
Push the down arrow to close the door.
If the door does not reverse direction, check the air
bleed and sensitivity of the reversing edge switch.

14
 INSTALLATION—KILL SWITCH INSPECTION

2. Turn the sensitivity adjustment screw clockwise until

Reversing
continuity is achieved. Then turn the sensitivity
Edge Switch
(On Side Air Bleed screw 2 full turns counterclockwise for a standard
Opposite Adjustment setting. Some doors may require a further adjust-
Door Motor) Screw ment counterclockwise. (See Figure 37.)
NOTE: Testing the reversing edge is the best way
to determine sensitivity.

3. Reattach the wires and resistor; then replace the

access cover.
NOTE: If the reversing edge is too sensitive, the
PVC Hose — Must Be Tight door may reverse direction during the clos-
on Lower Input Hose ing cycle without coming in contact with an
A7500227 object. If this occurs, readjust the revers-
ing edge switch.
Figure 36

3. The air bleed has been set at the factory and should
not require adjustment. If adjustment is necessary,
turn the air bleed adjustment screws located on the
front and back of the switch fully clockwise — but do
not overtighten. Then turn each screw back (coun-
terclockwise) one full turn.
Reversing Edge Switch Sensitivity Adjustment
KILL SWITCH INSPECTION
Kill switches have been mounted at each end of the bot-
tom bar assembly. The purpose of these switches is to
prevent the door from being operated if the breakaway
bottom bar becomes separated from one or both of the
side columns.

Take precautions to prevent the door from

The disconnect must be in the OFF posi-
tion and properly locked and tagged before
performing the following procedure.
1. The reversing edge switch is a normally open con-
tact. The PVC hose is on the lower air input post. To
adjust the switch, first remove the resistor from the
contact terminals and attach an ohmmeter across
the two terminals. (See Figure 37.)
Reversing
Edge Switch
Resistor
being opened or closed while performing
the following procedure.
1. Move the door so that the bottom bar assembly is
approximately head or chest height.
2. Push the breakaway bottom bar out of the side col-
umn. It should not be possible to restart the door.
If the kill switch operated properly: Reinstall the
bottom bar into the side column. (See “RESET-
TING BOTTOM BAR” on page 16)
If the kill switch did not operate properly: Check
wiring. If wiring is OK, repair or replace the switch.

Performing this adjustment without the

door in the JOG MODE may cause per-
sonal injury or death.
Remove Resistor
Sensitivity to Test and
Adjustment Screw Adjust Switch
A7500227

Figure 37

15
INSTALLATION—RESETTING BOTTOM BAR

NOTE: Should the door panel have been dam-

aged during the impact, remove the door
Whisker Switch from service and repair. If you have any
questions, contact your Rytec representa-
tive or call the Rytec Technical Support
Department at 800-628-1909.

Bottom Bar Foam Breakaway Tab

Assembly

Foam Tabs Out

of Side Column

A8700003

Figure 38 Side Column

Channel

A8700081
Foam Breakaway Tab
Figure 40

2. The door panel will momentarily pause and then

execute the reset procedure.
3. The door panel’s foam breakaway tabs will roll
upward above the side column’s channel. (See
Figure 41.)

Bottom Bar
Assembly

Foam Breakaway Tab

A8700081

Figure 39

RESETTING BOTTOM BAR

The Turbo-Seal Insulated Door is a fully automated self-
resetting door. After a strike and a clear sensor path, the
door will automatically reset the bottom bar. The pro-
Side Column
cess goes as follows:
Channel
1. The foam breakaway tabs have popped out of the
side column’s channel due to impact. (See Figure
40.) A8700071

Figure 41

16
 INSTALLATION—PATHWATCH LED™ WARNING LIGHTS

4. The photo eye senses if the path is clear of any NOTE: The Pathwatch LED’s are already pre-
obstructions. installed in the side columns at the factory.
Be sure to route cables away from all mov-
5. Then the door panel will guide itself into the channel
ing parts. Use cable ties as required.
and resume its normal operation.
(See Figure 42.)

Door Panel Has Been Reset

and Is Shown in Normal Amber and Red Pathwatch
Operating Position LED Warning Lights

RY-WI Cover

A8700017

Figure 43

Front
A8700080
1. Connect cable to front warning light.
Figure 42
2. Route front cable:
NOTE: The door function is fully automatic; it will
reset, rise to the open position, and rein- a. Down the side column.
sert the bottom bar according to factory- b. Through the angle iron bracket at the bottom of
installed parameters. Cycling the door and the side column.
checking for proper door operation is not
required unless prescribed, but an occa- c. Up the rear of the side column through the back
sional test of the self-repair system would angle corner pieces.
ensure its proper operation. Should slight d. Through the top access hole in the head assem-
adjustments of the door be needed, bly and to the rear junction box.
please contact your Rytec Technical Sup-
NOTE: Use the conduit mounted on the rear panel
port at 800-628-1909.
of the head assembly to route the cable
PATHWATCH LED™ WARNING LIGHTS across to the junction box.

The standard setting for the warning lights is: 3 seconds 3. Secure cable with plastic ties to the rear angle cor-
prior to the door closing, the lights will flash yellow and ner pieces.
then change to a steady red while closing. Adjustments 4. Connect cable to junction box per schematic.
to the closing time can be made through the System 4
Rear
Control Panel. Please contact your Rytec Technical
Support department at 800-628-1909 for assistance. 1. Connect cable to rear warning light.
(See Figure 43.) 2. Route rear cable:
IMPORTANT: Photo eyes are used as a safety a. Up the rear of the side column through the back
feature and not as a door opener. angle corner pieces.
Never try to interrupt either set
b. Through the top access hole in the head assem-
of photo eyes as the door is clos-
bly and to the rear junction box.
ing. Wait for the door to perform
its normal cycle before entering
or exiting doorway.

Patchwatch LED™ is owned by Rytec High Performance Doors.

17
INSTALLATION—PHOTO EYES

NOTE: Use the conduit mounted on the rear panel

of the head assembly to route the cable to
the junction box.
3. Secure cable with plastic ties to the rear angle cor-
ner pieces.
4. Connect cable to junction box per schematic.
PHOTO EYES
The photo eyes are provided as a safety feature. If the Receiver
photo eyes are correctly installed, interrupting either set Module
of eyes as the door is closing will reverse the direction Designation
of the door and hold it in the fully open position until the Alignment Light
interruption is removed. (Yellow)

Your Turbo-Seal Insulated Door is equipped with two

sets of photo eyes. The front set of eyes monitors the
front side of the door — they are mounted in holes 18
inches from the bottom. The rear set of eyes monitors A2500259
the back side of the door — they are mounted in holes
28 inches from the bottom. Figure 45

The transmitter and receiver can be identified in two Front

ways. The transmitter is designated SMT 3000 on the
white label or by a single green light that comes on at the
clear end of the transmitter. (See Figure 44.) The receiver
is designated SMR 3215 on the white label or by a yellow
light that illuminates only when it is in proper alignment
with the transmitter. (See Figure 45.)
NOTE: When the cable is connected to the photo
eye, there is only a ¹/₄-inch window to see
the green or yellow LED light.
Transmitter
Module
Designation
Power Light
(Green)
A2500258
Figure 44
1. Connect cable to front photo eye.
2. Route front cable:
a. Down the side column.
b. Through the angle iron bracket at the bottom of
the side column.
c. Up the rear of the side column through the back
angle corner pieces.
d. Through the top access hole in the head assem-
bly and to the rear junction box.
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable
across to the junction box.
3. Secure cable with plastic ties to the rear angle cor-
ner pieces.
4. Connect cable to junction box per schematic.
Rear
1. Connect cable to rear photo eye.
2. Route rear cable:
a. Up the rear of the side column through the back
angle corner pieces.
b. Through the top access hole in the head assem-
bly and to the rear junction box.
NOTE: Use the conduit mounted on the rear panel
of the head assembly to route the cable to
the junction box.

3. Secure cable with plastic ties to the rear angle cor-

ner pieces.
4. Connect cable to junction box per schematic.

18
 INSTALLATION—AIR CURTAIN

Testing Photo Eyes 3. Install right side of air curtain to mounting bracket
With the power on, the green light on the transmitter using two 10-24 x ³/₄-in. cap screws and ¹/₄-in. lock-
indicates the photo eye module is powered up. When washers. (See Figure 48.)
the yellow light on the receiver module is also lit, the
transmitter and receiver modules are properly aligned.
Placing your hand in front of the receiver breaks the light
path and causes the yellow light to go out. Removing
your hand causes the yellow light to go back on.
Hardware
Air Curtain Right Air Curtain
Mounting Bracket
NOTE: Hardware is located in the small parts carton.

1. Install left air curtain mounting bracket using two

¹/₄-20 x ³/₄-in. hex flange serrated machine screws and
¹/₄-in. hex serrated flange lock nuts. (See Figure 46.)

Air Curtain
A8700076

Figure 48

4. Repeat procedure for left side of air curtain.

Hardware (See Figure 49.)

Left Air Curtain

Mounting Bracket
Hardware

Hardware Left Air Curtain

Mounting Bracket

A8700074

Figure 46 Air Curtain

2. Repeat procedure for right mounting bracket.

(See Figure 47.)
A8700077
Hardware
Figure 49

5. Repeat procedure for opposite air curtain assembly.

6. Route electrical wiring to the junction box through
the angle brackets located behind the front panel of
the head assembly.
Hardware

Right Air Curtain

Mounting Bracket
A8700075

Figure 47

19
INSTALLATION—SIDE COLUMN HEATED BLOWER

Side Column Heated Blower
There are two holes are in the bottom of the side column.
These holes expose the interior of the yellow fiberglass
triangular extrusions. Warm air blows into these holes up
the triangular extrusions and exit two holes at the top of
the side column. (See Figure 50 and Figure 51.)
NOTE: Heated blowers are shipped loose and
holes are pre-cut in side columns.
NOTE: Use the wire chase in the side column to
route the cable to the power source. The
cable can be routed through a hole in the
head assembly. Leave excess cable in the
bottom of the side column to allow for
removal of bottom cover in the future.
3. Be sure that the cable doesn't interfere with the
travel of the counterweight.
4. Using the supplied Tek® screws, mount the heated
blower to the side column cover pre-drilled holes.
5. Plug supplied cord into end of heated blower.
6. Turn the thermostat control fully clockwise to set
blower heat to high.

Warm Air Top Exit Holes

Thermostat Control

A8700086

Figure 50
A8700088

Figure 52

7. Install side column covers and turn on the electrical

supply.
NOTE: The fan for the side column heaters must
be rotating for the defrost system to work
properly. During shipment the fan may
bind against the casing. If the fan is not
turning, rotate the fan on the shaft and the
fan should begin to turn. If not, check for
Warm Air Bottom Supply Holes
proper voltage to the fan and contact
Rytec Technical Support for assistance at
1-800-628-1909.

After 30 minutes the surface of the heater

housing should be warm to the touch and
frost should begin to dissipate. Please
contact Rytec Technical Support at 1-800-
A8700087 628-1909 with any questions.
Figure 51

1. Remove side column covers.

2. Starting from the bottom, route the supplied cord up
the side column through the head assembly and to
the junction box.

20
FINAL CHECKS
FINAL CHECKS
NOTE: Check all of the following door compo-
nents and systems once the door panel has
been cycled at least 20 times.
Side Columns: Check that side columns are plumb and
square and that all anchor bolts are secure and tight.
Head Assembly: Check that all mounting hardware is
in place and tight.
Bottom Bar: Smoothly travels up and down within the
side columns.
Limit Positions: Adjusted properly. Up and down travel
of the door should be as described in “DOOR OPEN-
AND CLOSE-LIMIT POSITIONS” on page 13.
Motor: Check that the door travels in the proper direc-
tion when the button is pressed.
Reversing Edge: Works properly. As the door is clos-
ing, if the reversing edge makes contact with an object,
the door should immediately return to the fully open
position as described in “REVERSING EDGE SWITCH
INSPECTION AND ADJUSTMENT” on page 14.
Timers: Automatic timers must be set to ensure that the
door closes properly, as described in the Rytec System
3 Drive & Control Installation & Owner’s Manual.
Activators: Operate as specified by manufacturer.
Caulk: Ensure that the side columns and head assem-
bly are caulked where they meet the wall of the building.
Counterweight Straps: Check the routing of all coun-
terweight straps as indicated in Figure 26. Ensure that
the straps are in full contact with all rollers.
Counterweights: Counterweights should be adjusted
as shown in Figure 21. Adjust if necessary.
Kill Switch: When the bottom bar assembly is knocked
out of the side column(s), the kill switch must operate as
described in “KILL SWITCH INSPECTION” on page 15.
Photo Eyes: Make sure the photo eyes are working as
described in “DAILY INSPECTION” on page 6 in the
Turbo-Seal Insulated Owner’s Manual.
Defrost System: Make sure the blowers are adjusted
and operating properly.
Insulated Panel Travel: The foam of the insulated
panel of the door varies in thickness and compression.
Therefore, the panel may require shimming. A 20”X20”
section of Rilon™ material shipped with the door to
use as shim material. This material can be cut to use
as shim material. (See Figure 53)
Operate the door several times and watch the yellow
plastic bottom bar travel as the door opens and closes.
The yellow plastic bottom bar should remain centered
in the opening throughout the travel of the door. You
may notice the bottom bar shifting left and right but
again it should remain in the center of the opening.
If the yellow bottom bar is traveling too far in one
direction it will be necessary to shim the panel to
correct the travel.
To shim the panel place a piece of the Rilon™ material
between the panel and the drum; when the door is in
the closed position.(See Figure 54)
Lock out and tag out the electrical supply
before placing the shim material between
the drum and insulated panel.
DO NOT attempt to perform this procedure
with the power on or serious injury could
result.
When the shim has been installed repeat testing of the
panel travel to ensure the shimming is correct.
It is possible that both sides may require shimming.
NOTE: Shim opposite the direction the bottom bar is
traveling. For example, if the bottom bar is
traveling to the right too far, shim on the left
between the drum and panel. Service Bulletin
#196 contains more detail. Can be found on
Rytec Knowledge Center website.
Figure 53
Figure 54
21
NOTES

22