The Smallest, Quietest & Safest Garage Door Operator in ...customdoorcontrols.com/images/Technicians_Manual_Small_File... · Operator Head Standard Mounting Instructions for on a

Technical Instruction Manual

© ZAP Controls UK Ltd.

The Smallest, Quietest & Safest Garage Door Operator in the World!

For Technical Support call or text: 931-510-4432

Email: [email protected]

Page 1*

Recommended parts that dealers should stock to service ZAP Operators (Listed in order of importance in each schedule) Schedule 1 (800R, 800, 8800) (Most important as a minimum) (Disregard 800-RL-US and AX20 Belt if not using Residential ZAP Operators)

Listed in order of importance in each schedule)

Schedule 1 (825-II, 8825-II) Schedule 2 (815RL/ In addition to schedule 1) 800-II-PB 800-II Complete Controller USA 800-RL-US 800-RL Complete Replacement Controller USA 8800-II-PB 8800-II Complete Controller USA 600600 (AX20) Belt 815-RLC ZAP Technicians Screwdriver 600601 (AX21) Belt 815-RLB 600612 (AX22) Belt 825-B ZA0093 RL Motor Cable assembly. 3.75m (12ft). 600602 (AX23) Belt 825-C/8825-B ZA0095 1.25m Bowden Cable for 815RL 600615 (AX25) Belt 825-D/8825-C 600614 (AX27) Belt 8825-D Schedule 3 Chain Hoist Operators (In addition to Schedule 1) 871 Interface Module 600624 (AX25.5) Belt 8826-II-B 850 Beeper Module 600614 (AX27) Belt 8826-II-C ZA0142 8m Motor Cable Assembly 600617 (AX29) Belt 8826-II-D ZA0168 M6 Set Screw for pulley keyway. (10 PK) ZA0084 (4") Driven Pulley ZA0169 M6 Lock Nut for Pulley keyway screw. (10 PK) ZA0085 (5") Driven Pulley 900005 Large Offset Torque arm for low headroom ZA0086 (6") Driven Pulley 501000 3mm Key Stock (10 Pack) 601200 Super Drive Bearing (2 Required for each operator) Schedule 4 Sheet Door Operators (In addition to Schedule 1) 600805 Small Super Drive Motor for 800 Models 600620 (AX35) Belt for 815-SD 600810 Large Super Drive Motor for 8800 Models 600621 (AX38) Belt for 815-SL/8815-SD 501626 Large Manual Over-ride Lever ZA0171 Fuse. 5 x 20mm. 1 Amp. (10 PK) Schedule 5 8825-II-S/8825-II-HP (In addition to Schedule 1) ZA0172 Fuse. 5 x 20mm. 2 Amp. (10 PK) 600614 (AX27) Belt 8825-II-S-A/8825-HP-A ZA0173 Fuse. 5 x 20mm. 3 Amp. (10 PK) 600617 (AX29) Belt 8825-II-S-B/8825-HP-B ZA0174 Fuse. 5 x 20mm. 4 Amp. (10 PK) 600621 (AX38) Belt 8825-II-S-C/8825-HP-C ZA0175 Fuse. 5 x 20mm. 5 Amp. (10 PK) 600609 (AX41) Belt 8825-II-S-D/8825-HP-D ZA0176 Fuse. 5 x 20mm. 6.3 Amp. (10 PK) 8800-II-HP-PB Controller 201802 Red N/C Button 600813 High Power Super Drive Motor for 8804-HP/8825-HP 201833 Open/Close N/O Button 500261 M6 X 20mm Screw for Super-Drives (10 PK) Schedule 6 (If using 8855) (In addition to Schedule 1) 500462 M6 Flange Nut For Super-Drives (10 PK) 600614 (AX27) Belt 8855-A 500262 M6 X 45mm SCREW for Super-Drives (10 PK) 600617 (AX29) Belt 8855-B ZA0073 2m Bowden Cable for 825/8825/8826 600603 (AX30) Belt 8855-C ZA0073 2m Bowden Cable for 825/8825/8826 600607 (AX31.5) Belt 8855-D ZA0102 3.75m Bowden Cable for Short Ht Low Head Application PC0013 MICROPROCESSOR FOR 8850-STD CONTROL UNIT ZA0081 5.5m Bowden Cable for Tall Ht and Low Head Application PC0015 MICROPROCESSOR FOR 8850-FS CONTROL UNIT ZA0157 Cir-clip for 8800 Series Motor Pulley (10 pack) 600812 High Speed Turbo Drive Motor for 8855 Models 501601 D-Shackle (Pack of 10) 8850-PB Turbo Drive controller ZA0158 M5 Shake-proof lock washer for Bowden Cable (10 Pack) ZA0159 M5 Nut for Bowden Cable (10 Pack) Schedule 7 (Accessories) ZA0160 E clip for Bowden Cable (10 Pack) 850 Beeper Module ZA0154 M4x8mm Pozi screw for 800 Series Mtr Pulley (10 pack) 871 Interface Module ZA0155 M5x20mm MG Washer for 800 Series Mtr Pulley (10 Pack) 8070 Auto Lock ZA0156 M4 Spring Washer for 800 Series Motor Pulley (10 Pack) 872 Adapter Module PC0025 V02.0 Microprocessor Chip for 800-II Control Unit 401000 Retro reflective photo cells PC0026 V02.0 Microprocessor Short Run Chip for 800-II C.U 401001 Through Beam Photo Cell PC0028 V02.0 Microprocessor Chip for 8800-II-PB Control Unit PC0029 V02.0 Microprocessor Short Run Chip for 8800-II C.U. 601412 Microprocessor Chip Extraction Tool 600219 46mm Drive Pulley for 825-C&D Models 600220 50mm Driven Pulley for 825-B Models ZA0048 100mm (4") Driven Pulley for 825/8825-B ZA0049 125mm(5") Driven Pulley for 825/8825-C/8825-HP-AZA0050 150mm(6") Driven Pulley for 825/8825 & 8825-HP-B

Page 2*

Operator Mounting Instruction



Page 3*

Operator Head Standard Mounting Instructions for on a solid torsion shaft.

ZAP Models 815-RL, 825, 8825, 8826, 8825-S, 8825-HP, 8855

Materials Needed �� Appropriate operator for door size

(See model application chart) �� 3mm Allen Key, 10mm Wrench �� Appropriate mounting fasteners

Fully read the instructions provided with the operator.

Remove and separate all contents from the box.

It is important to follow the steps in order to prevent misalignment of the operator.

Locate the torque arm, torque arm bolt and spacer. Attach the torque arm and spacer to the operator into a position that you consider the approximate distance to an open bolt hole on the track assembly. (Figure A)

Slide the operator on the shaft and into position. (Figure B)

Check that the positioning of the Torque arm is correct. (Figure C) If necessary, slide the operator off the shaft and adjust the position of the torque arm. Reposition operator back onto shaft. Note-the torque arm should always be positioned in a horizontal manner, never vertically. (Figure D)

Secure the torque arm to the track assembly through an existing bolt hole using either the provided fastener or one of suitable size to accommodate your needs. Tighten the bolt securely into place. (Figure E)

Using the provided key stock. Insert it fully into the keyway. (Figure F)

Tighten the set screw securely into place being careful not to over tighten. (Figure G)

Then tighten the lock nut on the set screw. Repeat process for second set screw. (Figure H)

Locate the second set screw on the pulley and repeat the processes for tightening the set screw and lock nut. (Figure G & H)

To prevent accidental loss of keyway should the set screws accidentally back out, Use electrical tape to wrap the key stock. (Figure I)

Figure C

Figure B

Figure D

Figure E

Figure F Figure G

Figure A

Figure H Figure I

Page 4*

Operator Head Standard Mounting Instructions on a hollow torsion shaft.

ZAP Models 825, 8825, 8826, 8825-S, 8825-HP, 8855


(See model application chart) �� 3mm Allen Key, 10mm Wrench, drill, 1/4” Drill bit, �� Appropriate mounting fasteners.

Fully read the instructions provided with the operator.


It is important to follow the steps in order to prevent misalignment of the operator.

Locate the torque arm, torque arm bolt and spacer. Attach the torque arm and spacer to the operator into a position that you consider the approximate distance to an open bolt hole on the track assembly. (Figure A)

Slide the operator on the shaft and into position. (Figure B)

Check that the positioning of the Torque arm is correct. (Figure C) If necessary, slide the operator off the shaft and adjust the position of the torque arm. Reposition operator back onto shaft. Note-the torque arm should always be positioned in a horizontal manner, never vertically. (Figure D)

Secure the torque arm to the track assembly through an existing bolt hole using either the provided fastener or one of suitable size to accommodate your needs. Tighten the bolt securely into place. (Figure H)

Using the 3mm Allen wrench, tighten one of the set screws into position creating a mark on the torsion shaft. (Figure E) Loosen the set screw and slide the operator out of the way exposing the score mark.

Using the 1/4” drill bit and drill, drill a small countersink into the shaft being careful not to drill all the way the way through the wall of the shaft. (Figure F)

Slide the operator back into position and tighten the set screw into the countersink being mindful not to over tighten. (Figure E) Tighten the lock nut on the set screw. (Figure G) Repeat process for second set screw.

Re-secure the torque arm to the track assembly through an existing bolt hole using either the provided fastener or one of suitable size to accommodate your needs. Tighten the bolt securely into place. (Figure H)

Figure C

Figure B

Figure D

Figure E

Figure F

Figure G

Figure A

Figure H

Page 5*

Inverted Mounting

ZAP Models 825, 8825, 8826, 8825-S, 8825-HP, 8855


(See model application chart) �� 3mm Allen Key, 10mm Wrench, drill, 1/4” Drill bit, �� Appropriate mounting fasteners.

Note:It is not advisable to mount the ZAP 815-RL Residential operator in an inverted fashion.

Assembly and Mounting Follow the assembly instructions and basic mounting techniques for standard installation on hollow and solid torsion shafts.

Inverted mounts may happen outboard or inboard of the cable drum. For mounts inboard of the cable drum, ensure there is clearance between the operator and the door at the point where the door passes the operator.

Bowden Cable It will be necessary to loop the Bowden cable over either the jamb and track if mounted inboard of the cable drums and over the motor if mounted outboard of the cable drums. Using a cable clamp to hold the Bowden cable in place for this application is advisable, but it must not be so tight as the clamp, bind or compress the sleeve of the Bowden cable assembly. A heavy duty nylon wire tie will also suffice when there is sufficient access to secure the nylon wire tie.

Mounting inboard of the cable drum. With the door in the closed position and the spring tension completely relieved by completely unwinding the torsion springs using the proper tools for accomplishing the task, remove the bearing plate and cable drum of the door.

Position the inverted operator in the direction for the side of the door that best suits mounting of the torque arm. (Figure A)

Never mount the torque arm into concrete or block work using a concrete anchor. Only mount to steel or to wood jambs that have been properly secured and will not work loose with the applied torque of the operator. (Figure B) If no mount to the wall or track is available for securing the torque arm, it is ok to develop your own mount using angle iron to mount otherwise as exampled in Figure C.

Loop the Bowden Cable over the cable drum and track assembly, and secure as described above in the Bowden cable section above.

Mount the Bowden cable mounting bracket located at the end of the Bowden cable sheath securely as described in the Bowden cable mounting instruction. Continue with operator installation and set up normal.

Mounting outboard of the cable drum. Position the inverted operator in the direction for the side of the door that best suits mounting of the torque arm. (Figure A)

Never mount the torque arm into concrete or block work using a concrete anchor. Only mount to steel or to wood jambs that have been properly secured and will not work loose with the applied torque of the operator. (Figure B)

Loop the Bowden Cable over the operator and secure as described above in the Bowden cable section above.

Mount the Bowden cable mounting bracket located at the end of the Bowden cable sheath securely as described in the Bowden cable mounting instruction.

Continue with operator installation and set up normal.

Figure A

Figure B

Figure C

Page 6*

Rear Mount Torsion Mounting

ZAP models 815-RL, 825, 8825, 8826, 8825-S, 8825-HP

Materials Needed �� As described in the standard mounting instructions. �� Appropriate Bowden Cable for height of door (See Bowden Cable section Below) �� Part# 900005 Additional Large offset torque arm.

Torque arm It may also be necessary to reach around the cable drum if it is mounted to the outside of the torsion shaft bearing plate. To achieve this attach the additional torque arm to the torque arm that is attached to the operator as exampled in (Figure A)

Assembly and Mounting Follow the standard assembly instructions and basic mounting techniques for a standard installation on hollow and solid torsion shafts.

Bowden Cable It will be necessary to change the Bowden to a longer Bowden Cable assembly to accomplish a rear mount torsion application. The following sizes of Bowden cables are available to accommodate different height doors: Part# 501255 12.30 Feet Fits low headroom doors to 10’ High Part# 501256 17.75 feet Fits low headroom doors between 11’ to 16’ High

Securing the Bowden cable to the horizontal track. It will be necessary to attach the long Bowden cable to the horizontal track towards the header of the door. This can be typically achieved by drilling spaced hole into the horizontal angle iron attached to the horizontal track and utilizing a heavy duty nylon cable tie to secure the Bowden along the horizontal track. (Figure B)

Mount the Bowden cable mounting bracket located at the end of the Bowden cable sheath securely as described in the Bowden cable mounting instruction.

Continue with operator installation and set up normal.

Figure B Figure A

Page 7*

Front Mount Low Headroom Torsion Mounting

For Future Expansion

Page 8

Standard Mounting Instructions

ZAP Models 815-SD, 815-SL, 8815-SD


(See model application chart) �� 4mm Allen Key, 10mm Wrench, Large Phillips Screw Driver, Adjustable

wrench.


Determine hole diameter in end of barrel and select appropriate tongue for the application.

Bolt the appropriate tongue for door to the Pulley (Finger tight) (Figure A)

For Installation on a new install door:

Install operator before installing door by sliding operator over the shaft.

Align and insert the tongue into hole located on the end of the drum.

Mark the position and slide the operator out far enough to tighten the fasteners securely.

Slide the operator back into position.

Position operator so that it will be vertical when door is installed. (Figure B) Note: the flat spot on the bottom of the pulley boss is designed to rest on the door support bracket.

Tighten set screws being careful not to over torque. (Figure C)

Install the door in accordance with the manufacturers instructions.

For electrical operation, it is important that the door roll (curtain) is level.

For Retrofit Installation:

With the door fully raised and secured to prevent its unrolling, remove spring tension per the door manufacturers instructions.

On the end of the door you wish to install the opener, unbolt the curtain shaft from its support bracket.

Using a mechanical lift raise that end of the door to a height sufficient to allow half the diameter of the operator driven pulley to pass over door support bracket.

Hold the operator 90 degrees to the wall and slide the operator over the shaft and into position.

Once on the shaft and passed over the door support bracket, rotate the operator to a vertical position.

Align and insert the tongue into hole located on the end of the drum.

Mark the position and slide the operator out far enough to tighten the fasteners securely.

Slide the operator back into position.

Position operator so that it will be vertical when door is installed. (Figure B) Note: the flat spot on the bottom of the pulley boss is designed to rest on the door support bracket.

Tighten set screws being careful not to over torque. (Figure C)

Figure B

Figure A

Figure C

Page 9*

Bowden Cable and Over-Ride Lever Mounting

ZAP Models 825, 8825, 8826, 8825-S, 8825-HP, 815 SD/SL, 8815-SD, 825-SS

Materials Needed �� Drill�� 1/4” Drill bit, Appropriate mounting fasteners. �� Appropriate wrenches

Installation: After the operator has been mounted properly, locate the mounting bracket on the end of the Bowden cable black sheath. (Figure A)

The Bowden cable may be mounted to either the Jamb or the track assembly. If mounting the Bowden cable bracket to the track assembly, you must mount the over-ride lever to the track assembly as well. If mounting the Bowden cable bracket to the door jamb, then the over-ride lever must be mounted to the door jamb as well. Never combine the two methods of mounting.

After locating the Bowden cable mounting bracket, bring it to the desired surface you wish to mount it to, either the track assembly or the door jamb. (Figure B)

Next, lift the bracket at least 2 to 4 inches to allow flexibility in the Bowden cable and mark for drilling or mounting. The flexibility created in the Bowden cable is necessary to ensure proper tensioning of the operator belt. This also allows enough flexibility in the Bowden cable to permit the removal of the operator in the event of the need to replace the operator belt after wearing out, without having to disassemble the Bowden cable assembly. (Figure B)

If track mounting, use the drill and 1/4” bit to drill the to marked holes in the track assembly. Using the provided flat head fasteners for mounting the Bowden Cable secure the Bowden cable bracket into place.

If mounting to the door jamb, use a fastener of appropriate size and design for the material to which you are mounting. (Figure C)

It is not advisable to mount the over-ride lever directly to the over-ride lever. Add an minimum of five lengths of the provided chain to the D shackle to facilitate future adjustment. If extra length is required to reach the desired mounting height of the over-ride lever, attach the provided extension chain to the “D” Shackle on the end of the Bowden Cable to reach that height. (Figure D)

Locate the over-ride lever and adjust the hook out to the fully extended position. (Figure E)

Insert the hook of the over-ride lever into a link in the extension chain. Pulling down (Figure F) on the lever to take up the belt slack on the operator, position the over-ride lever in the desired location (Figure G) and mark for drilling or mounting. (Figure H)

Remove the over-ride lever from the chain or “D” shackle and mount the over-ride lever in the marked position. (Figure I)

Re-insert the hook into the “D” shackle or extension chain (Figure J) and proceed to the Setting proper belt tension with the over-ride lever instruction page.

On the Chain hoist model operator (8826), note that the first push down of the over-ride lever is simply lifting the chain hoist off of the spur gear. A secondary push down on the lever is required to tension the belt.

Figure A Figure B

Figure C Figure D

Figure E

Figure F

Figure G

Figure H

Figure I

Figure J

Page 10*

ZAP Models 825, 8825, 8826, 8825-S, 8825-HP, 815 SD/SL, 8815-SD, 825-SS

Connect the over-ride lever to the Bowden cable tensioning system. (Figure A)

Press down on the over-ride lever until the belt feels fully tensioned without locking the lever down.

Looking at the handle of the lever as if it were the hand of a clock, it should be located just above the 3:00 o’clock or 9:00 o’clock position, depending upon how you are looking at it.

If it is lower than that (Figure B), adjust the hook tighter until the correct position is achieved when pressing down of the lever. (Figure C)

Once proper tension is achieved, lock the handle into place. (Figure D)

Figure B

Figure A

Figure C

Figure D

Bowden Cable Tensioning

Page 11*

Controller Mounting & Wiring Instruction



Page 13*

Controller Mounting Instruction

Mounting Instruction for ZAP Controllers 800RL, 800-II-G, 800-II, 8800-II, 8850, 8800-II-HP


(See model application chart) �� Phillips screw driver, Slotted screw driver, small technicians slotted screwdriver,

appropriate mounting screws.

Mounting the controller

It IS permissible to mount this controller in a freezer / refrigerated environment. It IS permissible to mount this controller in a high or remote location. It IS permissible to mount this controller in a wet location provided the wet location mounting instruction is complied with.

Using a standard screwdriver, insert it into the cover retaining screws located in each corner of the controller. (Figure A)

Unplug the cover an place it in a secure place where it will not be stepped on or knocked to the ground. (Figure B)

Using a general purpose screw with a head diameter small enough to fit into the corner pillars of the controller, mount the controller a minimum of 5’ above the ground. Do not mount through the back of the controller case by removing the circuit board as this may allow moisture to enter the controller or short circuit the control board if it touches the fastener used. Mounting through the back of the controller case will void the manufacturers’ warranty if damage occurs. (Figure C & D)

Only mount the controller with the conduit access holes pointed down. Only use the holes provided on the bottom of the controller to introduce conduit or wiring into the controller. Moisture can and will condense in conduit due to the warmth generated by the controller. If the controller is mounted upside down and conduit is not used, any liquid spilled on top of the controller can enter into the controller and drip the board causing a short circuit. Introducing conduit in any fashion other than from the bottom of the controller will void the manufacturers’ warranty if damage occurs.

You are not limited to mounting the controller at the five foot height. The controller may be mounted high by the operator or remotely, as long as the distance away from the operator does not exceed the length of the provided motor cable. (Figure E)

Wet location mounting. See the wet location modification.

Remote wall station mounting. A remote wall station may then be run in a series from the controller. See remote wall station wiring pages.

Figure A

Figure B

Figure C

Figure D

Figure E

Page 14*

Wet Location Controller Mounting Instruction

Mounting Instruction for ZAP Controllers 800-II, 8800-II


(See model application chart) �� Wet Location Motor Cover 8259 for 825 and 8825 Operators �� 503016 Un-drilled Blank Controller Case for 8800-II Models �� 503005 Un-drilled Blank Controller Case for 800-II Models �� Nema 4 Three Button Station �� Phillips screw driver, Slotted screw driver, small technicians slotted screwdriver,

appropriate mounting screws.

ZAP Wet Location Modification Specification for Car/Truck wash Applications�� The Carwash Cover must be applied to the operator.

Mounting the controller

1. Mount the controller up high by the motor assembly or in a remote location away from the direct spray of the wash mechanisms ensuring proper mounting techniques as described in the installation instructions to prevent moisture form entering the controller. 2. All wiring introduced into the controller should be via conduit or wet location compression fittings must be used to seal the wiring. 3. A wet location approved 3 button control station should be mounted next to the door and wired via conduit to the ZAP Controller. (Not Available through ZAP) 4. Replace the controller case lid with the no button version supplied in the carwash kit

Wiring for Wet Location 3 button station.After removing ZAP 3 button case lid, remove the wires from the terminal strip that plugs onto the circuit board at terminal block 5. Wire the external wet location approved 3 button control station as shown here to the plug removed from the case lid wires. Locate terminal block 5 on the main ZAP control board and plug the wires back onto the terminal strip.

Figure A

Figure B

Figure C

Figure D

Page 14*

STOP

CLOSE

OPEN OPEN

STOP

CLOSE

COMMON

Materials Needed �� Appropriate operator for door size (See model application chart) �� Small technicians slotted screwdriver

ZAP Controller Power Wiring Instruction

ZAP Controllers are designed to accept only 115VAC in North America and 230VAC in Europe. Note the voltage selector switch located on the main board in (Figure A), highlighted in yellow. Please ensure this set to the correct local voltage.

All wiring plugs are removable for easy wiring access with the exception of the grounding terminal.

Power wiring access on the control board is located in the area heighted in red (Figure A).

Always utilize the pre-drilled holes in the bottom of the controller case to introduce wiring into the controller. (Figure B)

If using conduit, always introduce the conduit through the pre-drilled holes in the bottom of the controller case. (Figure B)

Wiring Diagram: (Figure C) 115VAC Only for North America

Neutral

Live

Ground

Figure A

Figure C

Figure B

Wiring Instruction for ZAP Controllers

Zap Controllers 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850

Page 15*

Power Supply Wiring for ZAP Residential Controllers

Model 800-R

The ZAP 800-R controller is pre-wired for a 110V power supply. Simply plug it into a 110V outlet.

Page 16*

Motor Wiring

For ZAP Controllers 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850


(See model application chart) �� Small technicians slotted screwdriver

Motor Wiring: All wiring plugs are removable for easy wiring access with the exception of the grounding terminal.

Insert the provided motor wiring cable in through one of the pre-drilled holes provided in the bottom of the controller case. (Figure A Highlighted in yellow)

Always utilize the pre-drilled holes in the bottom of the controller case to introduce wiring into the controller. (Figure B)

If using conduit, always introduce the conduit through the pre-drilled holes in the bottom of the controller case. (Figure B).

Remove the plug labeled M1 and M2 Dc Motor. (Figure A Highlighted in Orange)

Insert the motor wires into the plug and tighten the connections using the small technicians screw driver.

Plug the terminal back onto terminals M1 and M2. (Figure A Highlighted in Orange)

Working the cable up the jamb, secure cable to Jamb or track with wire ties or other cable securing devices being careful not cut or staple the wire. (Figure C)

Loop and secure the excess motor cable to the upper part of the jamb or wall leaving enough excess to plug the wire into the motor. (Figure D)

Plug the motor cable into the plug located on the motor in the case of the 800 series (Figure E) or onto the plug wire connector on the 8800 series. (Figure F)

Figure A

Figure B

Figure D

Figure C

Figure E Figure F

Page 17*

Motor wiring for ZAP Residential Controllers

Model 800-R

The ZAP 800-R controller is pre-wired for motor wiring. (Figure A)

Do not relocate these wires for switching motor direction.

Page 18*

(Figure A)

Controller Setup



Page 19*

Commercial Controller Set Up

ZAP Controllers 800-II-G, 800-II, 8800-II, 8800-II-HP


(See model application chart)

Once the door operator is fully installed, release the over-ride lever and lift the door to a position approximately 2 feet off the ground. Re-engage the over-ride lever.

Press the open Button (Figure A) and observe that the open LED is illuminated. (Figure B) Verify the direction of door travel. Press stop.

If the door traveled in the close direction. Remove the plug on terminals M1 & and M2 and reverse the motor wires. Recon-nect the terminals. (Figure C)

Release the over-ride lever and lower the door to the floor. Re-engage the over-ride lever.

Press open to begin the open calibration process. (Figure A) Observe that the open LED is illuminated. (Figure B) When the door has reached the fully open position and stopped, the open led should turn off immediately. If it does not consult trouble shooting section.

Press close to begin the close calibration process. (Figure D) Observe the close LED is illuminated. (Figure E) When the door has reached the fully closed position and stopped, the close led should turn off immediately. If it does not consult trouble shooting section.

Repeat the above process a total of 2 more cycles. On the third cycle the opera-tor should be calibrated and running at full speed.

After completing the calibration process, re-check the belt tension as described in the Bowden cable setting section as the belt may have tensioned more on one side than the other during initial set up.

If the door does not reach full height or closure during calibration, consult the trouble shooting section.

If the door does not reach the fully closed position during calibration, consult the troubleshooting section.

If the door stops midpoint during calibration, consult the trouble shooting section.

Figure E

Figure D

Figure C

Figure B

Figure A

Page 20*

Residential Controller Set Up

ZAP Controller 800-R

Materials Needed �� Appropriate operator for door size (See model application chart)

Once the door operator is fully installed, but before any accessories are installed, place the case lid into the service position. (Figure A)

Release the over-ride lever and lift the door approximately 2 feet off the ground.

Re-engage the over-ride lever. To determine the motor direction, press the button on the controller case lid. (Figure A) The open led should illuminate (Figure B) and the door will run in either the open or close direction. Now press the button on the case lid again to stop the motor.

If the door runs in the closed direction, isolate the main A/C power supply and set DIP switch #7(Figure C)(Motor Polarity Switch) to the opposite position. DO NOT MOVE THE SWITCH WHILE THE MOTOR IS RUNNING.

Release the over-ride lever and lower the door to the floor. Re-engage the over-ride lever.

It is now necessary to complete the initial calibration process. This particular process is required only for the residential operator.

Inside the controller, Press and hold down on the black reset button to begin the open calibration process. (Figure D) While holing the reset button press and hold down the program button (Figure E) You are now holding down both buttons. Release the reset button only while continuing to hold down the program button. Watch for one flash of the ACK LED. (Figure F) Release the program button.

Press the case lid button to open the door. Observe that the open LED is illuminated. (Figure G) When the door has reached the fully open position and stopped, the open led should turn off immediately. If it does not consult trouble shooting section.

Press the case lid button to close the door. Observe the close LED is illuminated. (Figure E) When the door has reached the fully closed position and stopped, the close led should turn off immediately. If it does not consult trouble shooting section.

Repeat the above process a total of 2 more cycles. On the third cycle the operator should be calibrated and running at full speed.

If the door does not reach full height or closure during calibration, consult the trouble shooting section.

If the door does not reach the fully closed position during calibration, consult the trouble-shooting section.

If the door stops midpoint during calibration , consult the trouble shooting Section.

Figure F

Figure D

Figure C

Figure B

Figure A

Figure E

Figure G

Figure H

Page 21*

Accessory Installation and Wiring



Page 22*

850 beeper Module

For use in ZAP Controllers 800-R, 800-II, 800-II-G, 8800-II, 8800-II-HP, 8850

Figure A

Figure B

Materials required to accomplish task: �� 850 Beeper Module

Locate the terminals labeled buzzer as indicated in Figure A.

Align the 850 Beeper module connector onto to the 3 pin buzzer connection.

Press into place ensuring that the module seats firmly into place. (Figure B)

The module 850 Beeper is now ready to use.

Page 23*

ZAP 840 Receiver

For ZAP Controllers 800-R, 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850

Figure A

Figure B

For use with ZAP Transmitters only

Materials required to accomplish task: �� 840 Receiver �� 2416 or 2414 Antenna �� ZAP transmitter

Locate the terminals labeled RX Socket indicated. (Figure A)

Align the 840 Receiver onto to the 3 pin RX Socket connection.

Press into place ensuring that the module seats firmly into place.

The module 840 receiver is now ready to program. (See programming instruction section)

After programming, install the antenna.

If using the 2416 internal antenna plug it onto the receiver. Ensure that it runs in front of the transformer. (Figure B)

If using the 2414 external antenna, Mount the antenna outside and neatly route the wire in through the bottom of the controller case and plug onto the receiver. (Figure C)

Figure C

Page 24*

External Receiver to ZAP Residential Controller

Materials required to accomplish task: �� External receiver from desired manufacturer �� Transmitters from desired manufacturer �� 16-20 awg 3 conductor cable

This installation is to be performed after the operator is installed and initial set up has been performed verifying successful installation and calibration of the operator.

The wiring connection is made at the three terminals highlighted in Red (Figure A)

The 24V power supply of the radio receiver is wired and terminated into the terminal labeled 24V located on the left hand side of the three position terminal block labeled ACCESSORY RADIO. (Figure B)

The common terminal of the radio receiver is wired and terminated into the terminal labeled GND, located on the right hand side of the three position terminal block labeled ACCESORY RADIO. (Figure B)

The relay or cycle terminal of the radio receiver is wired and terminated into the terminal labeled RLY, located in the middle of the three position terminal block labeled ACCESSORY RADIO. (Figure B)

Figure A

Figure B

Page 25*

For use in ZAP Controllers 800-R

8070 Auto-Lock Installation

For use in ZAP Controllers 800-R, 800-II, 800-II-G, 8800-II, 8800-II-HP, 8850

Materials required to accomplish task: �� ZAP 8070 Auto-Lock Kit

This installation is to be performed after the operator is installed and initial set up has been performed verifying successful installation and calibration of the operator. For dual application with the 871 interface module, see 872 Adapter Module.

Isolate the power supply before wiring any device into a ZAP Controller.

Mounting the 8070 Auto-Lock Solenoid Bolt Assembly

Do not remove the rubber band holding the shoot bolt in the solenoid until installation is complete.

Position the assembly on the door track above a roller ensuring there is at least 3/8”distance between the bottom of the shoot bolt and the top of the desired roller. Mark the center position of the shoot bolt . Drill a 7/16” hole to allow the shoot bolt to pass through the track. Reposition the Solenoid assembly with the shoot bolt aligned in the center of the drilled hole and mark the U-Bracket mounting holes. Using a 1/8” Drill Bit, drill pilot holes from the out-side of the track. After drilling the pilot holes, use a 1/4” drill bit to drill the mounting holes from the inside of the track. Using the provided flat head screws or track bolts, bolt the solenoid bolt assembly to the track ensuring the shoot bolt is centered in its hole allow free travel. Once bolted into place, remove the rubber band holding the shoot bolt in the solenoid. Remove the securing pin from the bolt and test to see that the bolt travels freely by pushing it in and releasing from the inside of the track with your finger. (figure A)

Take the provided wiring cable and connect the female spade terminals to the solenoid. Secure the cable neatly along the track and wall and introduce it into the inside of the ZAP Controller through the pre-drilled wiring access located on the bottom of the controller.

Taking the 8067 Auto-Lock module in hand (figure B), insert the two provided wires from the Auto-Lock solenoid into the two terminals on the 8067 Module as indicated in figure C and highlighted in red.

With wiring of the Auto-Lock completed and the power supply isolated so there is no power to the controller, plug the 8067 Auto-Lock Module onto the 10-pin socket connector as shown in figure D, ensuring that all 10 pins are properly seated.

Plug the operator back into the power supply.

Cycle the door open, while listening and observing that the shoot bolt was activated and withdrew enough to allow the roller to pass. After ensuring that all rollers freely clear the shoot bolt and that it fully extended itself back into the track after the open cycle was completed, cycle the door closed and observe the same.

Figure B

Figure C

Figure D

Figure A

Page 26*

871 Receiver Interface Module

For use with ZAP Controllers 800-II, 8800-II, 8800-II-HP, 8850

Materials required to accomplish task: �� External receiver from desired manufacturer �� Transmitters from desired manufacturer �� ZAP 871 Receiver Interface Module �� 16-20 awg 3 conductor cable



The common terminal of the radio receiver is wired and terminated into the 871 module terminal labeled COM. (Figure A)

If cyclic operation by radio control is desired, the relay or cycle terminal of the radio receiver is wired and terminated into the 871 module terminal labeled CYCLE. (Figure B)

The 24V power supply of the radio receiver is wired and terminated into 24V terminal of the 871 Module. (Figure A)

Some manufacturers receivers may not power up sufficiently when wiring to the 24V on the 871 Module. An alternative method is to first verify that your receiver is capable of accepting 34VDC. If so, you may wire the power supply of your receiver to the 24V terminal on the main ZAP Circuit Board. It is a 3 position terminal block labeled TB7 located on the right side of the main circuit board. (Figure B)

If use of the Auto-Close timer is required, the relay or cycle terminal of the radio receiver should be wired and terminated into the 871 module terminal labeled Open. (Figure C) This will prevent an accidental stop signal from being sent via radio control by only allowing an open signal to be sent to the ZAP Controller. This will allow the Auto-Close feature to perform its function after timing out from the last radio control input without interruption.

With wiring of the radio receiver completed and the power supply isolated so there is no power to the controller, plug the 871 Interface module onto the 10-pin socket connector as shown in figure D, ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and proceed to programming your receiver per the manufacturers instructions.

Figure B

Figure A

Figure C

Figure D

Page 27*

871 FS (Fire-Station) Module

For use in ZAP Controllers 800-II, 8800-II, 8800-II-HP, 8850

For Use with Auto-Close Timer in situations where it is preferred that the Auto-Close Timer does not begin it’s count until the vehicle has left the facility.

Materials required to accomplish task: �� ZAP 871-FS Module �� Suitable 4 wire through beam photo cell �� 16-20 awg 3 conductor cable


The 871-FS is a special variant if the 871 Interface Module which uses a photo eye connected to the COM and Cycle inputs to inhibit the auto-close function until a vehicle has passed through the photo eye.

You should employ a primary set of through beam 4 wire photo eyes as a safety device. Please refer to wiring instructions for ZAP Photo eyes 401001. While the photo eyes used with the 871-FS may act as a safety device, they are not intended to be used as a primary safety photo eye and should not be used as such. Retro-reflective photo cells should not be used were reflective tape is used on vehicles

Wiring the photo cells used with the 871-FS


Mount the photo cells in a position where a vehicle will break the beam as a vehicle leaves the facility. It should be at a height where a person will not break the beam as they walk through or near the door opening.

Wire the N/C contacts of the photo-eye to the Cycle and Com inputs of the 871-FS. (Figure A)

Unplug the terminal block from TB3. Remove the close wire from the terminal block (Figure B) and wire to the close terminal on the 871-FS (Figure C)

When the door is opened fully the 871 Module will continue to drive the open signal to the control panel which will stop the door from closing. Moving the close wire to the close input of the 871-FS will enable the close button to operate normally.

Wiring of external radio control devices must only be wired to the open input when using the auto-close timer. Wire the contact terminal of the external receiver to the open terminal of the 871-FS and the com terminal of the receiver to the com terminal on the 871-FS. Wire the 24V Terminal of the receiver to the 24V Terminal of the 871-FS (Figure D)

Some receivers may not power up sufficiently when wiring to the 24V on the 871-FS Module. An alternative method is to first verify that your receiver is capable of accepting 34VDC. If so, you may wire the power supply of your receiver to the 24V terminal on the main ZAP Circuit Board. It is a 3 position terminal block labeled TB7 located on the right side of the main circuit board. (Figure E)

With wiring of the radio receiver completed and the power supply isolated so there is no power to the controller, plug the 871-FS onto the 10-pin socket connector as shown in figure D, ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and proceed to programming your receiver per the manufacturers instructions.

Figure C

Figure F

Figure B

Figure A

Figure D

Figure E

Page 28*

872 Adapter Module

For use in ZAP Controllers 800-II, 800-II-G, 8800-II, 8800-II-HP, 8850

External Radio Receiver to 871 Interface Module while using the 8070 Auto-Lock

Materials required to accomplish task: �� External receiver from desired manufacturer �� Transmitters from desired manufacturer �� ZAP 871 Receiver Interface Module �� 8070 Auto Lock Kit �� 872 Adapter Module �� 16-20 awg 3 conductor cable



Note the positions of the connector plugs in figure A & C and wire 871 Module and Receiver per 871 Interface Module Wiring instructions.

Plug the 871 Module onto the 872 adapter module where indicated in figure B.

Note the position of the connector plug in figure C and wire the 8070 Auto Lock per 8070 Auto Lock Instruction.

Plug the 8070 Auto Lock Module onto the 872 Adapter Module where indicated in figure D.

Ensure you have isolated the power supply and plug the 872 Adapter Module w/ 871 Interface and 8070 Auto Lock Module in place on the 872 Adapter Module onto the 10 pin socket connector located on the main ZAP Controller Board. As indicated in figure E.

Restore the power supply and test the auto-lock by cycling the door.

Program the external receiver to your manufacturers transmitters per the manufacturers instructions and test.

Figure A Figure B

Figure C Figure D

Figure E

Page 29*

Residential Photo Cells (Residential Operator only)

Genie through beam photo cells to the safety reversing feature.

Materials required to accomplish task: �� Genie Residential Photo Cells


Mounting the sender and the receiver:

Bolt the included mounting brackets to the sender and the receiver. After attaching the brackets, bolt ea unit to a jamb bracket of suitable size to extend the photo cell sender/receiver beyond the interior of the track.

Mount the jamb brackets to the door jamb at the appropriate height required.

Wiring using the 12V Photo Eye connections inside the ZAP Controller:

Connect the two wires from both the Genie Transmitter and Receiver Photocells to terminal block TB9 on the Zap 800-R panel. (Figure A)

Set DIP Switch number 3 to the ON position

(Figure A)

Page 30*

401000 Retro Reflective Photo Cell

For use on ZAP Controllers 800-R, 800-II-G, 800-II, 8800-II, 8800-HP, 8850

Materials required to accomplish task: �� 401000 photo cell �� 2ea Track jamb mounting brackets of suitable size to extend beyond

inside of track.


Mounting the sender receiver and reflector:

Bolt the included mounting bracket to the sender/receiver. After attaching the sender receiver to the bracket, bolt the unit to a jamb bracket of suitable size to extend the photo cell sender/receiver beyond the interior of the track.

Mount the jamb bracket to the door jamb at the appropriate height required.

Bolt the reflector to a jamb bracket of suitable size to extend the reflector beyond the interior of the track.

Mount the jamb bracket to the door jamb at the appropriate height required.

Wiring using the 24V Power Supply inside the ZAP Controller:

Terminate the sender/receiver brown wire (power) into the 24V terminal located on TB7 (highlighted in purple) as shown in Figure A and indi-cated with the brown dot.

Terminate the sender/receiver blue wire (common) Into the 0V connection on TB7(highlighted in purple) as shown in Figure A and indicated with the blue dot.

Terminate the safety black wire (common) to the Com terminal on TB2 (highlighted in orange) as shown in Figure A and indicated with the black dot.

Terminate the safety white wire (safety) to the Safety terminal on TB2 (highlighted in orange) as shown in Figure A and indicated with the white dot.

Switch DIP Switch 2 to the off (Down) position. (Figure B)

Figure A

Page 31*

Figure B

401001 Through Beam Photo Cells

For use on ZAP Controllers 800-R, 800-II-G, 800-II, 8800-II, 8800-HP, 8850

Materials required to accomplish task: �� 4010001 photo cell �� 2ea Track jamb mounting brackets of suitable size to extend beyond

inside of track.


Mounting the sender and the receiver:

Bolt the included mounting brackets to the sender and the receiver. After attaching the brackets, bolt ea unit to a jamb bracket of suitable size to extend the photo cell sender/receiver beyond the interior of the track.

Mount the jamb brackets to the door jamb at the appropriate height required.

Wiring using the 24V Power Supply inside the ZAP Controller:

Terminate the sender and receiver brown wire (power) into the 24V terminal located on TB7 (highlighted in purple) as shown in Figure A and indicated with the brown dot.

Terminate the sender/receiver blue wire (common) Into the 0V connection on TB7 (highlighted in purple) as shown in Figure A and indicated with the brown dot.

Terminate the black wire of the receiver photo eye to the common terminal of TB2 as highlighted in orange in figure A and indicated with the black dot

Terminate the white wire of the receiver photo eye to the safety terminal of TB2 as highlighted in orange in figure A and indicated with the white dot.

Figure A

Page 32*

Materials required to accomplish task: �� External Loop Detector w/loop �� 6-20 awg 2 conductor cable



Wiring a N/C Loop as a safety

The common terminal of the N/C loop is wired and terminated into the common terminal labeled Common on TB5. (Figure A)

The contact (relay) terminal of the N/C loop is then wired and terminated into the Safety terminal on TB5 (Figure A)

With wiring of the loop completed, restore the power supply.

N/C Loop connection to function as a safety


Page 33*

Figure A


Series Controller applicable to: 800-II, 800-II-G, 8800-II, 8800-HP, 8850

Materials required to accomplish task: 8830 Battery Backup System 14-18 awg 6 conductor cable


After properly mounting the 8830 Battery Backup through the corner pillar mounting holes, next to the ZAP Controller, ensure that you plug the four batteries onto the battery backup circuit board as highlighted in yellow in figure A.

After isolating the power supply to the ZAP Controller, run a six conductor cable between the 8830 Battery Backup (figure B) and the ZAP Controller (figure C) using the pre-drilled case wiring outlets.

800-II, 800-II-G, 8800-II, 8800-HP Using the two six terminal connectors provided with the 8830 Battery Backup, wire and terminate the 6 conductor cable as indicated by the following chart and highlighted colors indicated in figures B&C:

Controller Battery Backup MOT to MOT V+ 24V to +24V V1+ to +16V RL5 to CNTRL 5 RL6 to CNTRL 6 GND to COMMON

8850Taking one of the two six terminal connectors provided with the 8830 Battery Backup, cut off one terminal, making it a five position terminal. Run a six conductor cable from the 8830 Battery Backup to the ZAP Controller and termi-nate the wires as indicated by the following chart. Note you will wiring both control 5 and 6 from the 8830 Battery Backup to RL6 in the ZAP 8850 Controller.

Controller Battery Backup MOTOR SUPPLY to MOT V+ 24V to +24V 12-16V to +16V RL6 to CNTRL 5 to CNTRL 6 GND to COMMON

Restore power to the controller. The “on charge” led should illuminate. The battery backup system should remain on charge for a minimum of 24 hours before attempting its use.

Figure A

Figure B

Figure C

Page 34*

8030 Battery Backup

Dock light/Courtesy Light


Materials required to accomplish task: �� Dock Light or Interior Light from desired manufacturer �� Properly rated wiring for desired light

ZAP Controls does not supply dock lights and or interior lighting equipment.

After mounting desired light in desired position, introduce the light’s wiring cable into the controller case through the provided pre-drilled holes in the bottom of the controller. If using conduit, always introduce the conduit through the pre-drilled holes in the bottom of the controller case as exam-pled in figure A.

Wire the ground, neutral and live wires as indicated in figure B.

Set mode selector (DIP switch 6) to desired position. See figure C.

�� Switch on for on in any position but fully closed.

�� Switch off for 3 minute timer after last cycle of operation.

Figure C

Figure A

Figure B

Ground Neutral/Live

Page 35*

Residential Courtesy Light

For use in ZAP Controllers 800-R

Materials required to accomplish task: �� Interior Light from desired manufacturer �� Properly rated wiring for desired light

ZAP Controls does not supply interior lighting equipment.



If the Lighting output is to be used then the lighting wires should be routed by a qualified electrician to the orange connector at the bottom left hand side of the circuit board. A convenient conduit outlet is provided in the bottom of the case. The lighting circuit wiring should be rated at 3 Amps.

If using conduit, always introduce the conduit through the pre-drilled holes in the bottom of the controller case as exampled in figure A.

After mounting desired light in desired position, introduce the light’s wiring cable into the controller case through the provided pre-drilled holes in the bottom of the controller.

Wire the ground, neutral and live wires as indicated in figure B.

Set mode selector (DIP switch 6) to desired position. See figure C.

�� Switch on for on in any position but fully closed.

�� Switch off for 3 minute timer after last cycle of operation.

Figure C

Figure A

Figure B

Page 36*

Additional 3 Button Wall Station


Materials Needed �� External 3 button Station, �� 16-20 awg 4 conductor cable



Remove case lid from controller .

Unplug the case lid plug from TB 5 and remove the red wire from the plug-in terminal.

Using your 4 wire cable, insert a wire into the stop position if the plug-in terminal and terminate the other end of that wire into the external 3 button controller stop terminal. (red wire diagram)

Now, attach another wire to the red wire that was removed by means of a wire nut and terminate the other end of that wire into the common strip of the external 3 button controller, creating a loop through both the external 3 button station stop button and the ZAP Case lid stop button circuit. (red wire diagram)

Wire in parallel from the open connection on the case lid plug to the open button connection on the 3 button station. (orange wire diagram)

Next, wire in parallel from the close connection on the case lid plug to the close button connection on the 3 button station. (green wire diagram)

Open

Close

Stop

Page 37*

Additional One Button Wall Station on 3 button controllers

For use in ZAP Controllers 800-II, 8800-II, 8800-II-HP, 8850

To Function an additional One Button Controller for cyclic operation.

Materials Needed �� 871 Interface Module �� External 1 button Station, Unlighted door bell button, �� 16-20 awg 2 conductor cable



The common terminal of the wall station is wired and terminated into the 871 module terminal labeled COM. It is highlighted in green and shown in figure A.

The cycle terminal of the wall station is wired and terminated into the 871 module terminal labeled CYCLE. It is highlighted in yellow and shown in figure A.

With wiring of the wall station completed and the power supply isolated so there is no power to the controller, plug the 871 interface module onto the 10-pin socket connector as shown in figure B, ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and test.

Figure A

Figure B

Page 38*

Additional One Button Wall Station on 1 button controllers

For use in ZAP Controllers 800-II-G,


Materials Needed �� External 1 button Station, Unlighted door bell button, �� 16-20 awg 2 conductor cable



The common terminal of the wall station is wired and terminated into the Common terminal labeled COM on TB5. (Figure A)

The cycle terminal of the wall station is wired and terminated into the Open terminal labeled OPEN on TB5. (Figure A)

With wiring of the wall station completed, restore the power supply and test.

Page 39*

Figure A

Additional One Button Wall Station on Residential Controllers

For use in ZAP Controllers 800-R,


Materials Needed �� External 1 button Station, Unlighted door bell button, �� 16-20 awg 2 conductor cable



The common terminal of the radio receiver is wired and terminated into the terminal labeled GND, located on the right hand side of the three position terminal block labeled ACCESORY RADIO. (Figure A)

The relay or cycle terminal of the radio receiver is wired and terminated into the terminal labeled RLY, located in the middle of the three position terminal block labeled ACCESSORY RADIO. (Figure A)

With wiring of the wall station completed, restore the power supply and test.

Page 40*

Figure A

Materials required to accomplish task: �� External ceiling pull from desired manufacturer �� 6-20 awg 2 conductor cable



It is not recommended to use cyclic operation while using the auto-close timer function. Ceiling pull should only be used to open when using auto-close timer.

Use of photo cells wired to the safety reverse function is recommended when using this function.

Wiring a spst ceiling pull for use while using the Auto-Close Timer.

The common terminal of the ceiling pull is wired and terminated into the common terminal labeled Common on TB3. (Figure A)

The contact (relay) terminal of the ceiling pull is then wired and terminated into the OPEN terminal on TB3 (Figure A)

With wiring of the ceiling pull completed, restore the power supply.

Alternative wiring a spst ceiling pull for use while using the Auto-Close Timer.Materials Needed �� 871 Interface Module �� 16-20 awg 2 conductor cable

The common terminal of the ceiling pull is wired and terminated into the 871 module terminal labeled COM. (Figure C)

The contact terminal of the ceiling pull is wired and terminated into the 871 module terminal labeled OPEN. (Figure C)

With wiring of the ceiling pull completed and the power supply isolated so there is no power to the controller, plug the 871 interface module onto the 10-pin socket connector as shown in figure D, ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and test.

Turning on the Auto-close timer

Flip DIP Switch 4 to the on position. See Figure B. Default timer setting is 15 seconds. Follow programming instructions to change.

SPST Ceiling Pull to function open while using the auto-close timer


Figure B

Page 41*

Figure A

Figure C

Figure B

Materials required to accomplish task: �� External ceiling pull from desired manufacturer �� ZAP 871 Receiver Interface Module �� 16-20 awg 2 conductor cable


It is not recommended to use the auto-close timer while wired for cyclic operation.


Use of photo cells wired to the safety reverse function is recommended when using this func-tion.

Wiring a spst ceiling pull for use for cyclic operation. (Open,Stop,Close,Stop)

Do not use this method if using the auto-close timer.

The common terminal of the ceiling pull is wired and terminated into the 871 module terminal labeled COM. (Figure A.)

The contact terminal of the ceiling pull is then wired and terminated into the CYCLE terminal of the 871 module terminal labeled OPEN. (Figure A)

With wiring of the ceiling pull completed, plug the 871 Interface module onto the 10-pin socket connector as shown in (Figure B), ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply.

SPST Ceiling Pull to function Cyclic Operation


Figure B

Figure A

Page 42*




It is not recommended to use cyclic operation while using the auto-close timer function. Loop should only be used to open when using auto-close timer.


Wiring a N/O Loop

The common terminal of the N/O loop is wired and terminated into the common terminal labeled Common on TB3. (Figure A)

The contact (relay) terminal of the N/O loop is then wired and terminated into the OPEN terminal on TB3 (Figure A)


Alternative wiring a N/O Loop detector to open.Materials Needed �� 871 Interface Module �� 16-20 awg 2 conductor cable

The common terminal of the N/O Loop is wired and terminated into the 871 module terminal labeled COM. (Figure C)

The contact (relay) terminal of the N/O Loop is wired and terminated into the 871 module terminal labeled CYCLE. (Figure C)

With wiring of the loop completed and the power supply isolated so there is no power to the controller, plug the 871 interface module onto the 10-pin socket connector as shown in figure D, ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and test.

If use of the auto-close-timer is desired when using a N/O Loop to open.Turning on the Auto-close timer

Flip DIP Switch 4 to the on position. See Figure B. Default timer setting is 15 seconds. Follow programming instructions to change.

N/O Loop connection to function open


Figure B

Page 43*

Figure A

Figure C

Figure B




It is not recommended to use cyclic operation while using the auto-close timer function. Loop should only be used to open when using auto-close timer.


Wiring a N/O Loop

The common terminal of the N/O loop is wired and terminated into the common terminal labeled Common on TB3. (Figure A)

The contact (relay) terminal of the N/O loop is then wired and terminated into the Close terminal on TB3 (Figure A)


Alternative wiring a N/O Loop detector to close.Materials Needed �� 871 Interface Module �� 16-20 awg 2 conductor cable

The common terminal of the N/O Loop is wired and terminated into the 871 module terminal labeled COM. (Figure B)

The contact (relay) terminal of the N/O Loop is wired and terminated into the 871 module terminal labeled . (Figure B)

With wiring of the loop completed and the power supply isolated so there is no power to the controller, plug the 871 interface module onto the 10-pin socket connector (Figure D), ensuring that all 10 pins are properly seated. Once it is properly plugged in, restore the power supply and test.

Do not use in conjunction with the auto-close-timer..

N/O Loop connection to function close


Figure B

Page 44*

Figure A

Figure C

Dock Interlock


Dock Interlock

Materials required to accomplish task: �� 82-DTLM �� 16-20 awg 2 conductor cable



Wiring the door open interlock

The 82–DTLM provides a pair of contacts that close when the door has reached the fully open position.

The common terminal of the Dock interlock relay device is wired and terminated into one of the terminals labeled Interlock on the 82-DTLM. (Figure A)

The contact (relay) terminal of the device to be interlocked is wired and terminated into one of the terminals labeled Interlock on the 82-DTLM. (Figure A)

Once the terminals are wired, ensure the power supply is disconnected from the operator.

Carefully align the 82-DTLM socket connector with the 10 Pin socket connector on the main controller board and plug the 82-DTLM onto the 10 pin connector. (Figure B)

Ensure the socket connector is fully seated (Figure C)

Restore the power supply to the operator and test.

Figure A

Figure B

Figure C

Page 45*

Truck Restraint Interlock


Truck Restraint Interlock

Materials required to accomplish task: �� Contacts from a device that will close when truck restraint is engaged. �� 16-20 awg 2 conductor cable



Wiring the interlock

The common terminal of the truck restraint interlock relay switch to be wired is terminated into the TB4 terminal labeled COM. (Figure A)

The contact (relay) terminal of the truck restraint interlock switch is wired and terminated into the TB4 terminal labeled interlock. (Figure A)

Once the terminals are wired, Turn DIP Switch number 3 to the off (down) position. (Figure B)

Restore the power supply to the operator.

It will then be required for the truck restraint interlock relay circuit to be closed before door operation can be possible.

Figure A

Figure B

Page 46*

Interlock to prevent door operation.


Interlock to prevent door operation.

Materials required to accomplish task: �� Contacts from a device that will close when door operation is required. �� 16-20 awg 2 conductor cable



Wiring the door interlock

The common terminal of the relay switch to be wired is terminated into the TB4 terminal labeled COM. (Figure A)

The contact (relay) terminal of the relay switch is wired and terminated into the TB4 terminal labeled . (Figure A)

Once the terminals are wired, Turn DIP Switch number 3 to the off (down) position. (Figure B)


It will then be required for the circuit to be closed before door operation can be possible.

Figure A

Figure B

Page 46*

Interlocking 2 ZAP Controllers in the door open position


Interlocking 2 ZAP Controllers Example: Shared track system on Rasco Bug Screen Doors

Materials required to accomplish task: �� 2 ea 82-DTLM �� 16-20 awg 4 conductor cable



This wiring requires 2 ZAP operators.

Use of auto-close timer should not be used in this application.

Both ZAP Controllers should be mounted beside each other.

Wiring the door open interlocks of 2 ZAP controllers

The 82–DTLM provides a pair of contacts that close when the door has reached the fully open position. (Figure A)

The ZAP Controller provides a pair of contacts that require a relay on the other end of the wiring be closed to enable operation of the ZAP Controller. (Figure B)

The common terminal of the interlock on the main ZAP Control Board A (Figure B) is wired and terminated into one of the terminals labeled Interlock on the 82-DTLM into ZAP Controller B. (Figure A)

The interlock terminal of the main ZAP Control Board A (Figure B) is wired and terminated into the other terminal labeled Interlock on the 82-DTLM into ZAP Controller B. (Figure A)

The common terminal of the interlock on the main ZAP Control Board B (Figure B) is wired and terminated into one of the terminals labeled Interlock on the 82-DTLM into ZAP Controller A. (Figure A)

The interlock terminal of the main ZAP Control Board B (Figure B) is wired and terminated into the other terminal labeled Interlock on the 82-DTLM into ZAP Controller A. (Figure A)

Once the terminals are wired, ensure the power supply is disconnected from the operator.

Carefully align both of the 82-DTLM’s socket connector with the 10 Pin socket connector on the each of the main controller boards and plug the 82-DTLMs onto the 10 pin connectors. (Figure B)

Ensure the 82DTLMs are fully seated (Figure C)

Turn Dip Switch number 4 to the off (down) position in both controllers. (Figure D)

It should no be required for both operators to be in the fully open position and turned off before either operator will function closed.

Restore the power supply to the operator and test.

Figure A

Figure B

Figure C

Page 48*

Figure D

Door Closed Interlock


Creating a sally port control circuit between two doors.

Materials required to accomplish task: �� 82-TLM �� 16-20 awg 2 conductor cable



Wiring the door interlock

The 82–TLM provides a pair of contacts that close when the door has reached the fully closed position.

The common terminal of the device to be interlocked is wired and terminated into one of the terminals labeled Common on the 82-TLM. (Figure A.)

The contact terminal of the device to be interlocked is wired and terminated into the other terminal labeled Interlock on the 82-TLM. (Figure A.)

Once the terminals are wired, unplug the power supply from the operator.

Carefully align the 82-TLM socket connector with the 10 Pin socket connector on the main controller board and plug the 82-TLM onto the 10 pin connector as shown in figure B.

Ensure the socket connector is fully seated as shown in figure C.


Figure A

Figure B

Figure C

Page 49*

Accessory “On” Door Open


Turning on accessories when the door is open

Materials required to accomplish task: �� 82-DTLM �� 16-20 awg 1 conductor cable



Wiring the accessory

The 82–DTLM provides a contact that will close a relay to send a signal to cause an accessory to turn on upon the door entering it’s open cycle. Likewise the low voltage input will cease upon door closure turning off the device.

If the accessory requires a specific voltage input of 24VDC

Place jumper wire between the 24V terminal on the 82dtlm and the common terminal on the light control section of the 82dtlm (Figure A).

If the accessory will accept voltage input of up to 33VDC

Place jumper wire between the 24V terminal on the main ZAP Controls board (Figure B) and the common terminal on the light control section of the 82dtlm.

If the accessory will accept voltage input of 120VDC

Place jumper wire between the 120V Live terminal on the main ZAP Controls board (Figure C) and the common terminal on the light control section of the 82dtlm.

Common / Ground ConnectionIf necessary, wire your common connection to the 0V Connection on TB 7 (Figure B).

AlternativeIf your device has it’s own power supply and it is desired to only activate an accessory via a relay that closes the circuit. Wire your switch wires to the dock interlock switch located at the top of the 82DTLM. This relay will close when the door fully opens. (Figure D)

Installing the 82dtlmOnce the terminals are wired, unplug the power supply from the operator.

Carefully align the 82-DTLM socket connector with the 10 Pin socket connector on the main controller board and plug the 82-DTLM onto the 10 pin connector as shown (Figure E).

Ensure the socket connector is fully seated.


Figure A

Figure B

Figure D

Page 50*

Figure C

Figure E

Safety Edge


Materials required to accomplish task: �� Edge sensing system from desired manufacturer configured in a normally closed

circuit.

ZAP Operators utilize a current sensing system that does not require the use of a safety edge. The operator possesses the unique ability to sense obstructions on any part of the door with out the use of a safety edge.

We recognize that there are some circumstances where a safety edge may be required by the specifying agency and or local code.

We recommend that if a reversing edge is mandated on your sectional door, that you utilize the Miller Edge MIR-T1 Patriot Telescoping non contact sensing edge or the MIR-Z1 Z Flap non contact sensing edge.

If a reversing edge is mandated on your rolling sheet door, we recommend that you utilize the Miller Edge MIR-Z1 Z Flap non contact sensing edge.

These types of units require interruption, much like a photo cell, to cause function and are best suited for use on ZAP Operators.

To utilize any safety edge on a ZAP Operator it must be configured to function in a normally closed circuit.



Follow your sensing edges instructions for configuration into a normally closed circuit.

Wire the Normally Closed contacts to the safety and common terminals on TB-3. these are not polarity specific. (Figure A)

For 24V DC power, wire the power wire to the 24V connection on TB-7 (Figure B)

Wire the power wire to the 24V connection on TB-7 (Figure C)

Turn DIP Switch number 2 to the off (down) position. (Figure D)

Verify that the safety LED is not illuminated.

Cycle door and test function of the reversing edge.

Page 51*

Figure A

Figure B

Figure C

Figure D

Future expansion

Page 52*

Function Programming



Page 53*

The following functions can be programmed using the program button, which is located at the top of the controller circuit board. (Figure A)

When the program button is pressed and held a sequence of flashes of the Acknowledge LED follows at 4-second intervals. (Figure B)

If the 850 Beeper Module is fitted then the Beeper sounds with the flashes of the LED. See installation guide for instructions on installing the 850 Beeper Module. (Figure C)

1st flash or beep: ZAP transmitter program mode.

2nd flash or beep: Auto-Close timer program mode.

3rd flash or beep: Close Delay program mode.

4th flash or beep: ZAP transmitter code erasure mode.

5th flash or beep: Door part-open program mode.

6th flash or beep: Cancel part open mode.

7th flash or beep: Close Slow/Close Fast program mode.

The program button should be released after the appropriate flash or beep to enter the required program mode.

All of the programmed functions are stored in a non-volatile memory, which is retained during a power interruption.

The following functions may be accessed from controller case lid buttons.

Door Operation Counter

Service Due Reminder

Auto Close Defeat

Figure A

Figure B

Figure C

Commercial Operator Programming Sequences

Overview

Page 54*

Transmitter Code Programming

Series Controller applicable to: 800-R, 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850

Materials Needed �� 840 Receiver (Figure A) �� Either the 2416 (Internal) or the 2414 (External) antenna

This programming function should not to be performed until after the operator is installed and initial set up has been completed, verifying successful installation and calibration of the operator.

Refer to installation instruction for installation instruction for 840 receiver.

To program a Zap transmitter code into memory: Remove the antenna from the 840 receiver.

Press and hold the required transmitter button. (Figure B)

Notice that the LED light on the 840 receiver is illuminated indication the 840 receiver is reading the signal. (Figure C)

Hold the transmitter at arms length away from the control box to prevent the signal being transmitted from swamping the receiver.

Inside the controller, press and hold the Program button. (Figure D)

Release the program button after the first LED flash or beep if an 850 Beeper is installed. (Figure E)

Two flashes of the ACK LED or beeps from the beeper module , if installed will confirm that the code has been stored into memory.

Three flashes or beeps indicate that no code data was present in which case repeat the programming sequence.

Now release the transmitter button.

Up to 60 transmitter codes can be stored in memory. Repeat he programming sequence for each of the new transmitters. (Each transmitter has a different operating code)

Erasing all transmitter codes.

Inside the controller, press and hold the Program button. (Figure D)

Release the program button after the 4th LED flash or beep if an 850 Beeper is installed. (Figure E)

Two flashes of the ACK LED or beeps from the beeper module , if installed, will confirm that the transmitter codes have been erased.

Figure A

Figure B

Figure C

Figure D

Figure E

Page 55*


Commercial Operator Auto Close Programming

Series Controller applicable to: 800-II-G, 800-II, 8800-II, 8800-II-HP

Materials Needed �� None


The factory set Auto-Close timer delay is 15 seconds.

To use the factory set time delay:

Start with the door in the fully closed position.

To enable the Auto-Close timer, set DIP switch No. 4 to ON. (Figure A)

Press the OPEN button.The door will open and then close after the factory set time delay.

To program in a specific time delay other than 15 seconds: Start with the door in the fully closed position.

To enable the Auto-Close timer, set DIP switch No. 4 to ON. (Figure A)

Press and hold the program button. (Figure B)

Release the button after the 2nd flash of the ACK LED or beep if the 850 beeper module is installed. (Figure C)

Next press the OPEN push button.

After the door has fully opened and the operator open LED has turned off. Begin timing on your watch the desired close delay. When the desired time delay is reached, press the CLOSE push button twice. The desired delay is now stored into the memory and will be retained during any power interruptions. The programming process pressing the button twice will ensure the door closes regard-less of obstruction for security reasons.

If you prefer that the door should reopen and stay open following an obstruction strike, then only press the close button once, instead of twice, as described above.

If you wish to change programmed delay, simply repeat the programming function.

Figure A

Figure B

Figure C

Page 56*


Commercial Auto-Close Timer Temporary Defeat

Series Controller applicable to: 800-II, 8800-II, 8800-II-HP, 8850

Materials Needed �� 850 Beeper Module

To achieve proper defeat of the auto-close timer it is necessary to install the 850 Beeper module.

This programming function should not to be performed unless the auto-close timer is being used and it is necessary to defeat (stop) the auto-close timer from timing out and closing the door for one particu-lar cycle. This function is used for example, when it is necessary for the door to not close automatically after opening to receive a delivery or to hold the door open for ventilation purposes.

Installing the 850 Beeper Module:

Set the Controller case lid cover to the maintenance position.

Locate the buzzer plug in the upper left hand corner of the ZAP Controller circuit board. (Figure B)

Align the terminals of the buzzer plug with the terminals on the 850 beeper and press into place.

To Defeat (stop) the auto-close timer for 1 cycle:

Press and hold the STOP push button.

Next, press and hold the Close push button. (Figure D)

Release both buttons simultaneously after the 1st beep. (Figure D)

To resume normal auto-close function:

Close the door by pressing the close push button. (Figure E)

The auto close function will automatically resume on the next operation.

Figure A

Figure B

Figure C

Page 57*


Figure D

Figure D

182 Advanced Warning Light Module

Future Expansion Series Controller applicable to: 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850

Page 58*


282 Advanced Warning Light Module

Future Expansion Series Controller applicable to: 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850

Page 59*


Commercial Operator Delay Close Programming

Series Controller applicable to: 800-II-G, 800-II, 8800-II, 8800-II-HP, 8850


This programming function should not to be performed until after the operator is installed and initial set up has been completed, verifying successful installation and calibration of the operator. This programming function is required for use of modules 182 and 282, for use of an advance warning light for pending door closure.

To program in a close time delay:

Start with the door in the fully open position by pressing the open push button and allowing the door to open fully.

Next, press and hold the program button. (Figure A)

Release the button after the 3rd flash of the ACK LED or beep if the 850 beeper module is installed. (Figure B)

Next press the Close push button. (note that the door will not close)

Begin timing the desired delay with your watch. (up to 15 seconds)

After reaching the desired delay timing, Press the close push button.

The door will now close.

After the door has fully closed, cycle the door open and test the close delay function.

Changing the programmed delay:

Simply repeat the programming function.

Figure A

Figure B

Page 60*


Commercial Operator Part Open Programming




Part Open Programming Requirement:

For high doors, there may be a requirement to only open the door to a pre-determined height.

Start with the door fully closed.

Press and hold the program button. (Figure A)

Release the button after the 5th flash of the ACK LED or beep if the 850 beeper module is installed. (Figure B)

Now, press the open button; the door will now start opening.

At the required open position, press Stop.

You will then receive two ACK LED flashes or beeps from the 850 Beeper (if installed) will confirm successful programming.

The door will now open to this programmed position and stop.

After the stops at the programmed height, if it is required to have the door to continue to the fully open position, press the Open button again and the door will open fully. To erase the part open position:




Figure A

Figure B

Page 61*


Commercial Operator Close Slow/ Close Fast Programming




ZAP Commercial controllers have the ability to select the speed of door closure. A slow close may be requested for doors as a safety feature.

To change the programming from normal fast speed close to slow close:




The door is now programmed to close slow.

To revert back to normal speed operations:

Repeat the above process


Figure A

Figure B

Page 62*


Commercial Operator Audible Door Operations Counter


Materials Needed �� 850 Beeper Module (Figure A)


Remove the Case lid cover of the Controller leaving the plug wires connected to the ZAP Control board. The case lid should be secured in the offset maintenance position.

To enable audible operation of the door operations counter, simply install the 850 beeper module .

Installing the 850 Beeper Module: Set the Controller case lid cover to the maintenance position. Locate the buzzer plug in the upper left hand corner of the ZAP Controller circuit board. (Figure B)


Interrogation of the Door Operations Counter:

Press and hold both the STOP push button.

Next press and hold the OPEN push button.

Release them after a bleep is heard.

The beeper will then indicate the total door operations since the door was installed by sounding long bleeps for 1000's of operations and short bleeps for 100's of operations.

Two long bleeps and three short bleeps for example indicate that the door has completed 2300 operations.

If there is no response after releasing the buttons the door has completed less than 100 operations.

Figure A

Figure C

Figure C

Figure B

Page 63*


Residential Audible Service Due Reminder

Series Controller applicable to: 800-R

Materials Needed�� 850 Beeper Module (Figure A)


Description:A Service Due Reminder is a standard feature incorporated into every ZAP residential control unit. This prompts the customer to call the installation company to initiate service on the door at regular maintenance intervals. The model 850 Beeper module is required to activate the audible reminder . A visual reminder is incorporated as well where as after the service due reminder activates the door operator will now have a 10 second delay before closing on every cycle until the service due reminder is reset after maintenance is performed. The Service Due Reminder activates after 1500 complete door operations.

Installing the 850 Beeper Module:Set the Controller case lid cover to the maintenance position.

Locate the buzzer plug in the upper left hand corner of the ZAP Controller circuit board. (Figure B)


Enabling the Service Due Reminder: Unplug the power to the Controller and wait a few seconds.

Press and HOLD the button on the case lid.

Plug in the power to the Controller.

Wait for the 2nd beep from the beeper module.

Release the case lid button.

The beeper will sound twice to confirm the Service Due Reminder in enabled. Resetting the Service Due Reminder after door maintenance:Repeat the enable sequence.

Disabling the Service Due Reminder:Unplug the power to the Controller and wait a few seconds.

Press and HOLD the button on the case lid.

Plug in the power to the Controller.

Wait for the 3rd beep from the beeper module.

Release the case lid button. The beeper will sound twice to confirm the Service Due Reminder in disabled.

Figure A

Figure B

Figure C

Page 64*

Residential Operator Programming Sequences

Troubleshooting



Page 65*

Troubleshooting

Basic troubleshooting Commercial Operator

Inspect the operator to verify proper installation.

Locate the torque arm and verify that it is installed in a horizontal manner and that all fasteners are properly tightened. (Figure A)

Verify the set screws are properly tightened and the lock nuts are tightened done securely. (Figure B)

Inspect the back of the drive pulley to verify that the pulley retaining screw is tight. (Figure C)

Verify the motor cable is properly plugged into the motor. (Figure D)

Inspect the motor cable as it travels to the operator to verify there is no damage to or staples through the motor cable.

Inspect the mounting of the Bowden cable to ensure that it has been mounted cor-rectly. (Figure D) The Bowden cable may be mounted to either the Jamb or the track assembly. If the Bowden cable bracket was mounted to the track assembly, the over-ride lever must also be mounted to the track assembly. If the Bowden cable bracket was mounted to the door jamb, then the over-ride lever must also be mounted to the door jamb as. The two methods of mounting should never be mixed. Inspect the mounting of the Bowden cable and ensure it is mounted correctly.

Release the over-ride lever from its locked position.

Raise the door manually to verify that it functions properly and is well balanced.

Reconnect the over-ride lever to the tensioning system.

Press down on the over-ride lever until the belt feels fully tensioned without locking the lever down. (Figure E) Looking at the handle of the lever as if it were the hand of a clock, it should be located just below the 3:00 o’clock or 9:00 o’clock position. If it is lower than that, adjust the hook tighter (Figure F) until the correct position is achieved when pressing down of the lever. Once proper tension is achieved, lock the handle into place. (Figure G)

Figure A

Figure D

Figure E Figure F Figure G

Figure B

Figure C

Page 66*

Verifying Potentiometers

Remove case lid cover and place in service position. (Figure A)

Observe that the power LED is illuminated.(Figure B)

With small technicians slotted screw driver, verify the potentiometers are not broken.

Potentiometers rotate from approximately the 8 o’clock to the 4 o’clock position, (Figure C see red highlights) Insert screw driver into the close sensitivity potentiometer (Figure D) and gently turn it all the way to the left or counter clockwise until a stop is felt.

Note position of the screw driver blade when stop is felt. It should be pointing in either the 8 & 2 o’clock position or the 10 & 4 o’clock position. If the screwdriver blade is pointed between 10-4 remove the screwdriver and re-insert at the 8-2 o’clock position. If no stop is felt and the screw driver continues to rotate. The potentiometer is broken. Replace board. Note if this is the issue the board can be repaired. (Contact Us.) Now gently turn the screw driver all the way to the right and verify the stop exists in that direction. It should stop at approximately the 4 o’clock position. (Figure E) If no stop is felt and the screw driver continues to rotate. The potentiometer is broken. Replace board. Note if this is the issue the board can be repaired. (Contact Us.)

If a stop is felt in both directions rotate the potentiometer from the 4 o’clock position to the 12 o’clock position. This is the factory setting. Repeat above steps with the power clamp potentiometer.

Figure C

Figure D

Figure D

Figure B

Figure A

Page 67*

Troubleshooting

Basic Troubleshooting Commercial Operator

Remove case lid cover and place in service position.

Ensure Power light is on, Check voltage supply switch.

Press open button to see if control board open led illuminates and if door moves. (Figure A)

If Yes–press stop.

If open led illuminates and door does not move, Press Stop. Check motor wire connections and re-verify voltage supply switch is on 115V.

If open led does not illuminate, press red program button (Figure B) 1 time and release to see if either the open or close led illuminate.

If LED illuminates, the problem may be in the open or close button wiring. Check terminal connections on back of control buttons to ensure they are tightened. If they are, set voltmeter to ohms. Unplug case lid from main board. Place red lead on terminal that houses orange (open) wire. Place the black lead on terminal that houses common (black) wire and verify the open button circuit is good. Once test leads are in place depress the open button to check. Replace open button if no continuity is found. If the problem is in the close button, repeat steps for checking the open button. If buttons are good. Replace four position plug with new plug and check. If Open or close LED does not illuminate, contact us.

If LED does not illuminate, the problem may be in the stop circuit. It is a N?C circuit. To check the stop circuit. Check terminal connections on back of control buttons to ensure they are tightened. If they are, set voltmeter to ohms. Unplug case lid from main board. Place red lead on terminal that houses red (stop) wire. Place the black lead on terminal that houses common (black) wire and verify the open button circuit is good. There is no need to press the stop button as it is a N/C button. Replace if bad. If stop button is good, place an alligator clip jumper wire between the stop and common terminals on the main circuit board. (Figure C) Press the program button again one time. If Open or close LED does not illuminate, contact us.

If all lights function and you have verified the voltage selector switch is set properly and still the door does not move, remove terminals m1/m2 (Figure D) from the board. Set your voltmeter to VDC 200. Perform a factory reset on the board. Place the red lead on m1 and the black lead on m2. Press the open button and get a voltage reading. After ramping up it should read approximately 53+- Volts dc. Press stop. Now press the close button. It should also read approximately 53+ - Volts DC. Go to the motor head. Unplug motor wire from motor. Insert leads into the terminals and check voltage again as described above. If no voltage, replace motor wire. If voltage is good, plug the motor back into place. Check voltages again with the motor plugged in. If voltage drops significantly, contact us.

Figure A

Figure B

Figure C

Page 68*

Troubleshooting

Figure D

Release the Over-ride lever and operate the door manually to verify that it is well balanced and fully operational.

Inspect the top section to ensure it is not too tight against the header. (Figure A)

Inspect the jambs to verify the door is not too tight against the jambs or weather seal. Also inspect the track to verify that it is not too tight against the door both on the verticals and the horizontals. (Figure B and C)

After inspecting all aspects of the door operation, reconnect the over-ride lever to the Bowden cable tensioning system. (Figure D)

Press down on the over-ride lever until the belt feels fully tensioned without locking the lever down. (Figure D)

Looking at the handle of the lever as if it were the hand of a clock, it should be located just below the 3:00 o’clock or 9:00 o’clock position. (Figure D)

If it is lower than that, adjust the hook tighter (Figure E) until the correct position is achieved when pressing down of the lever.

Once proper tension is achieved, lock the handle into place. (Figure E)

Figure D Figure E Figure F

Figure A

Figure B

Figure C

Basic Troubleshooting Residential Operator

Page 69*

Troubleshooting

After inspecting the Bowden cable mounting, remove case lid cover and place it in the service position ensuring that it remains plugged onto the circuit board.

Verify the power led is illuminated. Verify the safety led is not illuminated. If it is, turn on DIP switch 2 to override the safety and address the problem after cyclic operation has been restored . (Figure B White arrows)

Locate the potentiometers and verify they are not broken by having been turned too far.(Figure B, highlighted orange) Gently turn the close sensitivity potentiometer all the way to the left or counter clockwise until a stop is felt. It should not rotate a full turn before the stop is felt. Now rotate the knob all the way to the right until the stop is felt. It also should not rotate a full turn until the stop is felt. If both stops are present the potentiometer has not been turned too far. Once you have verified this, center the position of the potentiometer between the two stops. Repeat the process for the power clamp potentiometer. If the stops do not exist, the potentiometers have been broken.

If the controller is fitted with a voltage selector switch, ensure it positioned to the proper voltage. 115V is for North America, 230V is for Europe. (Figure C) Unplug operator before switching if set incorrectly.

Unplug the operator for 30 seconds and then re-connect power.

Locate the motor wire plug (Figure D—M2,S1,M1) and verify it is properly plugged in.

Perform a factory reset. Switch the stop override DIP to off. Now, press and hold the reset but-ton. Next, press and hold the program button. Release reset and wait for the first flash and turn on stop override on while the acknowledge light is still lit, release program. You should now get continuous flashes from the acknowledge light ( We recommend that you count at least 5 of them to make sure that the correct programming sequence was followed). You then need to do a standard calibration reset.

Locate the black reset button, red program button, and ACK led light (Figure E) to perform the calibration reset.

Press the black reset button and hold it down. While holding down the black reset button, press and hold down the red program button. You will now be holding down both buttons. Release the black reset button only while continuing to hold down the red program button. Continue to hold down the red program button until there is one flash of the ACK (acknowledge) led. Then release the red program button. You will then receive two confirming flashes of the ACK led.

Locate the open and close leds.(Figure F&G) Press the case lid cover button. Looking inside at the led lights, verify the open led is illuminated, and the door is moving upward. Watch the open led and verify that when the door reaches the fully open position and has stopped moving that the open led turns off immediately. (Figure F)

Now press the case lid button again. Looking inside at the leds lights and verify it is the close led that is illuminated and the door is closing. Watch the close led and verify that when the door reaches the fully closed position and has stopped moving that the close led turns off immedi-ately. (Figure G)

Repeat this process two more times to complete the calibration process of the operator.

If the door fails to operate fully in open direction, release the over-ride lever and re-inspect the door for proper operation at the point of stoppage. If no significant resistance can be found, Adjust the power clamp potentiometer by turning clockwise slightly to increase power. Note , the max power clamp should never have to be set at the maximum setting.

If the door fails to operate fully in close direction, release the over-ride lever and re-inspect the door for proper operation at the point of stoppage. If no significant resistance can be found. Adjust the close sensitivity potentiometer by turning counter-clockwise slightly to decrease the sensitivity of the operator. It may be necessary to increase power slightly as well. Note , the max power clamp should never have to be set at the maximum setting. Nor, should the close sensitivity setting have to be set at the fully decreased setting. If this occurs, contact us.

Figure A

Figure B

Figure D

Figure E

Figure C

Figure F

Figure G

Basic Troubleshooting Residential Operator

Page 70*

Troubleshooting

115v Volt-

Commercial Operator

Disconnect power for 30 seconds. (Figure A)

Reconnect power.

Press and hold reset button. (Figure B)

Now, press and hold program button. (Figure C) (holding both down)

Release the reset button only while continuing to hold down on the program button.

Wait for one flash of the ACK led (Figure D)

Release the program button (Figure C)

You will receive two confirming flashes of the ACK led. (Figure D)

Figure A

Figure B Figure C Figure D

Control Reset for all commercial controllers

Page 71*

Troubleshooting

115v Volt-

Commercial Operator


Reconnect power.

Press and hold reset button. (Figure B)

Now, press and hold program button. (Figure C) (holding both down)

Release the reset button only while continuing to hold down on the program button.

Wait for second flash of the ACK led (Figure D)

Release the program button (Figure C)

You will receive two confirming flashes of the ACK led. (Figure D)

Figure A

Figure B Figure C Figure D

Factory Reset for commercial series II controllers with software version 2V01 and 2V02

Page 72*

Troubleshooting

115v

Voltage selector

Residential Operator


Reconnect power. (Figure A)

Locate and switch the stop override DIP to off. (Figure B)

Now, press and hold the reset button. (Figure C)

Press and hold the program button. (Figure D)

Release reset and wait for the first flash and turn on stop override on while the acknowledge light is still lit. (Figure C)

Release the program button. (Figure D)

You should now get continuous flashes from the acknowledge light (Figure E) (We recommend that you count at least 5 of them to make sure that the correct programming sequence was followed).

You will then need to do a standard calibration reset.

Figure A

Figure C Figure E Figure B

Factory Reset

Page 73*

Troubleshooting

Figure D

115v

Voltage selector

Residential Operator

Locate the black reset button (Figure A), red program button (Figure B), ACK led light (Figure C),

Press the black reset button and hold it down. (Figure A)

While holding down the black reset button, press and hold down the red program button.(Figure B) (You will now be holding down both buttons.)

Release the black reset button only while continuing to hold down the red program button. (Figure A)

Continue to hold down the red program button until there is one flash of the ACK (acknowledge) led. (Figure B)

Then release the red program button. (Figure C)

You will then receive two confirming flashes of the ACK led.

Figure A Figure C

Calibration Reset

Page 74*

Troubleshooting

Figure B

24V Power Troubleshooting

115v Voltage selector switch

1. Ensure Power led is illuminated (Figure A) 2. Set voltmeter to VDC 200. 3. Insert black lead into 0V terminal. (Figure C) 4. Place Red lead onto 24V power terminal. (Figure D) It should read approx. 31-33VDC 5. If figure D has no voltage, See step 6. 6. Remove cover of 24v fuse with a small screwdriver or needle nose pliers.(Figure B) 7. Leave black lead of voltmeter in 0V (Figure C) 7. Place Red lead onto bottom of 24V Fuse. (Figure E) It should read approx. 31-33VDC. 8. Place red lead onto top of the 24V fuse. (Figure F) It should read approx. 31-33VDC. 9. If voltages are missing on Figure F, remove 120V power supply 10. Remove fuse and replace with 2 amp 5x20mm fuse. 11. If figure D, E, or F, has high voltage, (in excess of 39VDC) Replace board.

Figure B

Figure D

Figure A

Figure C

Figure F

Figure E

Figure G

Page 75*

Troubleshooting

115v Voltage selector switch

1. Isolate power supply 2. Remove cover of 24v fuse with a small screwdriver or needle nose pliers.(Figure A) 3. Remove 24V Fuse 4. Replace fuse with 2 amp 5x20mm glass tube fuse. 5. Replace fuse cover. 6. Ensure all accessories are plugged in and wired properly 7. Restore power supply

Figure A

24V Fuse replacement

Page 76*

Troubleshooting

1. Ensure Power led is illuminated on main board 2. Verify 24V Circuit is good. (see 24V Power supply troubleshooting) 3. If circuit is good, remove 120v power supply. 4. Unplug 871 Interface module from 10 pin socket header. 5. Unplug white plug from 871 interface module.(Figure A) 6. Plug 871 Module back onto 10 pin socket header ensuring it is fully and properly seated. 7. Restore 120V Power supply. 8. Using a small screwdriver, momentarily jump the common and cycle terminals on 871 module.(Figure B) A. If operator cycles, problem is in control wiring or device wired to 871. 9. Using a small screwdriver, momentarily jump the common and cycle terminals on the receiver. A. If operator cycles, problem is in receiver wired to 871.

Figure A Figure B

871 Interface Module Trouble shooting.

Page 77*

Troubleshooting

1. Ensure Power led is illuminated on main board

2. See 24V Power Supply Troubleshooting to verify 24V power is not blown.

3. Unplug operator, Check Auto-lock 8067 card to verify it is installed correctly.

3. Cycle door to see if solenoid energizes. A. Yes, proceed to step 3. B. No, proceed to step 5.

3. Check auto-lock solenoid to verify it is not too close to roller and striking it before withdrawing fully. Reposition if necessary.

4. Verify solenoid bolt travels in and out freely and is not bent. Replace entire assembly if bent.

5. Unplug motor wires at terminals m1 and m2.

6. Unplug solenoid wires at auto-lock solenoid.

7. Set voltmeter to VDC 200.

8. Insert terminals of voltmeter into each terminal of Auto-lock wires.

9. Press open button and check voltage at wire terminals. If yes, replace solenoid and bolt. If no, check wires to see if broken. If so, replace wiring.

8070 Auto-lock Troubleshooting

Page 78*

Troubleshooting

1. Door does not fully open before turning off. Verify proper operator is installed. Verify operator is properly installed. Check to see if door binding at that position. Check door balance in the up position to see if heavy and adjust. Verify track radius not too tight. Verify horizontal tracks are not too tight to door. Increase power clamp potentiometer slightly. Contact technical support.

2. Door does not fully close before turning off. Verify proper operator is installed. Verify operator is properly installed. Verify door balance is correct and spring tension is not too high. Verify top section seal is not too tight against header or section too tight against seal. Verify vertical tracks not too tight against door. Verify door is not too tight against jamb or seal. Increase power clamp potentiometer slightly. Decrease close sensitivity slightly. Contact technical support.

3. Door opens slightly and stops or sets back down on floor Check for broken torsion spring. Verify door is unlocked if slide lock is used. Verify auto-lock is disengaging if used. Verify proper operator is installed. Verify operator is properly installed. Verify door balance and adjust if necessary Verify door is not too tight against door jamb. Verify that the door operates freely. Increase power clamp potentiometer slightly. Contact technical support.

4. Door attempts to close but reverses in the radius of track Verify proper operator is installed. Verify operator is properly installed. Verify door balance and adjust if necessary Verify door operates freely through the radius. Verify horizontal tracks are not too tight to door. Verify vertical tracks not too tight against door. Decrease close sensitivity slightly. Increase power clamp potentiometer slightly. Release door and lower to a position below the obstruction point and re-engage and cycle down. Contact technical support.

5. Operator does not turn off when fully cycled Up or Down Verify proper operator is installed. Verify operator is properly installed. Verify Bowden cable is installed properly. Verify proper belt tension is applied. Decrease power potentiometer slightly Increase close sensitivity slightly if problem occurs in the close cycle. Contact technical support.

Commercial Operator Troubleshooting Guide

Page 79*

Troubleshooting

1. Door will not open (Open light does not turn on when open pressed) Verify Case lid cover plugged into main board. Consult basic troubleshooting section. Call technical support.

1. Door will not open (Open light does turn on when open pressed) Verify proper voltage setting. Verify Motor terminals plugged in. Verify no breakage in motor wires. Verify motor wires are plugged in at motor. Consult basic troubleshooting section. Call technical support.

1. Door will not close Verify Case lid cover plugged into main board. Verify Safety LED is not illuminated. Check photo cells if applied. Check to see if safety override is on if no photo cells applied. Consult basic troubleshooting section Call technical support.

4. Door always running slow. Consult basic troubleshooting section Call technical support.

5. Door running slow in close direction. Consult programming section for close slow programming. Call technical support.

6. Door pauses 10 seconds before closing. Consult programming section for service due reminder programming. Call technical support.

7. External Radio controls or other external device does not function Consult 871 Interface troubleshooting section. Call technical support

Commercial Operator Troubleshooting Guide

Page 80*

Troubleshooting

Future expansion

Page 80*

Troubleshooting

Documents

The Smallest, Quietest & Safest Garage Door Operator in ...customdoorcontrols.com/images/Technicians_Manual_Small_File... · Operator Head Standard Mounting Instructions for on a