R Y T E C

PredaDoor
NXT ®

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: [email protected], Parts E-mail: [email protected]
[Revision: AB 11/1/18, R1060168-0, ©Rytec Corporation 2009]
 TABLE OF CONTENTS
PAGE

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

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOLS AND EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLOOR LOOP EQUIPMENT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BASIC JOB REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICIAN’S RESPONSIBLITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL ARRANGEMENT OF DOOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

Wood, Block, Brick, or Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Insulated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOCATING CENTERLINE OF DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

SPREADER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Door without Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Door with Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

BOTTOM BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ENCODER MAGNET, ENCODER AND WIRELESS ANTENNA. . . . . . . . . . . . . . 10

Install the encoder magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Install the encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install the wireless antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wire the encoder to the System 4 controller . . . . . . . . . . . . . . . . . . . . . . . 11
PHOTO EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Testing Photo Eye Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ELECTRICAL WIRING ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CONTROL PANEL AND ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . 14

DOOR OPEN- AND CLOSE-LIMIT POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Close-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Open-Limit Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . 15

Reversing Edge Switch Air Bleed Check . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reversing Edge Switch Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . 16
PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . 16

Kill Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Kill Switch Air Bleed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Kill Switch Sensitivity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RESETTING BOTTOM BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PHOTO EYE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ALUMINUM HOOD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ABS HOOD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
 INTRODUCTION—DOOR SERIAL NUMBER(S)

INTRODUCTION IMPORTANT: When installing multiple doors

of the same model but in
The information contained in this manual will allow you
different sizes, verify the serial
to install your Rytec PredaDoor NXT® Door in a manner
number on the control panel
that will ensure maximum life and trouble-free
with the one on the side column.
operation.
Left Side Column
Any unauthorized changes in procedure, or failure to
follow the steps as outlined in this manual, will Drive Motor
automatically void the warranty. Any changes to the Right Side
working parts, assemblies, or specifications as written Column
that are not authorized by Rytec Corporation will also
cancel the warranty. The responsibility for the
successful operation and performance of this door lies
with the owner of the door.

DO NOT OPERATE OR PERFORM MAINTENANCE

Serial Number
ON THIS DOOR UNTIL YOU READ AND UNDER- Location
STAND THE INSTRUCTIONS CONTAINED IN THIS
MANUAL.
Rytec
If you have any questions, contact your Rytec representative System 4
or call the Rytec Technical Support Department at 800-628- Control Panel
1909. Always refer to the serial number of the door when
calling the representative or Technical Sup- port. The serial
number plate is located on the small edge of the left side
column. (See Figure 1.)

NOTE: Left side column shown.

Figure 2

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:

Serial Number
Decal WARNING is used to indicate the potential
for personal injury, if the procedure is not
A7700034 performed as described.
Figure 1

The wiring connections in this manual are for general

information purposes only. A wiring schematic is pro-
vided with each individual door specifically covering the CAUTION is used to indicate the potential for
control panel and electrical components of that door. damage to the product or property damage, if
That schematic was shipped inside the control panel. the procedure is not followed as described.
DOOR SERIAL NUMBER(S) IMPORTANT: IMPORTANT is used to relay information
Your DOOR SERIAL NUMBER information can be that is CRITICAL to the successful
found in three universal locations. These are at the completion of the procedure.
small edge of the left side column (shown in figure 1), on
NOTE: NOTE is used to provide additional
the drive motor, and on the System 4 control panel.
information to aid in the performance of
(See Figure 2.)
the procedure or operation of the door, but
not necessarily safety related.
1
INSTALLATION—TOOLS AND EQUIPMENT REQUIRED

INSTALLATION 3. The customer must guarantee 100% access to the

door opening during the installation. No traffic
TOOLS AND EQUIPMENT REQUIRED should be allowed through the door during the
1. Socket and wrench set. installation.

2. Concrete anchor bolts (1/2-in. diameter). 4. If an electrician is used, that person must make all
(See “ANCHORING METHODS” on page 3.) electrical connections. The electrician should be
present one hour after installation begins.
3. Threaded rod (1/2-in. diameter).
(See “ANCHORING METHODS” on page 3.) 5. The Rytec control box and a fusible disconnect
should be installed prior to the start of the door
4. Two ladders (taller than the door opening height). installation. (See Figure 1 for layout.)
5. Forklift. ELECTRICIAN’S RESPONSIBLITIES
6. Carpenter’s level (4-ft. minimum length). For complete details on the responsibilities of the
7. Carpenter’s square. electrician, refer to the Rytec System 4 Drive & Control
Installation & Owner’s Manual.
8. Hammer drill.
9. Masonry drill bit (1/2-in. diameter). GENERAL ARRANGEMENT OF DOOR PARTS
10. Three or four bar clamps (1-ft. length). Figure 3 shows the location of the major components
of your PredaDoor NXT. This illustration should be
11. Hammer and mallets. used as reference only and should not be used as part
12. Crowbar or pry bar. of the installation instructions.
13. Assorted hand tools (pliers, tape measure, etc.).
Drive Motor/Gearbox
14. Assorted shim stock.
Left Side Column
15. Water level, line level, or transit.

FLOOR LOOP EQUIPMENT REQUIREMENTS Fused

Fabric Roll Right Side
Disconnect Column
1. Wet-type concrete saw.
2. Wet vac.
3. 200–500 feet of 16-gauge, 19-strand, type XLPE,
copper, crosslink polyethylene jacket wire (or
equivalent). The length of wire is determined by the
size of the loop. Rytec
System 4
4. Bondo® P606 flexible embedding sealer (or Control Panel
equivalent) — required to fill grooves in floor. For
cold temperature sealing applications, Bondo P610 Photo Eye
speed set must be added to the P606 to ensure (Left)
proper curing of the filler.
5. Water supply and garden hose (for concrete saw).
NOTE: For complete floor loop installation
instructions, refer to the installation
Bottom Bar
instructions provided with your floor loop.
Photo Eye
BASIC JOB REQUIREMENTS A7700040
(Right)

1. A forklift must be supplied by the customer, dealer, Figure 3

or installer.

2. Two installers are required. NOTE: The above illustration shows the front side
NOTE: One installer must be a qualified electrical of the door. Left and right are determined
technician, and all electrical work must when viewing the front side of the door.
meet applicable codes. If the installer is
not qualified, an electrician must be
present during installation.
2
 INSTALLATION—ANCHORING METHODS

ANCHORING METHODS Insulated Walls

Correct anchoring of the side columns to the wall and
the floor is important for the smooth and safe operation Insulated Wall
of the door. The wall material should be strong enough
to support the weight of the door and all wall anchors. Side
Through Bolt Column
Figure 4 through Figure 7 show anchoring methods for or Threaded Rod
various types of walls. Use the method that is best
suited for your particular installation site.
All necessary anchoring hardware and material required
for the installation of this door is the responsibility of the
door owner. If you have any questions, call your Rytec
representative or the Rytec Technical Support
Department at 800-628-1909.
Aluminum-Clad Lumber
(Front and Back Side — Full Length)
NOTE: Use 1/2-in. diameter threaded through bolts
A0500039 Figure 6
or 1/2-in. diameter threaded rods to anchor
the door to all wall applications. Use 1/2-in.
diameter concrete anchor bolts to anchor
the door to a concrete floor or wall. Insulated
Wall
If expansion anchors are used, a quarterly
inspection should be implemented for safe Through Bolt or
Threaded Rod
and secure door operation Side Column

Concrete, Block, or Brick Walls

Concrete Wall
Side Aluminum-Clad Lumber
Column (Back Side — Full Length)

Expansion A0500038
Figure 7
Anchor

LOCATING CENTERLINE OF DOOR OPENING

NOTE: Accurate measurements are critical for the
A0500005 proper installation and operation of your
Rytec door. Verify all measurements.
Figure 4
1. Measure the width of the door opening.
Wood Walls

Wood Wall
Side Column

Crush Plate
(1/2-in. Thick,
6-in. x 8-in. Steel)

Through Bolt or
Threaded Rod

Figure 5

3
INSTALLATION—LOCATING SIDE COLUMNS

Half of Door
Production Centerline of
Width Opening

Centerline of
Opening

Overall Width
of Door Opening Extend and Mark
Half Width of
Door Opening A0500002 Edges of Door Along Floor
A0500001
Figure 8 Figure 9

LOCATING SIDE COLUMNS 3. With a carpenter’s square placed against the wall,
mark both sides of the door along the floor. Extend
1. Locate the layout drawing of the door. It should be the line along each edge.
attached to the small parts carton packed inside the
shipping crate. This drawing identifies the 4. Check the floor for level across the door opening.
production width of your door. The floor must be level within 0.12 in. from side to
side. If one side of the opening is higher than the
2. Using the centerline as a reference point, lay out other, a shim under the side panel will be required.
and mark half of the door’s production width along
the floor. (See Figure 9.) Figure 10 and Figure 11 show two methods that
can be used to ensure level side columns.
NOTE: Contact the Rytec Technical Support
Department if the floor is more than 1 in.
out of level.
This door is equipped with a breakaway
bottom bar assembly. To ensure that it
works properly, the width of the door Line Level
opening must not be smaller (narrower)
than the production width of the door.

If the width of the opening is narrower than

the width of the door, do not proceed with
the installation. Contact your Rytec
representative or Rytec Technical Support
Department at 800-628-1909.

This Dimension Must Be

Equal on Both Sides of
Door Opening Shim Plate
(If Required)
A0500003
Figure 10

4
 INSTALLATION—SIDE COLUMNS

Motor Mount Side

This Dimension Column Has Wire
Access Hole
Must Be Equal on
Both Sides of Door
Opening

Water Level

Shim Plate
(If Required)
A0500004

Figure 11 A7700020

SIDE COLUMNS Figure 12

NOTE: The standard mounting location for the 2. Stand the drive motor side column on the floor and
motor/gearbox assembly on a PredaDoor tight against the wall. To determine on which side of
NXT door is on the left but can be ordered the door to place the side column, be sure that the
to be mounted on the right. DO NOT access holes are facing away from the door opening.
change the location of the drive motor 3. Align the inside edge of the side column with the
without first contacting your Rytec production width line laid out earlier on the floor.
representative or the Rytec Technical The side column must be located on the outside
Support Department at 800-628-1909. edge of the layout line. (See Figure 13.)
The PredaDoor NXT has only one access
Anchor Holes
hole in each side column.
(Three Anchors
Required)
1. Remove the drive motor side column from the ship-
ping crate. The drive motor side column is identified
by the wire access hole along its outside edge.
(See Figure 12.) Anchor Hole for
Door Opening
Over 9 ft. 6 in.

Production Width Line

(Side Column Must Be
Located on Outside
Edge of Line)

Anchor Holes
(Two Anchors
Required)
Left Side Column

A7700021

Figure 13

5
INSTALLATION—SPREADER ASSEMBLY

Serrated-Flange
Hex Screw
It is critical that the side columns are
(Two on Each End)
mounted level and square to the wall and
floor, both vertically and horizontally. A
4-ft. level and carpenter’s square are
recommended for this procedure.

The use of bar clamps to secure the side L-Shaped Support

columns to the wall during installation is Bracket (Mounted to
Top of Header
recommended, as these hold the columns
Extrusion)
securely in place, while allowing for slight
adjustments of either side column during
the installation of the head assembly.
Spreader
NOTE: All necessary anchor hardware and material is Extrusion
the responsibility of the door owner.

4. Once the side column is properly positioned, secure

it to the wall using the appropriate anchors. (See Serrated-Flange Hex
“ANCHORING METHODS” on page 3.) Anchor Nut (Two on Each End)
A8500004
holes have been provided in the side column. (See
Figure 13.) DO NOT tighten the anchor hardware at Figure 14
this time.

NOTE: Use 1/2-in. diameter expansion shell 2. Attach the spreader assembly to the inside face of
stud- type anchors for concrete walls or each side column using two 3/8-16 x 1 1/4-in.
1 / 2 - in. diameter threaded through bolts serrated-flange hex screws and nuts at each end of
for brick walls and other applications the assembly. Face the spreader so the brush is
where expansion bolts are not acceptable. toward the front of the door. (See Figure 15.)
Use a tape measure to ensure that proper
width alignment is maintained between L-Bracket (Fits
the side columns, at the top and bottom Behind Inside
ends of each column. DO NOT tighten the Face of Side
anchors at this time. Column)

5. Mount the other side column to the wall in the same Serrated-Flange
manner as outlined above for the first side column. Hex Nut (Two
on Each End)
SPREADER ASSEMBLY
Door without Hood Assembly
Serrated-Flange
1. Attach an L-shaped support bracket to each end of Hex Screw (Two
the spreader extrusion using two 3/8-16 x 1 1/4-in. on Each End)
serrated-flange hex screws and nuts. The brackets
and mounting hardware were shipped in the small
parts carton. (See Figure 14.)
Inside Face of
Side Column
A7700025

Figure 15

3. Check that the side columns are plumb and square

with the floor and wall.
4. Tighten all anchor hardware securing both side
columns (or pullouts) to the wall.
6
 INSTALLATION—HEAD ASSEMBLY

5. Remove any bar clamps that may have been used

to temporarily hold the side columns (or pullouts) to 3. Attach the spreader assembly to the U-brackets
the wall. using two 3/8-16 x 1 1/4-in. serrated-flange hex
screws and nuts at each end of the assembly.
Door with Hood Assembly Face the spreader so the brush is toward the front
NOTE: DO NOT change the location of the drive of the door. (See Figure 17.)
motor without first contacting your Rytec Serrated-Flange
representative or the Rytec Technical Hex Screw
Header
Support Department at 800-628-1909. (Two Each Side)
Extrusion
1. Identify the drive motor side column by the wire
access holes along its outside edge. This is
important for the proper installation of the spreader
assembly.

2. Attach a spreader assembly U-bracket on the

outside face of each side column using two
3/8-16 x 1 1/4-in. serrated-flange hex screws and Support
nuts for each bracket. The U-brackets and Bracket
mounting hardware were shipped in the small parts
carton. (See Figure 16.)

IMPORTANT: Attach the large U-bracket to the drive

motor side column with the screw hole Serrated-Flange
located 6-3/4 in. from the end of the Hex Nut
bracket, nearest to the outside face of (Two Each Side)
the side column. (See Figure 16.)
A8500153
Left Side Column

Figure 17
6-3/4 in.
4. Check that the side columns are plumb and square
with the floor and wall.

Large
5. Tighten all anchor hardware securing both side
U-Bracket columns (or pullouts) to the wall.
6. Remove any bar clamps that may have been used
Small to temporarily hold the side columns (or pullouts) to
U-Bracket the wall.

Large U-Bracket HEAD ASSEMBLY

(Drive Motor
Side Column) 1. Before removing the head/fabric roll assembly from
the shipping crate, locate four ¹/₂-13 x 1¹/₄-in. serrated-
flange hex screws, four ¹/₂-13 serrated-flange nuts,
and the flange bearing assembly in the small parts
carton.
NOTE: On a door configured with pullouts, the
Serrated-Flange four 1 1/4-in. long serrated-flange hex screws
Hex Screw (Two Serrated-Flange mentioned above in step 1 were not shipped
Each Side) Hex Nut (Two with the door. Instead, the longer 1/2-13 x 6-in.
Each Side)
A8500152 hex screws that were installed earlier will be
used to attach the head assembly to the side
columns.
Figure 16

7
INSTALLATION—HEAD ASSEMBLY

Also, some oversized doors (with or with- out

pullouts) require a steel spacer between both side IMPORTANT: If your door is oversized, two
columns and the head assembly. If your door is large spacers were included in
oversized, locate two 9-in. x 1 3/4-in. steel spacers the small parts carton. Failure to
shipped in the small parts carton. (The spacers are install a spacer between the
further identified by a hole at each end.) motor mounting bracket and
flange bearing assembly could
If spacers were included in the small parts result in damage to the door.
carton but the door does not include (See Figure 18 and Figure 19.)
pullouts, four 1/2-13 x 2-in. serrated-flange
hex screws were substituted for the slightly 5. Attach the motor mounting bracket to the side
shorte4 1/2-13 x 1 1/4-in. screws mentioned column using two 1/2-13 x 1 1/4-in. serrated-flange
above in step 1. The 2-in. screws were hex screws and nuts (or two 1/2-13 x 2-in. screws
shipped in the small parts carton. and nuts). Doors with 3 or more windribs will have
spacers for the drive and non-drive side to shim the
2. Remove the head/fabric roll assembly from the drum roll assembly away from the rear spreader.
shipping crate. Failure to install these spacers (if supplied) will
cause the drum roll to jamb against the rear
spreader due to the diameter of the drum roll.
Doors with 2 windribs or less will not have the shim
material. DO NOT tighten the hex nuts at this time.
Before lifting the roll assembly, secure (See Figure 18.)
both side columns to the building wall.
Motor Mounting
Secure the roll assembly to the forklift Bracket
IMPORTANT: Install spacer between
before lifting. Failure to secure the side motor mounting bracket and side
columns or the roll assembly can result in column (if spacer is supplied).
serious injury and property damage. DO
NOT remove the forklift until the assembly
is secured to both side columns. Side Column

Use care when handling the fabric roll to

ensure that the fabric is not torn or dam-
aged. DO NOT remove the shipping bands
holding the fabric to the roll.

IMPORTANT: The fabric and bottom bar, un-roll

from the back of the drum
assembly. Serrated-Flange
Hex Screws and Nuts
3. Using a forklift, lift the head/fabric roll (Hex Nuts Only If
Pullouts Were Used
assembly in place. A7500247
4. Position the head assembly in front of the pair of
holes near the top of each side column. Align the
holes in the motor mounting bracket with the Figure 18
holes in the side column. (See Figure 18.)

6. Slide the flange bearing assembly over the drum

shaft at the non-drive end of the head/fabric roll
assembly. (See Figure 19.)

IMPORTANT: If your door requires spacers, be

sure to install a spacer between
the flange bearing assembly and
the side column. (See Figure 19.)

8
 INSTALLATION—HEAD ASSEMBLY

IMPORTANT: Install spacer between flange

bearing assembly and side column (if spacer
Pullout
is supplied).
Serrated-Flange
Serrated-Flange Hex Nut
Hex Screw Tighten Each
(Two Required) Mounting
(Two Required) Set of Nuts on
6-in. Screws Bracket

Head/Fabric Side
Roll assembly Column
Flange
Figure 20
bearing
assembly

Figure 19 Tighten Hex Screws

Level (Tighten Hex Nuts If
7. Bolt the flange bearing assembly to the side column using Pullouts Are Used)
two 1/2-13 x 1-1/4-in. serrated-flange hex screws and nuts
(or two 1/2-13 x 2-in. screws and nuts if spacers are
required, or nuts only if 6-in. screws were installed earlier).
DO NOT tighten the hex nuts at this time.

IMPORTANT: If the drum/fabric roll assembly

cannot be made level by adjusting the flange
bearing mounting bracket up or down, verify that
the side columns are plumb, square and level and
make any necessary adjustments.
Tighten Flange
8. Place a carpenter’s level along the length of the Bearing Set Screw
drum/fabric roll assembly and adjust the flange Adjust Bracket Up or
bearing mounting bracket up or down, as required, Down as Required
until the drum/fabric roll assembly is level.
Figure 21
Tighten the hardware securing the motor and the
flange bearing mounting brackets to the side
columns. Then tighten the set screw to lock the
flange bearing to the drum shaft. (See Figure 20
and Figure 21. DO NOT remove the shipping bands holding the
fabric material to the drum roll assembly at this
time.

9. Do not remove the shipping bands securing the

For a door with pullouts, verify that the two hex nuts fabric material to the drum roll. Only remove the
threaded on each 6-in. screw are tight against their fasteners securing the drum assembly to the forklift.
associated side column and mounting bracket. Then lower and move the forklift out of the way.
Failure to tighten all eight nuts could result in
damage to the side columns. (See Figure 21.)

9
 INSTALLATION—THE BOTTOM BAR

THE BOTTOM BAR

THE ENCODER MAGNET, ENCODER AND
1. Check the brake release lever located on the motor/ WIRELESS ANTENNA
brake assembly. The brake must be in the UP
engaged position. (See Figure 22.) Locate the wireless antenna parts box (labeled part
number H1060612-1A) in the crate. The box holds the
encoder magnet, the wireless antenna, and the
encoder. The wireless antenna is pre-installed on its
mounting bracket, and the encoder is pre-installed on
its white mounting plate.

Manual
break
release

Crank-mounting location

Figure 24
Figure 22
NOTE: When released, the motor brake will default to
the ENGAGED position.
2. Cut and remove the shipping bands holding the The wireless antenna and the encoder are
fabric to the roll. connected by a pre-installed wire. Make sure the
antenna is supported while the encoder is installed.
3. Insert the plastic tabs on the bottom bar into the slot Excess tension can damage the wire.
of each side column. (See Figure 23.)
Install the encoder magnet
1. Remove the two hex set screws from the magnet
and apply a mild thread lock to each.
Plastic Tabs on Bottom Bar
Fit into Slot in Side Column

Figure 23

Figure 25
2. Slide the magnet over the drum shaft. Re-install
and tighten the set screws. (See Figure 25.)

10
 INSTALLATION—ENCODER

Install the encoder Install the wireless antenna

1. Locate two (2) M10 x 25 hex screws in the small
parts hardware bag. Also, locate the two hex
mounting screws for the wireless antenna, which
are in the bag taped to the antenna mounting The wireless antenna is fragile.
bracket. You will need them for the next step.
1. Lift the wireless antenna assembly into place and
2. Slide the encoder and white mounting bracket over install the two hex mounting screws
the encoder magnet. (See Figure 26.) Make sure (See Figure 27.)
the wireless antenna is supported during this step
so that excess tension is not put on the connecting
wire.

Figure 27
Wire the encoder to the System 4 controller
Figure 26
1. Locate the encoder cable in the small parts box
3. Install and tighten the two screws. and connect to the encoder.
2. Route the encoder cable to the System 4 controller
and connect per the provided schematics.

11
INSTALLATION—PHOTO EYE
PHOTO EYE The transmitter and receiver can be identified two ways.
The transmitter is designated SMT 3000 on the white
The photo eye is a safety measure and therefore
label or by a single green light that comes on at the clear
needed for proper door operation. When installing photo
end of the transmitter. (See Figure 31.) The receiver is
eyes on the back side of the door, make sure the
designated SMR 3215 on the white label or by a yellow
installation is opposite from the front. The end result
light that illuminates only when it is in proper alignment
would be photo eye beams that crisis cross. (See
with the transmitter. (See Figure 32.)
Figure 29 and Figure 30.)
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. (See
Figure 32.)

Transmitter
Module
Designation
Power Light
Photo Eye (Green)
Transmitter

Photo Eye
A7700040 Receiver

Figure 29 A2500258

Figure 31
IMPORTANT: When installing the rear set of
photo eyes, be sure that the
assembly is installed in reverse
order from the front. This is to
prevent crosstalk between the
photo eyes. (See Figure 30.)

Receiver
Module
Designation
Alignment Light
(Yellow)

A2500259

Figure 32
A7700046

Figure 30

12
 INSTALLATION—PHOTO EYE

1. Install the photo eye assembly on the motor mount

side column with two 1/4-20 x 3/4-in. serrated-
flange hex screws. The mounting holes are located
approximately 40 in. from the floor. (See Figure 33.)
NOTE: Photo eyes and mounting hardware are
shipped in the small parts carton. The two
sets of photo eyes provided must both be Photo Eye
properly installed. (See Figure 29.) Cable

Serrated-Flange
Hex Screw
(Two Required)

Cord
Grip
A7500316

Figure 34

4. Install photo eye assembly on the non-drive side

column with two 1/4-20 x 3/4-in. serrated-flange
hex screws.
Assembly 5. Feed photo eye cable through the cord grip.
Photo Eye Remove all slack in the cord between the photo eye
A7500315 and grip. Tighten the cord grip.
NOTE: Mounting hardware for the second set of
Figure 33
photo eyes has been provided. If this hard
ware will not work for your application, any
additional required hardware becomes the
responsibility of the installer.
2. Install the cord grip in the side column, just below
6. Mount the second photo eye assembly on the wall
the photo eye assembly. (See Figure 34.)
adjacent to the back of the door. The photo eye
3. Feed photo eye cable through the cord grip. emitter and receiver are to be mounted at the same
Remove all slack in the cord between the photo eye height as the photo eye assembly on the front of the
and grip. Tighten the cord grip. (See Figure 34.) door, but as close to the door as possible.
Testing Photo Eye Modules
When power is on, the green light indicates the photo
eye module is powered up. When the yellow light on
the receiver module is also lit, the transmitter and
receiver modules are properly aligned.
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.

13
INSTALLATION—ELECTRICAL WIRING ROUTING

ELECTRICAL WIRING ROUTING

1. Locate the Rytec control box and fused disconnect
as shown in Figure 35.

Fused Disconnect
Plastic Cap
(Supplied by Door
Owner)

Encoder Wire
Rytec
System 4
4 ft. Side Column Cover
Control Panel

Note: Conduit to floor

loop (if required) is A7700039
supplied by door owner Figure 37

A7700040 IMPORTANT: Never run high and low voltage

wires together.
Figure 35
CONTROL PANEL AND ELECTRICAL
CONNECTIONS
Once the door has been assembled, see the Rytec
The fused disconnect must be in the OFF System 4 Drive & Control Installation & Owner’s Manual
position and the fuses removed before for information on control panel installation, electrical
wiring of the control box begins. connections, door limit settings, and initial door start-up
procedure.
2. Locate and remove the access covers and hole
plugs from the side column to gain access to the NOTE: If a floor loop is used, all wiring from the
wires. (See Figure 36.) fused disconnect to the control box and
from the control box to the motor mount
side column, as well as conduit running
from the control box to the floor, is pro-
vided by the door owner/installer or the
electrician. All wiring and conduit must
meet all local and state codes. Wires pro-
vided with the door are labeled with
terminal or contact numbers.

DOOR OPEN- AND CLOSE-LIMIT POSITIONS

Access Cover See the Rytec System 4 Drive & Control Installation &
Owner’s Manual for the proper procedure for setting the
open and close door limits. The door open- and close-
limit positions are detailed below.
Close-Limit Position
The close-limit position should be adjusted so that the
door travel allows the yellow vinyl loop on the bottom bar
A7700020 to gently seal against the floor. (See Figure 38.)
Figure 36 DO NOT allow the rubber reversing edge, enclosed in
the yellow vinyl loop, to come in contact with the floor.
3. Run wires from the encoder and over the top of the
motor mount side column cover. Run wires down to the
access hole in the side column cover. (See Figure 37.)

14
 INSTALLATION—PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT

PNEUMATIC REVERSING EDGE SWITCH

ADJUSTMENT

Damage to the rubber reversing edge or

other bottom bar parts can occur if the
door seal is allowed to seal too tightly
against the floor. Do not stand under the door panel when
making check. If reversing edge switch is
not working properly, panel could strike
person performing check.

Fabric Panel To check the reversing edge switch operation, run the
door through the down cycle. As the door is lowering,
tap the bottom of the reversing edge. If the reversing
Rubber
Reversing
edge switch is operating properly, the door should
Edge immediately reverse and run to the full open position.
Push the control box push-button to close the door after
the check is completed.
Yellow If the door does not reverse, check the air bleed and
Vinyl Loop sensitivity of the reversing edge switch. The switch is in
¹/₂ to 1 in.
the bottom bar on the side opposite the door motor.
Reversing Edge Switch Air Bleed Check
A7500195
1. The reversing edge switch is located inside the bot-
Figure 38
tom bar assembly. To inspect and/or adjust the
Open-Limit Position switch, remove the access cover from the face of
the bottom bar assembly. (See Figure 40.)
The open-limit position should be adjusted so that the
door travel allows the bottom bar assembly to stop at the
Access Cover
position shown in Figure 39.
NOTE: It is important that the plastic breakaway
tabs on the ends of the bottom bar are
above the black plastic tab on the side
column. This open-limit setting height
allows the door to be jogged to the proper
height to allow for the re-setting of the
Bottom Bar
bottom bar if the door is broken away.

A7500201
Plastic Tabs on Bottom Bar
Figure 40
Fit into Slot in Side Column

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

with the air input post so that air leakage cannot
occur and that vibration will not cause the hose to
fall off. Make sure the hose is not kinked.
(See Figure 41.)
3. The air bleed has been set at the factory and should
not require adjustment. To check the air bleed, turn
the air bleed adjustment screws located on the front
and back of the switch fully clockwise, but do not
overtighten. Then turn the screws counterclockwise
one full turn. (See Figure 41.)
A7700006
Figure 39

15
INSTALLATION—PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT

PNEUMATIC KILL SWITCH

Reversing CHECK AND ADJUSTMENT
Edge Switch
(On Side A kill switch has been mounted in the bottom bar
Air Bleed
Opposite assembly. The purpose of this switch is to prevent the
Adjustment
Door Motor) Screw door from being operated if the breakaway bottom bar
becomes separated from either side column.
Kill Switch Check

PVC Hose Must Be Tight

on Lower Input Hose Take precautions to prevent the door from
being opened or closed while performing
A7700042 the following procedure.
Figure 41
1. Raise or lower the door to approximately head or
Reversing Edge Switch Sensitivity Adjustment chest height and stop the door.
1. The reversing edge switch is a normally open con- NOTE: It should not be possible to restart the door
tact. The PVC hose is on the lower air input post. To until the door has been reassembled and
adjust the switch, first remove the wires and resistor the control system reset.
from the contact terminals and attach an ohmmeter
across the two terminals. (See Figure 42.) 2. Push the breakaway bottom bar out of the side
column. Door should not operate until control box is
2. Turn the adjustment screw, located on the face of the reset. (See Figure 43 and Figure 44.)
switch, clockwise or counterclockwise until continuity is
achieved. Then turn the screw two full turns If the kill switch did not operate properly: Adjust
counterclockwise. The ohmmeter should no longer show the kill switch and then recheck it. (See “Kill Switch
continuity. Turning the screw counterclockwise decreases Air Bleed Adjustment” on page 17.)
sensitivity. Turning the screw clock- wise increases If the kill switch operated properly: Reinstall the
sensitivity. (See Figure 42.) bottom bar into the side column. (See “RESET-
TING BOTTOM BAR ASSEMBLY” on page 18.)
Reversing
Edge Switch Resistor
Air Switch Bladder

Remove Wires Plastic Tabs Out

Sensitivity to Test and of Side Column
Adjustment Screw Adjust Switch

A7700042

Figure 42

3. Reattach resistor and wires and then replace the

Bottom Bar
access cover on the bottom bar.
NOTE: If the reversing edge is set too sensitive, A7700007
the door may reverse direction during the
Figure 43
closing cycle, without the reversing edge
coming in contact with an object. If this
occurs, readjust the reversing edge
switch.

16
 INSTALLATION—PNEUMATIC KILL SWITCH CHECK AND ADJUSTMENT

Air Bleed
Kill Switch (On
Adjustment
Same Side as
Screw (One
Door Motor)
on Front and
One on Back
Breakaway Tabs

PVC Hose Must

Be Tight on
Air Input Post
A7500202

Figure 46

3. The air bleed has been set at the factory and should
not require adjustment. To adjust the air bleed, turn
the air bleed adjustment screws located on the front
and back of the switch fully clockwise, but do not
Bottom Bar Assembly overtighten. Then turn each screw
counterclockwise one full turn. (See Figure 46.)
A7500324 4. To adjust the kill switch sensitivity, see “Kill Switch
Figure 44 Sensitivity Adjustment” on page 17.

Kill Switch Air Bleed Adjustment Kill Switch Sensitivity Adjustment

1. The kill switch is mounted in the bottom bar assembly, The kill switch assembly is a normally closed contact.
on the same side as the door motor. To access the The PVC hose is on the upper air input post.
switch, first remove the access cover. (See Figure 45.) 1. Remove the wires from the contact terminals and
attach an ohmmeter across the two terminals.
(See Figure 47.)
2. To adjust the switch turn the small adjusting screw
located on the face of the switch clockwise or
counterclockwise until continuity is achieved.
3. Turn the screw 2 fully clockwise for final adjustment.
NOTE: The ohmmeter should continue to show
continuity. Turning the screw clockwise
decreases sensitivity. Turning the screw
Access Cover
counterclockwise increases sensitivity.

Remove Wires Kill Switch (On

to Test and Same Side as
Adjust Switch Door Motor)
Bottom Bar

A7700009

Figure 45

2. Make sure the clear PVC hose is tight on the air

input post so that air leakage cannot occur and Sensitivity PVC Hose Must
Adjustment Screw Be Tight on Air
vibration will not cause the hose to fall off. Also
Input Post
make sure the hose is not kinked. (See Figure 46.) A7500202

Figure 47
4. Reconnect the wires onto the switch. Replace the
access cover on bottom bar.
17
INSTALLATION—RESETTING BOTTOM BAR ASSEMBLY

NOTE: If the kill switch is set too sensitive, it may

cause the door to stop during the opening
or closing cycle. If this occurs, readjust the
kill switch sensitivity setting.

RESETTING BOTTOM BAR ASSEMBLY

Access Cover

Photo Eye
If the bottom bar or door panel assembly
has been damaged, remove door from
service.

1. Position the breakaway tabs of the bottom bar in

front of the side column where the angled guide
plate is located. (See Figure 48.)

Side Column
A7500318

Figure 49

Angled Guide Plate 1. Check to see that the photo eye on the front side of
the door has been installed for a horizontal beam
across the door opening. (See Figure 50.)
Bottom Bar Must Be
Positioned in Front of
Side Column
Yellow Light on Photo Eye
Receiver Module Will Light When
Beam Is in Proper Alignment

A7700017

Figure 48

2. Press and hold the up arrow on the control panel

until the door is in the fully open position.
3. Press the down arrow and the door will close in
automatic mode and be ready for service.
NOTE: Check to make sure that the fabric is
inside each channel.
4. Perform operations check on the door.
PHOTO EYE ADJUSTMENT
The photo eye is always set at maximum adjustment. If
less sensitivity is required, contact the Rytec Technical
Support Department at 800-628-1909 before any A7500319
adjustments are made. (See Figure 49.)
NOTE: When adjusting photo eyes, be sure to Figure 50
adjust them BOTH.
18
 INSTALLATION—ALUMINUM HOOD (OPTIONAL)

2. Align the photo eyes on the front side of the door.

Centerline of
(See Figure 50.)
Head Extrusion
3. Adjust the photo eyes on the rear side of the door Self-Tapping and Center Cover
as required, dependent on the type of mounting Sheet Metal
Screw Center Cove
used by the installer.
NOTE: Pre-drilled mounting holes have been pro-
vided in the side columns to mount the
photoeyes. However, it is important to verify
A7500047
with the customer what type of equipment
is moving through the door. Large
equipment may allow the photoeye beam
to shoot under the equipment causing the
door to close on the equipment. Different
mounting locations may be required.

ALUMINUM HOOD (OPTIONAL)

NOTE: The following procedure is required
only if your door was shipped with an Figure 52
optional hood assembly.

A door with a production width of up to 8 ft. 3 in. will have

3. Three- or four-piece hood only: Install hood center
a one-piece hood. A door with a production width
section(s) and secure to hood end sections using
greater than 8 ft. 3 in. will have a three- or four-piece
#12 x 3/4-in. self-tapping sheet metal screws.
hood. The installation procedure is the same for either
(See Figure 53.)
style of hood except where noted.

Self-Tapping
1. Attach the hood end covers to their respective U-
Sheet Metal
bracket installed earlier on the side columns. Use two Screw
3/8-16 x 1 1/4-in. serrated-flange hex screws and nuts
for each end cover. (See Figure 51.)

Head Extrusion

Serrated-Flange
Hex-Head Screw
(Two Each Side) Serrated-Flange
Hex Nut (Two End Cover
Each Side)
End Section Covers
(Mount on Top of
Center Section Cover)

Figure 53

A8500016 End Cover

Figure 51

19
 INSTALLATION—ABS HOOD (OPTIONAL)

ABS HOOD (OPTIONAL) 3. Assemble the motor cover, motor bracket, hood
cap, and hood using 1/4-20 UNC x 3/4 serrated-
1. Attach the hood support assembly to the flange hex screws. (See Figure 55.)
top of the side columns using two
3/8-16 x 1-in. serrated-flange hex screws
Hood Cap
and nuts on each end. (See Figure 54.)

2. Attach the center hood cover section Hood

(one-piece hood) or the end hood cover 1/4-20 UNC x 3/4
sections (three- or four-piece hood) to the Serrated-Flange
head extrusion. (See Figure 52.) Secure Hex Screw
cover to extrusion and end panels using
#12 x 3/4-in. self-tapping sheet metal
screws. Motor
Bracket
INSTALLATION—ABS HOOD
(OPTIONAL)

Serrated-Flange Hex Nut

(Two Each Side

Serrated-Flange Hex-
Head Screw Cover
(Two Each Side)

Figure 55

Hood Support 4. Install the center hood piece(s) and other hood cap.

NOTE: Pay close attention to the reliefs in the hood

assembly. The middle hood sections overlap each
piece for a smooth and clean assembly. The two
hood caps tuck under the middle hood sections,
followed by screws to tighten and finish off the
A9800019
assembly.
Figure 54

20
 INSTALLATION—FINAL CHECKS

FINAL CHECKS
Side Columns: Check to see that the side columns are
installed plumb and square and that all anchor bolts are
securely tightened.
Header Assembly: Check all mounting hardware to
see if it is tight.
Head Assembly: Fabric roll must be level. All mounting
hardware must be tight.
Caulking: See that side columns and head assembly
have been caulked where they meet the building wall.
Bottom Bar: The bottom bar must travel up and down
in the side column without binding.
Open and Close Limits: Check that limits are set
properly. Downward travel of the door panel must stop
when the yellow vinyl loop seals against the floor as
shown in Figure 38. Upward travel should be as shown
in Figure 39.
Motor Operation: Verify that the motor cycles the door
in the proper direction when keys on front of the control
box are pressed.
Reversing Edge Switch: Door should return to full
open position if reversing edge on the bottom bar comes
in contact with an object during the down travel of the
door panel. See “PNEUMATIC REVERSING EDGE
SWITCH ADJUSTMENT” on page 15 for test and
adjustment procedures.
Kill Switch: Door travel should stop when the bottom
bar is disengaged from one or both of the side columns.
See “PNEUMATIC KILL SWITCH CHECK AND
ADJUSTMENT” on page 16 for test and adjustment
procedures.
Timers: Timers must be set to ensure proper closing of
the door. See Rytec System 4 Drive & Control
Installation & Owner’s Manual for more information on
timer settings.
Activator Settings: Recheck all settings and adjust
as required.
Coil Cord: Run the door through two or three cycles.
Check the coil cord when the door is in the closed
position. The coil cord should not contact the floor or
hang in front of or interfere in any way with the photo
eye.
Photo Eyes: Check to see that front and rear photo
eyes are operating properly. See “PHOTO EYE
ADJUSTMENT” on page 18 for adjustment procedure.
Refer to PredaDoor NXT Owner’s Manual for proper
complete operating, inspection, and maintenance
procedures.

21
NOTES

22