ALBANY ULTRASECURE RR3000L (01) PDF MANUAL

ALBANY ULTRASECURE RR3000L (01) PDF SUMMARY:

What is the purpose of the manual?

The contents of this manual are designed to help you operate and maintain the Rapid Roll™ high-speed doors. DO NOT operate or perform maintenance on the high-speed door unless you have read through the instructions in this manual.

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What does the safety alert symbol indicate?

The safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the safety alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

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What does DANGER indicate?

DANGER indicates a hazard that, if not avoided, will result in death or serious injury.

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What does WARNING indicate?

WARNING indicates a hazard that, if not avoided, could result in death or serious injury.

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What does CAUTION indicate?

CAUTION indicates a hazard that, if not avoided, might result in minor or moderate injury.

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What does CAUTION, when used without the alert symbol, indicate?

CAUTION, when used without the alert symbol, indicates a situation that could result in damage to the door.

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What is NOTICE used for?

NOTICE is used to inform you of a method, reference, or procedure that could assist with specific operations or procedures.

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What are the functions controlled by the programmable UltraSmart™ control panel?

All operation functions are controlled through the programmable UltraSmart™ control panel. The bottom edge of the door provides the safety capability of reversing the door if it strikes an object and is designed to break away from the side rails if the door is struck by a vehicle.

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What happens if an impact occurs and the door is pushed out of the side rails?

If an impact occurs and the door is pushed out of the side rails the BacFlap Auto-Reset System quickly and easily repairs the door. Pressing the Open keypad on the control panel will open the door and the door panel will automatically reset itself into the side rails.

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What is the function of the BacLight™ Safety System?

Each door is equipped with the BacLight™ Safety System to prevent injury. Two separate sets of light strips function as safety controls to prevent the door from closing, or stop the door if it is closing, and any portion of the light beam is broken by a person or object.

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What does the Disconnect switch do?

This switch disconnects the supply power to the control panel.

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What does the Open keypad do?

This keypad opens the door and stops the delay timer from closing the door. The timer is started by pressing the Reset / Menu keypad.

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What does the Stop keypad do?

This keypad stops the opening or closing of the door.

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What does the Close keypad do?

This keypad closes the door and stops the delay timer.

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What does the Display show?

The display shows operation, functions and error codes of the door operation.

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What does the Jog Up keypad do?

This keypad opens the door at a slower speed than normal door operation. The door will open as long as the keypad is pushed.

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What does the Jog Down keypad do?

This keypad closes the door at a slower speed than normal door operation. The door will close as long as the keypad is pushed.

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What does the Manual Close Delay keypad do?

This keypad sets the time delay of the door closing in manual mode. The time delay is changed (increased or decreased) in one-second intervals by pressing and releasing the keypad to display the time delay setting.

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How do you change the delay time on the Manual Close Delay?

Press the Up Arrow or the Down Arrow keypad to change the delay time. If the time is set to .00., the door will remain open until this activator is triggered. The display will remain on for four seconds after this button is released. The set value is maintained in memory.

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What does the Auto Close Delay keypad do?

This keypad sets the time delay of the door closing once it has reached the selected open position in automatic mode. The time delay is changed (increased or decreased) in one second intervals by pressing and releasing the keypad to display the time delay setting.

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How do you change the delay time on the Auto Close Delay?

Press the Up Arrow or the Down Arrow key to change the delay time. The display will remain on for four seconds after this button is released. The set value is maintained in memory.

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What does the Reset / Menu keypad do?

This keypad resets error codes. This button is used while in the program mode to leave the present level and return to the previous program level. While in the main menu, this button will exit the program mode.

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What does the Enter keypad do?

This keypad is used to select menu options while in the program mode.

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What do the Up Arrow and Down Arrow keypads do?

Up Arrow: This keypad scrolls up in the menu. Down Arrow: This keypad scrolls down in the menu.

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What information is shown on the control panel display?

The display on the front of the control panel shows two lines of information for the operator or service technician. The top line displays system status and the second line displays details of the function or specifics of errors.

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What is shown on the display during startup?

During startup the display will show the software version programmed into the control panel and whether or not the door is ready for normal operation.

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What will the top line display once the software has booted?

Once the software has booted the door is ready for operation the top line will display “Door Ready” unless there is a detected error.

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What will the top line display during normal operation?

During normal operation the top line will display “Door Ready”, “Opening – Full”, “Opening – Part”, “Closing”, and if a close door delay has been programmed “Auto1 Close Delay”, “Man1 Close Delay”, “Man2 Close Delay”, or “DTC Timer".

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What is shown on the second line of the display?

The second line on the display will show the activator name for the function, or the safety device that triggered a re-open. The activator is the device or input that triggered an action. The activator can be a manual input, signal from the light curtain or reversing edge, or a breakaway switch input.

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Table 1: Startup

Top Line	Bottom Line
Albany Door Systems	version.n.m
Door Not Ready

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Table 2: Normal Operation

Top Line	Bottom Line
Door Ready	0000000 The zeros indicate the number of door operations. The counter will advance with each full or partial door opening. version n.m (shown until first cycle)

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Table 3: Opening

Top Line	Bottom Line
Opening – Full	Auto 1 Auto 2 Man 1 Man 2 Open PB Open On Panel Photo 1 (Front) Photo 2 (Rear) Reversing Edge Breakaway
Opening – Part

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Table 4: Open Delay Timer Active

Top Line	Bottom Line
Auto1 Close Delay	(Activator)
Auto2 Close Delay	(Preventer) if any
Man1 Close Delay
Man2 Close Delay
DTC Timer

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Table 5: Open Commanded: Delay Timer Active

Top Line	Bottom Line
DTC Timer

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Table 6: Closing

Top Line	Bottom Line
Closing	Auto 1 Auto 2 Man 1 Man 2 Close Pb Close on Panel

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Table 7: Normal: Warning

Top Line	Bottom Line
Door Ready	Encoder Low Battery
	Module D Loop Open
	Module D Loop Short
	Module D Loop Error
	Module D Loop1 Open
	Module D Loop1 Short
	Module D Loop1 Error
	Module E Loop2 Open
	Module E Loop2 Short
	Module E Loop2 Error
	RevEdge Was Tripped

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What should you do if any of the warnings are displayed except for “RevEdge Was Tripped”?

If any of the following warnings are displayed except for “RevEdge Was Tripped”, please contact Albany Door Systems for diagnosis and repair. If the bottom line displays “RevEdge Was Tripped” it indicates that the door is open due to a reversing edge trip during the previous close cycle.

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How do you change the door closing time delay?

1. Press the Auto 1 Close Delay keypad. The time delay will be displayed in seconds at a flashing cursor. If no keypad is pressed the controller will automatically return to normal operation after approximately 4 seconds.
2. Press the Up Arrow or Down Arrow keypad to change the time delay in one second intervals.

After 4 seconds the display will return to normal operation and the time will be stored in memory. If the timer is set to “00” with the Man 1 Close Delay the door will remain open until this activator is triggered.

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What should you do if the door bottom bar separates from a side track?

In the event that the door bottom bar separates from a side track, do not attempt to force the bottom bar end(s) back into the track. The BacFlapt™ Auto-Reset System will reset the door for normal operation.

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What should you NOT do before resetting the door after the door bottom bar separates from a side track?

DO NOT reset the door until the break away flap(s) are out of the side rails on the side away from the wall. Pull the bottom rail of the door away from the wall so the break away flap or flaps are on the front of the side rails away from the wall.

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What should you do after the door bottom bar separates from a side track?

Note: After the door bottom bar separates from a side track, when the Open keypad is pressed the door will open higher than normal operation. It will open to the break away limit setting.

1. Press the Open keypad to automatically FULLY open the door; or, press and hold the Jog keypad to manually open the door high enough for the flaps to clear the guides at the top of the side rails. When using the Jog keypad DO NOT raise the door higher than necessary.
2. Press the Close keypad to close the door. The bottom bar ends will automatically track behind the guides and back into the side rails.
3. The door control will reset itself to the automatic mode.

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What limit should always be checked for correct height or set before the other limits are set?

The Closed Limit should always be checked for correct height or set before the other limits are set. When any limit is set all of the limits should be checked or set.

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What is the Closed Limit used for?

Used to set the fully closed position of the door. The door controller uses this position as the “zero” position to establish the height that the door moves to for two open positions and the breakaway position.

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What will happen if the Closed Limit is reset to a different position?

The Open, Partial, and Break Away limits are all relative to the Closed Limit. If the Closed Limit is reset to a different position, all the other settings will change relative to the new Closed Limit setting.

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What is the Full Open Limit used for?

Used to set the height that the door opens fully to.

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What is the Partial Open Limit used for?

Used to set the height that the door opens to if it is programmed for a lower opening in addition to the fully open position.

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What is the Break Away Reset Limit used for?

Used to set the height that the door will open to so the bottom rail can be seated in the side rails after it has been broken out of them. This height is set higher than the Full Open Limit.

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How do you enter the Limit Setup menu?

Enter the Limit Setup menu by pressing and holding the Up Arrow and Down Arrow keypads simultaneously for approximately 5 seconds. The control display will show: Limit Setup.

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After entering the Limit Setup menu, what will the control display show?

Press the Enter keypad. The control display will show: Closed Limit

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What should you always do before setting other limit positions?

Always set the Closed Limit before setting other limit positions.

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What happens if the door closes to the correct position and the Closed Limit does not need to be changed?

If the door closes to the correct position and the Closed Limit does not need to be changed the Up Arrow keypad is used to display Full Open Limit, Partial Open Limit, and BrkAway Reset Limit. Pressing the Enter keypad when any of the limits are displayed will allow that limit to be set.

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What happens if the Reset / Menu keypad is pressed at any time?

The Reset / Menu keypad can be pressed at any time to back out of the menu to the next higher level. When the Limit Setup is displayed pressing the Reset / Menu keypad will exit the program and return the door to normal operation.

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How do you set the Closed Limit?

1. Press the Enter keypad when Closed Limit is displayed;
2. Use the Jog Up or Jog Down keypads to move the door up or down so the door lightly rests on the floor sealing the bottom but does not compact the bottom edge or allow the door fabric to lose tension;
3. Press the Enter keypad to set the limit in memory. The display will show: Closed Limit.
4. Press the Up Arrow keypad once to display: Full Open Limit.

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How do you set the Full Open Limit?

1. Press the Enter keypad when Full Open Limit is displayed;
2. Use the Jog Up keypad to move the door up so the door opens to the desired height. If necessary, use the Jog Up or Jog Down keypads for final adjustment;
3. Press the Enter keypad to set the limit in memory. The display will show: Full Open Limit;
4. Press the Up Arrow keypad once to display:

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How do you set the Partial Open Limit?

1. Press the Enter keypad when Partial Open Limit is displayed;
2. Use the Jog Down keypad to move the door down to the desired height. If necessary, use the Jog Up or Jog Down keypads for final adjustment;
3. Press the Enter keypad to set the limit in memory. The display will show: Partial Open Limit.

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What do you do if the partial open position is not used?

If the partial open position is not used, press the Enter keypad to go to the next procedure to set the Break Away Limit.

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How do you set the Break Away Limit?

1. Press the Enter keypad when BrkAway Limit is displayed;
2. Use the Jog Up keypad to move the door up to the desired height. If necessary, use the Jog Up or Jog Down keypads for final adjustment;
3. Press the Enter keypad to set the limit in memory. The display will show: BrkAway Limit;
4. Press the Reset / Menu keypad once to display: Limit Setup;
5. Press the Reset / Menu keypad once to exit the menu and return to normal operation.

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Once inside the menu of the UltraSmart™ controller, what options may be used with your door?

Once inside the menu of the UltraSmart™ controller, many options may be used with your door. Following is a guide for the UltraSmart™ controller:

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What are the options under Limit Setup?

• Close Limit – Sets the close limit
• Full Open Limit – Sets the open limit
• Partial Open Limit – Used if a separate activator will be used to open the door to a height lower than the Full Open Limit setting.
• Breakaway Open Limit – The Breakaway Open Limit should be set so that the breakaway tabs are just above the BacFlaps™.

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What are the options under Set Timers?

• Open Run Timer – This timer is the backup in case the limit does not stop the door at the full open position. The door will go into a TIMER EXPIRED fault.
• Close Run Timer – This timer is the backup in case the limit does not stop the door at the close position. The door will go into a TIMER EXPIRED fault.
• Reverse Delay Timer – This timer will add a delay to reverse the door if reversed by an activator or safety device.
• Close Delay, Auto 1 – This Auto Close delay is located on the front of the controller.
• Close Delay, Auto 2 – This is the Auto 2 Auto Close used with Mod F (5 Input).
• Close Delay, Man 1 – This is the Man 1 Close Delay located on the front of the controller.
• Close Delay, Man 2 – This is the Man 2 Close Delay used with Mod F (5 Input).
• Delay to Close, Out P1
• Delay to Open, Auto 1
• Delay to Open, Auto 2
• Door Open Alarm Timer
• Air Lock Timer – This timer is used with Mod J (Air Lock).
• Defrost Cycle On – This sets how long the Tek heat lamps stay turned on (in seconds).
• Defrost Cycle Off – This sets how long the Tek heat lamps stay turned off (in seconds).

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What happens when entering the View Fault History menu?

Entering this menu will show the fault history of the door, up to the last 64 faults. Each fault will show the fault / out of how many total faults. The cycle count when the fault happened and the fault description.

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What are the options under System Options?

• Panel Open & Close Disable – Changing the option from NO to YES will disable the Open/Close/Stop push buttons on the front of the control box.
• PB & Panel Close Set to Jog only – Changing the option from NO to YES will make the Close button on the front of the control box jog the door only.
• PB & Panel Open Set to Jog only – Changing the option from NO to YES will make the Open button on the front of the control box jog the door only.
• RevEdge Auto Close – Changing the option from NO to YES will allow the door to Auto Close when the reversing edge is tripped. If the reversing edge is tripped 4 times in a row, the door will stop in the open position and read “REV EDGE WAS TRIPPED.” The AutoClose timer controls the AutoClose delay for this function.
• Photo Eye Auto Close – Changing this option from NO to YES will allow the door to AutoClose when the light curtain or photo-eye is tripped and the door is not in an AutoClose or Man1 Close Delay. The AutoClose timer controls the AutoClose delay for this function.
• Panel Open Man1 Auto Close – Changing this option from NO to YES will allow the door to close automatically using the MAN1 delay to close timer. If this option is YES, the STOP button will not work.

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What are the options under Module Configuration?

• Module A Activator – This module controls the inputs for all activators except floor loops.
• Module B Safety – This module controls the light curtains and/or photo-eye inputs along with the reversing edge and breakaway switches.
• Module C Drive – This module controls the Variable Frequency Drive (VFD), which controls the motor. The Emergency Up and Emergency Down buttons bypass the UltraSmart™ Controller to operate the door. THESE BUTTONS WILL NOT STOP AT THE OPEN AND CLOSED LIMIT SETTINGS.
• Module D Loop – This module is an optional module used for loop detectors.
• Module E Dual Loop – This module is an optional module used if separate loop detectors are required for each side of the opening.
• Module F 5 Input – This is an optional module in case extra activator inputs are required.
• Module G 4 Output – This is an optional module used when output signals are needed (example: door is not closed; door is closed, etc…)
• Module H Defrost – This module is used with the standard freezer package and controls the heat lamps, blower and has one output terminal.
• Module J Airlock – This is an optional module used with the Airlock option for the door.

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What do the error codes indicate?

Error codes are displayed for diagnostic purposes. Errors fall into basic groups that can be easily repaired or reset by the operator or must be repaired by a factory technician.

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What safety features can typically be reset by the operator?

Safety features designed into the door can typically be reset by the operator. These include the breakaway function and situations that prevent the door from closing. They also include some of the “soft” or “hard” errors.

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What are some of the “soft” or “hard” errors that require a service technician for repair?

Some of the “soft” or “hard” errors require a service technician for repair.

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What happens if a breakaway switch in the bottom rail has been activated?

If a breakaway switch in the bottom rail has been activated the following errors and instructions will be displayed. The “Clear Door Request” will display when there is an input trigger.

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How do you reset the error after a breakaway?

To reset the error the bottom rail must be reset in the side rails. See “Seating the Door in the Tracks” on page 5 under the OPERATOR SERVICE heading.

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Table 8: Breakaway

Top Line	Bottom Line
Clear Door Request	Breakaway
Bring Panel to Front	Press OPEN or JOG

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What does it mean when the door is open and prevented from closing?

One of the safety features of the door prevents the door from closing during normal operation if an unsafe condition occurs. Causes or “preventers” may be an object breaking the light curtain or the reverse edge contacting an obstruction.

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Table 9: Open: Prevented from Closing

Top Line	Bottom Line
Door Ready	Photo 1 (Front) Photo 2 (Rear) Reversing Edge Auto 1 Auto 2

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What do the soft errors indicate?

The following soft errors are triggered by an activator. The door becomes ready when the condition no longer applies, but no door motion is allowed.

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Table 10: “Soft” Errors

Top Line	Bottom Line
Clear Door Request	Auto 1 Auto 2 Man 1 Man 2 Open Pb Open On Panel

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Table 11: “Soft” Errors

Top Line	Bottom Line
Door Not Ready	Mod x No Response Encoder – Com Loss Em Stop
Clear Door Request	Rev Edge – Lost Signal BrkAway – Lost Signal

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What are the common corrective actions for troubleshooting?

Here are some common troubleshooting steps:

• Loss of main power: Check with meter across L1-L2, L2-L3, L1-L3.
• Blown fuse: Check with meter across 1L1-1L2, 1L2-1L3, 1L1-1L3 or 2L1-2L2, 2L2-2L3, 2L1-2L3.
• Loss of power: Check with meter across 1L1-1L2 at control transformer.
• Blown fuse: Check with meter across H1-H2 at control transformer across 1 and X2 at control transformer.
• E Stop Jumper loose or missing: Verify that jumper is between 1A and 1B on terminal strip of module board.
• If E stop button present: Check to see if E stop button activated.
• No input signal at Module A: Check activation input by pressing corresponding test button, LED should light and door open. If door opens: faulty activator or wiring to module. If door does not open by test button: faulty module.
• Held open by safety input or activator input: Check display readout. Check for lit LED on modules A and B. Remove corresponding wire on Module A. For lit LED -if door closes: faulty activator. If LED stays lit and door stays open: faulty module.
• Held open if loop installed: Held open if loop installed. Check loop module for lit LED. Remove loop wires from module terminal strip. If door closes: faulty loop wire. If door remains open and LED stays lit after removal of loop wires: faulty module.
• Reversing edge activated: Check display reset. Check for bad wire connection. Check that edge is not pinched.
• Breakaway activated: Check display reset. Check for bad wire connection. Check that edge is not pinched.
• Brake not disengaging: Check power at terminals 5 and 6 below module C for 24 VAC. Check power at terminals B1 and B2 for 3 phase power.
• No encoder change, no position change: Door jammed: clear jam. Broken drive shaft. Call manufacturer.
• Encoder com loss of signal: Check for loose connections or broken cable. Check encoder mounting. Call manufacturer.

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Table 12: “Hard” Errors

Top Line	Bottom Line	Cause
Opening “Full” Closing	Timer Expired
Correct and RESET	Motor Drive Fault Cycle Power OFF for 10 seconds	The RESET button must be pressed before door operation can continue
	No Encoder Change	During commanded movement, no position change for several seconds
	Door Open Alarm	Door Open timer expired

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What are the corrective actions for issues with the light curtain?

Here are some common troubleshooting steps:

• Red alarm LED on: Check power supply and cable Green LED should be on at all times.
• Yellow LED flashing: Remove cables from high voltage.
• Yellow LED always off: Check and adjust alignment of transmitter and receiver. Remove obstruction.
• No Green LED: Check across terminal 1 and 4 on Module B: Remove wires from terminal 1, 2, 3, 4. If 24 VDC present at terminal 1 and 4: isolate faulty light curtain. If 24 VDC not present at terminal 1 and 4 after removal of wires: faulty module.

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What is the first step to do if the motor drive has a fault?

To clear a fault press the Stop key, or cycle power.

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What are the corrective actions for the Motor Drive Fault?

• F3 power loss: Check incoming power.
• F4 Undervoltage: Check incoming power for low voltage or power interup-tions.
• F5 Overvoltage: Check for high incoming power.
• F6 Motor stalled: Increase accel time or reduce load so drive does not exceed set current in A089.
• F8 Heatsink overheat: Check for blocked or dirty heat sink fins, check fan.
• F13 Ground Fault: Check the motor and external wiring for the drive output terminals for a grounded condition.
• F38 Phase U to Ground F39 Phase V to Ground F40 Phase W to Ground: Check wiring between drive and motor. Check motor grounded phase. Contact manufacturer.
• F41 Phase UV short F42 Phase UW short F43 Phase VW short: Check the motor and drive output terminal wiring for shorted condition. Contact manufacturer.
• F70 Power Unit: Recycle power. If fault does not clear, call manufacturer.

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What kind of maintenance is needed for high-speed doors?

Albany Door Systems high speed doors are engineered for low maintenance operation. The door should be visually inspected daily for wear and tear, and operated to verify functions. Quarterly maintenance should be performed to clean components and to check all safety functions and check for mechanical and electrical integrity.

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What should you do during a Daily Inspection?

1. Inspect the door fabric for wear or damage.
2. Operate the door through several openings and closings. Verify that the door seats against the floor and that the door fabric remains tight and does not wrinkle. Verify that the door opens fully, slightly beyond the wall opening, and does not open too far.
   • If the door does not seat against the floor properly opens to the wrong position refer to “Setting Door Limit Adjustments” on page 6.
   • If the door fabric has diagonal wrinkles the door fabric roll at the top of the door is not level and perpendicular to the side rails. Leveling adjustments should be made as soon as possible to prevent wear or damage. Refer to the installation instructions or contact R-Bac.
3. With the door closing, place an object through the light curtain, or photoeyes, on each side of the door. Verify that the door stops immediately.
4. If a multiple panel door is installed, check the pins at each end of the ribs to verify that they are in place and centered.
5. Inspect the coiled electrical wire for wear or damage.
6. Check the light curtain slots for dirt or dust accumulation and clean as necessary.
7. While the door is closing, tap the bottom of the door edge and verify that the door stops and reverses to a fully open position.

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What is the procedure for a Quarterly Inspection?

1. Perform daily inspection.
2. Check all mounting hardware and verify that all nuts and bolts are tight. Hardware includes: wall anchors, cover hardware, motor mounting hardware, and bearing bolt nuts.
3. Check the break away function by performing the following steps:
   • Stop the door so the bottom rail is between waist and chest high.
   • Push the bottom bar out of one of the side columns.
   • Press the Open keypad and verify that the door opens to the break away opening height and that the bottom bar centers in the side rails.
   • Press the Close keypad and verify that the bottom rail is centered and the door closes fully.
4. Inspect all side and top weather seals for wear or damage.

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Table 1: Side Frame Parts

It lists components such as guide covers, spring covers, tension springs, belts, and rubber cable.

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Table 2: Panel Door Blade Parts

It lists lamella types, extension pieces, and window lamellas.

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Table 3: Barrel Complete Parts

It lists components such as spiral disks, dampener disks, and bracket belts.

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Table 4: Drive Unit Complete Parts

It lists gear motors, brakes, proximity switches, and cables.