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RYTEC SYSTEM 4 INSTALLATION & OWNER'S

MANUAL

Quick Links
Fault Codes
Table of Contents
Table of Contents
DOOR SERIAL NUMBER(S)
HOW TO USE MANUAL
REQUIRED TOOLS AND EQUIPMENT
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
Electrician's Responsibilities
SHIPPING CRATE
CONTROL PANEL
CONTROL PANEL INSTALLATION
CONTROLLER
Scrolling Display
USB Connector
Status LEDs
Plug-In Modules
SYSTEM INPUTS
Power Supply Lines
Motor
Motor Brake
Encoder
External Emergency Stop Switches (N.C. Contacts)
Breakaway Bottom Bar (Input 1 - N.C. Contact)
Photo Eye - Front (Input 2 - N.C. Contact)
Photo Eye - Rear (Input 3 - N.C. Contact)
Alternate-Action Activator (Input 4 - N.O. Contact)
Auto-Close Activator 1 (Input 5 - N.O. Contact)
 Auto-Close Activator 2 (Input 6 - N.O. Contact)
Open (Input 8 - N.O. Contact)
Close (Input 9 - N.O. Contact)
Stop (Input 10 - N.C. Contact)
Programmable (Inputs 11 and 12 - N.O. or N.C. Contact)
DC Power Supply - Photo Eyes
DC Power Supply - Auxiliary Device
Reversing Edge
Timers
MODES OF OPERATION
Run Mode
AUTOMATIC MODE
NON-AUTOMATIC MODE
Jog Mode
Parameter Mode
Display
SYSTEM CONTROLS
SERVICE LEVELS
INITIAL START-UP
Clock Setting Procedure
ACCESSING PARAMETERS
Parameter Messages
Navigating Parameters
Accessing Service Level 2
Setting Door Limits (Open, Intermediate, and Close)
Setting Automatic Delay Timers
SYSTEM RESET (MANUAL RESET)
DEFROST SYSTEM
WIRELESS REVERSING EDGE
 Parameters for Wireless System
OPERATOR LEVEL PARAMETERS
SERVICE LEVEL 2 PARAMETERS
CLOCK PARAMETERS
CLOCK INPUT SELECTION
SWITCHING CLOCK PROGRAMS
FAULT CODES
GENERAL OPERATION FAULT CODES
DOOR SAFETY/EMERGENCY FAULT CODES
REVERSING EDGE CIRCUIT FAULT CODES
DRIVE SYSTEM FAULT CODES (400-LEVEL CODES)
DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)
DOOR POSITION FAULT CODES
WIRELESS SYSTEM FAULT CODES
DELAY TIMERS
DOOR MESSAGES
SPECIAL STATUS MESSAGES
DOOR LIMIT MESSAGES
DOOR JOG MESSAGES
DOOR STATUS MESSAGES
PROGRAMMABLE TEXT MESSAGES
TROUBLESHOOTING WITH STATUS LEDS
MECHANICAL
INPUTS
OUTPUTS
PLUG-IN MODULES (OPTIONAL ITEMS)
ABBREVIATIONS
GENERAL - INCOMING POWER
GENERAL - ENCODER AND PHOTO EYES
NOTE: This schematic is provided for general information purposes
only. Due to varying require
ments for individual installations
another schematic is shipped
with each door and that sche
matic must be used for that spe
cific installation
GENERAL - RADIO CONTROL AND E-STOP
GENERAL - BOTTOM BAR CONNECTIONS
GENERAL - CONTROLLER DIMENSIONS
PARTS ORDERING INFORMATION
How to Order Parts
SERIAL NUMBER(S)
Substitute Parts
Return of Parts
ELECTRICIAN'S QUICK GUIDE
CONTROL PANEL - STANDARD PANEL
 System 4 ®

Drive & Control

RY-WI SYSTEM
TM

RYTEC HIGH PERFORMANCE WIRELESS TECHNOLOGY

Installation & Owner’s

Manual

[Revision: Dec. 19, 2011, 00152000, ©Rytec Corporation, 2011]

 TABLE OF CONTENTS
PAGE

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

HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

Electrician’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SHIPPING CRATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTROL PANEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Scrolling Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plug-In Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SYSTEM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power Supply Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External Emergency Stop Switches (N.C. Contacts) . . . . . . . . . . . . . . . . . 12
Breakaway Bottom Bar (Input 1 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . 13
Photo Eye — Front (Input 2 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . . 13
Photo Eye — Rear (Input 3 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . . . 13
Alternate-Action Activator (Input 4 — N.O. Contact) . . . . . . . . . . . . . . . . . 14
Auto-Close Activator 1 (Input 5 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . 14
Auto-Close Activator 2 (Input 6 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . 14
Open (Input 8 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Close (Input 9 — N.O. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 Stop (Input 10 — N.C. Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programmable (Inputs 11 and 12 — N.O. or N.C. Contact) . . . . . . . . . . . . 14
DC Power Supply — Photo Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DC Power Supply — Auxiliary Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reversing Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SYSTEM START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AUTOMATIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
NON-AUTOMATIC MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parameter Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SYSTEM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SERVICE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Clock Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ACCESSING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parameter Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Navigating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Accessing Service Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting Door Limits (Open, Intermediate, and Close) . . . . . . . . . . . . . . . . 23
Setting Automatic Delay Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SYSTEM RESET (MANUAL RESET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DEFROST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

WIRELESS REVERSING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parameters for Wireless System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SYSTEM PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

OPERATOR LEVEL PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SERVICE LEVEL 2 PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CLOCK PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CLOCK INPUT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

 SWITCHING CLOCK PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

GENERAL OPERATION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DOOR SAFETY/EMERGENCY FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

REVERSING EDGE CIRCUIT FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DRIVE SYSTEM FAULT CODES (400-LEVEL CODES). . . . . . . . . . . . . . . . . . . . . 44

DRIVE SYSTEM FAULT CODES (500-LEVEL CODES). . . . . . . . . . . . . . . . . . . . . 45

DOOR POSITION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

WIRELESS SYSTEM FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

DELAY TIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

MISCELLANEOUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

DOOR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

SPECIAL STATUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

DOOR LIMIT MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

DOOR JOG MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

DOOR STATUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

PROGRAMMABLE TEXT MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
TROUBLESHOOTING WITH STATUS LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

PLUG-IN MODULES (OPTIONAL ITEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
GENERAL - INCOMING POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

GENERAL - ENCODER AND PHOTO EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

GENERAL - RADIO CONTROL AND E-STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

GENERAL - BOTTOM BAR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

GENERAL - CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
PARTS ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

How to Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

SERIAL NUMBER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Substitute Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Return of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ELECTRICIAN’S QUICK GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

CONTROL PANEL — STANDARD PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

 INTRODUCTION—DOOR SERIAL NUMBER(S)

INTRODUCTION NOTE: Figure 2 shows a sample decal. Different

model doors have serial numbers that
NOTE: This manual is intended for the System 4 start with different numerals.
Drive & Control only. Installation and oper-
ation information specific to your door is
detailed in the installation and owner’s
manuals that were shipped with the door. Drive Motor
System 4
The installation and operation of the System 4 Drive & Control
Control® is not difficult, providing you follow the proce- Panel
dures outlined in this manual. Any unauthorized
changes to these procedures, or failure to follow the
steps as outlined, will automatically void our warranty.
Any changes to the working parts, assemblies, or spec-
ifications as written, not authorized by Rytec Corpora-
tion, will also cancel our warranty. The responsibility for
the successful operation and performance of this drive
and control system lies with the owner of the door.
DO NOT INSTALL, OPERATE, OR PERFORM MAIN-
TENANCE ON THIS DRIVE AND CONTROL SYSTEM
UNTIL YOU READ AND UNDERSTAND THE Left Side
INSTRUCTIONS IN THIS MANUAL. Column
Right Side
If you have any questions, contact your Rytec represen- Column
tative or call the Rytec Customer Support Department
at 800-628-1909. Always refer to the serial number of
the door that your control system is connected to when A9500221
calling the representative or Customer Support. Refer to
Figure 1
the installation manual or the owner’s manual provided
with your door for the location of the serial number plate.
The wiring connections and schematics in this manual
are for general information purposes only. A wiring
schematic is provided with each individual door, specif-
ically covering the control panel and electrical compo-
nents of that door. That schematic was shipped inside
the cardboard box containing the control panel.
DOOR SERIAL NUMBER(S)
Your DOOR SERIAL NUMBER information can be
found in three universal locations. These are at the
inside of either side column (approximately eye level),
on the drive motor, and on the inside door of the System
A5400013
4 control panel. (See Figure 1)
Figure 2
IMPORTANT: When installing multiple doors
of the same model but in differ-
ent sizes, verify the serial num-
ber in the control panel with the
one on the door assembly.

1
INTRODUCTION—HOW TO USE MANUAL

HOW TO USE MANUAL 3. Install all necessary conduit.

Throughout this manual, the following key words are NOTE: High- and low-voltage cables must be
used to alert the reader of potentially hazardous situa- routed in separate conduit. High voltage
tions, or situations where additional information to suc- must use metallic conduit.
cessfully perform the procedure is presented:
4. Run electrical power lines to fused disconnect.
5. Run power lines from disconnect to control panel.
6. Run power and control lines from control panel to
door head assembly (and defrost system if used).
WARNING is used to indicate the potential
for personal injury, if the procedure is not 7. Install conduit from control panel to floor for floor
performed as described. loop activators and wire activators (if used).

8. All cables must be cut to length. No excess of high-

or low-voltage cables should be present in the con-
trol panel.
CAUTION is used to indicate the potential
for damage to the product or property SHIPPING CRATE
damage, if the procedure is not followed The control panel was shipped from the factory in a
as described. cardboard box along with the contents of your Rytec
door.
IMPORTANT: IMPORTANT is used to relay
information CRITICAL to the NOTE: A door-specific electrical schematic is
successful completion of the located inside the control panel.
procedure.

NOTE: NOTE is used to provide additional infor-

mation to aid in the performance of the
procedure or operation of the door, but not
necessarily safety related.

REQUIRED TOOLS AND EQUIPMENT

1. Wall anchor hardware (¹
₄-in. diameter).
2. Carpenter’s level.
3. Hammer drill and masonry drill bit sized for wall
anchors (to install anchor hardware in concrete).
4. Assorted hand tools.
ADDITIONAL REQUIREMENTS
Labor and Site Requirements
1. An electrician is required for all electrical connec-
tions. (See “Electrician’s Responsibilities” below.)

IMPORTANT: All electrical work must be per-

formed in accordance with local
and state building codes.

2. 100% accessibility to the door opening during the

installation process. Traffic should not pass through
the opening during the installation procedure.
Electrician’s Responsibilities
1. Furnish and install fused disconnect(s).
2. Install Rytec control panel.

2
 SYSTEM OVERVIEW—CONTROL PANEL

SYSTEM OVERVIEW
CONTROL PANEL
The Rytec System 4 Drive & Control is a solid-state, IMPORTANT: The System 4 control panel
microprocessor-based control system designed exclu- allows for configurable supply
sively to operate your Rytec high-performance door. voltage. Voltages can range from
(See IMPORTANT below.) It combines an AC drive with 200–500 volts AC. The System 4
the latest in door control technology. can also be configured to
receive both single- and three-
phase voltages. The supply volt-
The AC drive system controls the drive motor through age MUST match the voltage
soft accelerations and soft decelerations. The operating andphase as listed on the electri-
parameters are accessed through the up (▲), down cal schematic provided with the
(▼), and reset (●) keys located on the keypad on the control panel. Failure to provide
front of the control panel. A scrolling display shows all the required voltage and phase
corresponding control and door status messages. may damage the controller. If
NOTE: The RESET key also serves as the ENTER voltage and phase do not match
key and the STOP key. supply, contact the Rytec Cus-
tomer Support Department at
800-628-1909.

3
SYSTEM OVERVIEW—CONTROL PANEL

A5400011
Figure 3

IMPORTANT: All conduit entering the control panel must enter from the bottom of the panel — High voltage
from the bottom left and low voltage from the bottom right. Installing conduit through the top
or sides of the control panel will void the warranty.

4
 INSTALLATION—CONTROL PANEL INSTALLATION

INSTALLATION
CONTROL PANEL INSTALLATION Fused
Disconnect
IMPORTANT: The control panel must be
installed in an area having a tem-
perature range of –4°F to 149°F.
Consult the factory if the temper-
atures approach these limits.

IMPORTANT: The fused disconnect and the

control panel must be installed
within sight of the door.

NOTE: The control panel and fused disconnect

are generally located adjacent to the drive System 4
end of the head assembly. Control Panel

Install the System 4 control panel and the fused discon-

nect as shown in Figure 4.
The System 4 control panel has three mounting loca- A9500221
tions on the black plastic enclosure. One is on the top of Figure 4
the enclosure in the center and two are at the bottom of
the enclosure ( See Figure 5). Use these mounting loca-
tions along with user-supplied hardware to securely
mount the panel at the chosen location.
Top Mount
IMPORTANT: The mounting surface must be
structurally sound and free of
mechanical shock or vibration.

IMPORTANT: All conduit entering the control

panel must enter from the bot-
tom of the panel — High voltage
from the bottom left and low volt-
age from the bottom right.
Installing conduit through the
top or sides of the control panel
will void the warranty.

Bottom Mounts

NOTE: Panel housing shown

A5400020 .disassembled for clarity.

Figure 5

5
INSTALLATION—CONTROL PANEL INSTALLATION

The System 4 panel door is hinged at the top for easy

access to the terminal blocks. To open the door, loosen
the six screws along the door face as shown in Figure 6
and lift the door slightly out to release screws. Then lift Door Hinge
the door up as shown in Figure 7. The door can be
removed from the controller by disconnecting the door Electrical
electrical harness and depressing the tabs at the top of Harness
the controller to release the hinges from the controller
body as shown in Figure 8.

A5400037

Figure 8

Mounting Screw

A5400033

Figure 6

A5400035

Figure 7

6
 INSTALLATION—CONTROL PANEL INSTALLATION

Grounding of the power supply is essen-

tial to the safety of personnel as well as the
operation of the System 4 Drive & Control.
A floating, ungrounded or open delta type
power supply can permit dangerously
high voltage between the chassis of the
drive and the internal power structure
components (see Figure 9). In many cases,
this voltage could exceed the rating of the
input MOV protection devices of the drive,
causing catastrophic failure of the System
4 Drive & Control. In all cases, the input
power to this controller must be refer-
enced to ground (see Figure 10). If the ser-
vice transformer cannot be grounded,
then an isolation transformer must be
installed with the secondary of the trans-
former grounded. Please consult the fac-
tory for additional information regarding
isolation transformers or service suitabil- A5500020
ity.
Figure 10

WIRING NOTE: All wiring from the fused discon-

nect to the control panel, from the control
panel to the optional junction box and the
door, and from the conduit between the
control panel and the floor (if a floor loop is
used) must be supplied by the owner of
the door. The wiring and conduit must
meet all local and state building codes.
Wires leading from the door are labeled
with the terminal numbers that are associ-
ated with the control panel. The high and
low voltage lines must run in separate con-
duit — otherwise, the warranty will be void.

Use shielded wire as indicated on the

schematic. If a wire cable is to be
A5500019 extended or spliced, a like cable must be
Figure 9 used throughout the entire length of that
cable. Likewise, if a shielded cable is to be
NOTE: Cables must be cut to length. There can- extended or spliced, a like cable must be
not be any excess cable present in the used throughout the entire length of that
control panel or any excessive cable bun- cable as well — otherwise, the warranty
dles present on the outside of the control will be void.
panel.
All conduit entering the control panel
must enter from the bottom of the panel
— High voltage from the bottom left
and low voltage from the bottom right.
Installing conduit through the top or
sides of the control panel will void the
warranty.

7
INSTALLATION—CONTROL PANEL INSTALLATION

IMPORTANT: The System 4 panel conduit con- IMPORTANT: The schematics shown through-
nection locations are NOT knock- out this manual are for informa-
outs. Do NOT use impact to tion purposes only. Due to
remove the conduit connection varying requirements of each
bosses, or damage to the panel customer, a schematic has been
housing can occur. A drill and prepared for your particular door
suitable drill bit should be used and it must be used for this
to remove the plastic for conduit installation. That schematic was
connection. (See Figure 11.) shipped inside the control panel.

The disconnect must be in the OFF position

and properly locked and tagged before wir-
ing of the control panel begins.

IMPORTANT: All conduit entering the control

panel must enter from the bot-
tom of the panel — High voltage
from the bottom left and low volt-
age from the bottom right.
Installing conduit through the
top or sides of the control panel
will void the warranty.
A5400021

Figure 11

IMPORTANT: If your door is to be mounted on

High voltage is present inside this control
a freezer, mount the control
panel. Do not touch the circuit board, elec-
panel and the fused disconnect
trical components, or wiring inside this
on the warm side of the wall. It
panel with power applied.
may also be necessary for you to
install more than one fused dis- You must wait at least five minutes after
connect. To ensure the equip- power is turned off before you can begin
ment is de-energized during work on the control panel or motor con-
maintenance or service, turn off nections. The drive control inside the
all disconnects. panel contains high-voltage capacitors
IMPORTANT: Protect the components inside which take time to discharge once power
the control panel from metal is turned off.
chips when installing conduit.
Seal inside the conduit and
panel if the conduit entering the
panel is coming from an area
having a different temperature
(warmer or colder) than the area
where the panel is located.

8
 INSTALLATION—CONTROL PANEL INSTALLATION

A small cardboard box has been shipped with the con-

trol panel. This box contains five ferrite core magnets.
These ferrite core magnets are to be installed on the
incoming L1, L2, and L3 supply voltage wires and also
on the T1, T2, and T3 motor connections. The ferrite
core magnets act as a filter for the incoming supply
power and voltage passing to the motor. These filters
help to reduce electrical noise in the power system. See
Figure 12 for proper installation of the ferrite core mag-
nets.
NOTE: Failure to install the ferrite core magnets
as illustrated will void the manufacturer’s
warranty.

Failure to install the ferrite core magnets

will void the manufacturer’s warranty and
potentially cause irreparable damage to
the System 4 control panel.

Supply Voltage
Magnet Location

Green Motor Connection

Ground Wire Magnet Location
A5400029-30

Figure 12

NOTE: It is not necessary to run the supply volt-

age ground wire (green wire) through the
ferrite core magnet.

9
INSTALLATION—CONTROLLER

CONTROLLER activators, safety devices, and any other input device

connected to the control system. (See Figure 14.)
Located inside the control panel is an electronic control-
ler. This controller includes a scrolling display, terminal For detailed information on troubleshooting the control
blocks and screws, and other miscellaneous electrical system using the status LEDs, see “TROUBLESHOOT-
components. (See Figure 13.) ING WITH STATUS LEDS” on page 52.

USB Connector
Scrolling
Display
24 V Short
LED

Battery

Service Switch
Green
Reversing
Red Edge LEDs
Run LEDs
(Green)

Ajar LED
Terminal Terminal Block(s)
Screws

Input LEDs
A5400016
A5400016
Figure 14
Figure 13

Scrolling Display
All door commands and door status messages appear
on the scrolling display. Also displayed are the cycle
counter, timer settings, alarm conditions, program set-
tings, and other miscellaneous messages.
The display is located near the top of the controller and
can be viewed through the window on the front of the
control panel.(See Figure 13.)
USB Connector
The USB drive logs the function of the door and allows
for programming the door using a Rytec encrypted soft-
ware program. Removing the USB drive will affect the
operation of the door. DO NOT remove the USB drive
unless informed by the Rytec Customer Support
Department to do so.
Status LEDs
Located on the controller are various light-emitting
diodes (LEDs). These diodes are helpful when trouble-
shooting the door and control system. The LEDs indi-
cate the operating status of the control system, the door,

10
 INSTALLATION—CONTROLLER

Plug-In Modules NOTE: The induction loop module for the System
4 (part #00122000) is different from the
For a door set up to be operated by a radio control or a
module for the System 3. The System 4
floor loop, a corresponding plug-in module for each type
module is physically smaller. Therefore,
of activator is required. The connectors for these mod-
the System 3 loop module will not fit in the
ules are located along the right edge of the lower printed
circuit board. (See Figure 15.) System 4 control. (See Figure 16.)

Loop Wire
Terminal Block
Radio Receiver
Module

Induction Loop
Module

A5400016 A5400024

Figure 15 Figure 16

11
INSTALLATION—SYSTEM INPUTS

SYSTEM INPUTS Power Supply Lines

Connect the power supply lines from the fused discon-
nect to the control panel as shown on the schematic that
was shipped with the door.

The disconnect must be in the OFF posi- Motor

tion and properly locked and tagged before Connect the motor wires to the control panel as shown
performing the following procedure. on the schematic that was shipped with the door.
NOTE: Motor cable cannot exceed 100 feet. Cut
all excess cable to desired length. Refer-
ence the electrical schematic that came
inside the control panel for proper ground-
Input terminals 200 through 293 support ing.
+24 VDC only. All remaining input termi-
nals are dedicated for specific devices. Motor Brake
Connecting any other voltage or device Connect the motor brake to the control panel as shown
other than those intended may result in on the schematic that was shipped with the door.
damage to the control system.
Encoder
NOTE: If the expansion board is installed in the Connect the encoder to the control panel as shown on
controller, there are additional input termi- the schematic that was shipped with the door.
nals 300 through 363.
External Emergency Stop Switches (N.C. Contacts)
All high-voltage connections (L1, L2, and L3 supply volt-
Factory-installed jumper wires are provided in the E-
age wires and the T1, T2, and T3 motor connections)
Stop connections. Refer to the door-specific electrical
are made on the lower left terminal blocks. These con-
schematic for information regarding E-Stop connection.
nections need to be in mettalic conduit entering from the
E-Stop 1 terminals are located at block X24, terminals
bottom left corner of the control panel. All low-voltage
240 and 241. E-Stop 2 terminals are at block X25, ter-
connections (+24 VDC) should enter the bottom right of
minals 250 and 251. E-Stop 3 terminals are at block
the control panel and terminate on both the top and bot-
X26, terminals 260 and 261.
tom circuit boards. (See Figure 17.)

Terminal Terminal Block(s)

Screws

A5400016

Figure 17

12
 INSTALLATION—SYSTEM INPUTS

Breakaway Bottom Bar (Input 1 — N.C. Contact) Photo Eye — Front (Input 2 — N.C. Contact)
The breakaway bottom bar signal is incorporated with Connect the front set of photo eyes to the control panel
the RY-WI wireless reversing edge signal. The break- (terminal 222 located on block X22) as shown on the
away electrical connections are connected to terminals schematic that was shipped with the door.
5 and 6 on the RY-WI mobile unit in the bottom bar. That
An interruption of this input (object between photo eyes)
signal is then transmitted from the mobile unit to the
while the door is closing will reverse the door and move
antenna located on the head assembly of the door. The
it to the open position. Only after the object is removed
antenna then sends the breakaway signal down the red
from between the photo eyes will the door be allowed to
wire (encoder cable) to terminal 271 in the controller.
close.
See the schematic that was shipped with the door.
If the door was initially opened by a non-automatic
If the bottom bar becomes disconnected from either activator, the door must be closed with a non-automatic
side column, a loss of this input will immediately stop activator. If the door was initially opened by an auto-
the door and “Door Ajar” will appear on the display. matic activator, the door will automatically close after
(See Figure 18.) the auto-close delay timer (ACL1 or ACL2) times out.
(See Figure 19.)

E r r o r J o g O n l y
F 0 6 0 D o o r A j a r
D o o r H e l d O p e n
P h o t o e y e F r 2 2 2

Figure 18

NOTE: If you find it necessary to reposition the

bottom bar in order to reattach it, the door Figure 19
can be jogged up or down by pressing and
holding the up (▲) or down (▼) key. Photo Eye — Rear (Input 3 — N.C. Contact)
Connect the rear set of photo eyes to the control panel
Push and hold the Stop, Reset and Enter (terminal 232 located on block X23) as shown on the
buttons until the system resets. schematic that was shipped with the door.
Once the bar is reattached and the control An interruption of this input (object between photo eyes)
system reset, the up (▲), down (▼), and while the door is closing will reverse the door and move
reset (●) keys will automatically return to it to the open position. Only after the object is removed
their normal operation. from between the photo eyes will the door be allowed to
close.
If the door was initially opened by a non-automatic
activator, the door must be closed with a non-automatic
activator. If the door was initially opened by an auto-
matic activator, the door will automatically close after
the auto-close delay timer (ACL1 or ACL2) times out.
(See Figure 20.)

D o o r H e l d O p e n
P h o t o e y e R r 2 3 2

Figure 20

13
INSTALLATION—SYSTEM INPUTS

Alternate-Action Activator (Input 4 — N.O. Contact) Open (Input 8 — N.O. Contact)

Connect the alternate-action activator to the control Connect the open input to the control panel (terminals
panel (terminals 210 and 211) as shown on the sche- 200 and 201) as shown on the schematic that was
matic that was shipped with the door. shipped with the door.
If this input is enabled (momentary contact) with the If this input is enabled (momentary contact) with the
door closed, closing, or stopped between the door lim- door closed, closing, or stopped between the door lim-
its, the door will open. When this input is enabled with its, the door will open. This input is ignored while the
the door open, the door will close. Typical activators tied door is opening.
to this input include pull cords, push buttons, and radio Close (Input 9 — N.O. Contact)
controls.
Connect the close input to the control panel (terminals
Auto-Close Activator 1 (Input 5 — N.O. Contact) 200 and 202) as shown on the schematic that was
Connect auto-close activator 1 to the control panel (ter- shipped with the door.
minals 210 and 212) as shown on the schematic that
If this input is enabled (momentary contact), the door
was shipped with the door.
will close if the door is open or stopped. This input is
If this input is enabled with the door closed, closing, or disabled when the door is closing and ignored if the door
stopped between the door limits, the door will open. The is closed or opening.
door will remain open as long as the input is enabled. Stop (Input 10 — N.C. Contact)
Once the input is disabled, the auto-close delay timer
(ACL1) will start. When the timer times out, the door will Input 10 is equipped with a factory-installed jumper.
automatically close. Refer to door-specific electrical schematics for informa-
tion regarding this connection.
An activated timer will automatically reset when the auto
input is enabled. To disable a timer, set the time delay Programmable
parameter (P:010) to zero (0) to turn timer off. (Inputs 11 and 12 — N.O. or N.C. Contact)
Typical activators tied to this input include floor loops Programmable inputs (if used) are connected to the
and motion detectors. (This input is exclusive of the control panel (terminals 290 and 291 or terminals 290
inputs described in “Plug-In Modules” on page 11.) and 292) as shown on the schematic that was shipped
with the door.
Auto-Close Activator 2 (Input 6 — N.O. Contact)
These inputs can be assigned various functions such as
Connect auto-close activator 2 to the control panel (ter- a third set of photo eyes or an air lock activator.
minals 230 and 233) as shown on the schematic that
was shipped with the door.
If this input is enabled with the door closed, closing, or
stopped between the door limits, the door will open. The
door will remain open as long as the input is enabled.
Once the input is disabled, the auto-close delay timer
(ACL2) will start. When the timer times out, the door will
automatically close.
An activated timer will automatically reset when the auto
input is enabled. To disable a timer, set its time delay
parameter to zero (0) seconds. Parameter P:015 = 0 to
turn timer off.
Typical activators tied to this input include floor loops
and motion detectors. (This input is exclusive of the
inputs described in “Plug-In Modules” on page 11.)

14
 INSTALLATION—SYSTEM INPUTS

DC Power Supply — Photo Eyes The rear set of photo eyes is connected to
terminal block X23. The +24 VDC is on ter-
Connect the 24 VDC power supply for the photo eyes to
minal 230, the –24 VDC is on terminal
the control panel as shown on the schematic that was
234, and the signal wire connects to termi-
shipped with the door.
nal 232.
NOTE: Reference the electrical schematic that
was provided inside the System 4 control NOTE: The photo eye power supply is a dedicated
panel. The instructions in this manual per- power supply for the photo eyes. Each set
tain to most doors; however, your door of photo eyes should be connected to the
may have different requirements. specific power supply for that particular set
of photo eyes. NO other electrical devices
The DC power +24 and –24 VDC (GND) should be connected to the photo eye
can be found at various locations through- power supplies.
out the System 4 control board. For exam-
ple, the front set of photo eyes is Reversing Edge
connected to terminal block X22. The +24 Anytime the door is closing and the reversing edge (bot-
VDC is on terminal 220, the –24 VDC is on tom edge) of the door makes contact with an object, the
terminal 223, and the signal wire connects door will reverse direction and move to the open posi-
to terminal 222. tion. The door will remain in the open position until the
control system is manually reset.
The rear set of photo eyes is connected to
terminal block X23. The +24 VDC is on ter- To ensure the reversing edge wiring has continuity, the
minal 230, the –24 VDC is on terminal control system monitors a resistor installed on the pres-
234, and the signal wire connects to termi- sure switch located in the bottom bar. If the control sys-
nal 232. tem does not detect the correct resistance, the control
system will not allow the door to close.
NOTE: The photo eye power supply is a dedicated
power supply for the photo eyes. Each set NOTE: The reversing edge signal is carried on the
of photo eyes should be connected to the pink wire in the encoder cable. The pink
specific power supply for that particular set wire is attached to terminal 272 on termi-
of photo eyes. NO other electrical devices nal block X27.
should be connected to the photo eye The reversing edge wires are connected
power supplies. to the Rytec Ry-Wi mobile unit installed in
DC Power Supply — Auxiliary Device the bottom bar. If you remove the Ry-Wi
cover you will find the reversing edge con-
Connect the 24 VDC power supply for an auxiliary nections on terminals 1 and 2 of the
device (such as a motion detector) to the control panel mobile unit. A resistance check performed
as shown on the schematic that was shipped with the on these two terminals should read 8,200
door. ohms or 8.2K ohms. If resistance value is
NOTE: Reference the electrical schematic that not found, one of the wires is broken or the
was provided inside the System 4 control resistor is bad.
panel. The instructions in this manual per-
NOTE: Reference your door-specific electrical
tain to most doors; however, your door
schematic for reversing edge connections.
may have different requirements.
These connections may be different for dif-
The DC power +24 and –24 VDC (GND) ferent models of doors.
can be found at various locations through-
IMPORTANT: After control system start-up,
out the System 4 control board. For exam-
test the reversing edge accord-
ple, terminals 200, 210, 220, 230, 270,
ing to the instructions provided
277, and 290 on the microcontroller board
in the owner’s manual that came
are all access points for +24 VDC connec-
with the door. You must verify
tion(s).
that the bottom bar reversing
The front set of photo eyes is connected to edge operates properly before
terminal block X22. The +24 VDC is on ter- placing the door into service.
minal 220 and the –24 VDC is on terminal
223, and the signal wire connects to termi-
nal 222.

15
INSTALLATION—SYSTEM INPUTS

Timers
The control system includes three programmable auto-
close delay timers. Each timer is assigned to a specific
input on the control panel and is set to delay closing the
door when opened by its associated activator.
Two timers (ACL1 and ACL2) can be programmed to
automatically close the door from the open position. The
third timer (ACL3) can be programmed to close the door
from the optional passage position. (The optional pas-
sage position is reserved for setting the open position of
the door to a height other than the open position.)
See “” on page 28 for additional information on setting
the auto-close delay timers and the optional passage
option.

16
 SYSTEM START-UP—MODES OF OPERATION

SYSTEM START-UP In the automatic mode, while the timer is running, at any
time an activator such as a floor loop or motion detector
MODES OF OPERATION is enabled, the timer will reset and the door will not be
allowed to close. It is only when the timer times out that
the door will begin to close. (To change the timer setting,
see “” on page 28.)
In summary, in the automatic mode, an activator is used
Once electrical power is connected to the
to open the door and a timer is used to close the door.
control system, the fused disconnect must
be placed in the OFF position and properly NON-AUTOMATIC MODE
locked and tagged before the door to the If a momentary contact activator such as a push button,
control panel can be opened. pull cord, or radio control is used to operate the door:
Once the fused disconnect is placed in the • The door will open when the device is activated.
OFF position, you must wait five minutes
for all electricity to dissipate from the con- • After passing through the door, a similar type of
trol panel — otherwise, severe electrical device must be used to close the door.
shock resulting in serious injury or even In summary, in the non-automatic mode, an activator is
death may occur. used to open and close the door.
Jog Mode
Jog mode can be set by pushing and holding the Stop/
Reset key and down key at the same time until the dis-
The control panel door must always be play reads “Jog Mode”. The door can then only be oper-
closed every time the control panel is pow- ated from the control panel using the up, down, and stop
ered up. There is a potential for serious keys.
personal injury in the case of component To exit jog mode, repeat the process of pushing and
failure. holding the Stop/Reset and down keys at the same time
The System 4 Drive & Control is configured for three until the display reads “Automatic”.
modes of operation: run, jog, and parameter mode. Parameter Mode
Run Mode The control system includes various parameters that
Run mode includes the automatic and non-automatic are used to operate your door. A number of parameters
modes of operation. are set at the factory. Other parameters must be set in
the field.
AUTOMATIC MODE
The parameters, beginning on page 28, are organized
If a momentary contact activator such as a push button,
according to the Operator/Service Level authorized to
pull cord or radio control is used to activate the door:
access each parameter. Table 5 lists the parameters
• The door will open when the device is activated. available at the Operator Level. Table 6 lists the param-
• A timer, internal to the control system, will start up eters available at Service Level 2.
when the door is open. Display
• When the internal timer times out, the door will The scrolling display shows all door status and system
automatically begin to close. information messages. Figure 21 through Figure 23
If a maintained contact activator device such as a floor detail information typically displayed during routine con-
loop or motion detector is used to activate the door: troller functions and system errors.

• The door will open and remain open for as long as

Status Line
the device is active.
• Once the device becomes inactive, the internal
timer will start up.
• When the internal timer times out, the door will
automatically begin to close.
Information Line — Activated Inputs,
Errors, Failures, Etc.

Figure 21

17
SYSTEM START-UP—SYSTEM CONTROLS

NOTE: If the photo eyes are activated during a • Operator Level — password not required. Access
door close cycle, the door will move to the limited to auto-close timers and select defrost con-
open position and the display will indicate trol functions (if configured with defrost control).
which set of eyes is activated.
• Service Level 2 — password required (password is
(See Figure 22.)
the number “10”). Access to Service Level 1 param-
eters as described above, activator parameters,
and other miscellaneous parameters. All remaining
parameters are available as read-only.
NOTE: The control counts in hexadecimal. When
D o o r H e l d O p e n entering the number 10 you will see letters
P h o t o e y e F r 2 2 2 appear after the number 9. When you con-
tinue past the letter F the number 10 will
display.

The service switch in the control box is factory set to the

Figure 22 “ON” position. This allows access to all password levels.
NOTE: If a system error is detected, the status of Access to all parameters can be disabled by placing the
the door and the associated fault code will service switch to the OFF position and locking the con-
appear on the display. (See Figure 23.) trol panel door. Cycling power off and on places the con-
troller in the run mode.

Door Operated through If the controller is in any service level and there is no
Up/Down Keys Only keypad activity for 30 minutes, the controller will auto-
matically reset and return to the run mode.
▲
E r r o r - J o g ▼ O n l y
F 0 6 0 D o o r A j a r

Fault Code Associated

Problem

Figure 23

SYSTEM CONTROLS
All door commands and control system menus are
accessed through the control panel keypad. The keypad
includes three keys: up (▲), down (▼), and reset (●).
During normal operation with the door closing or closed,
momentarily pressing the up (▲) key will automatically
move the door to the open position. Pressing the down
(▼) key will move the door to the closed position. Press-
ing the reset (●) key as the door is moving in either
direction will immediately stop the door.
NOTE: The RESET key also serves as the
ENTER key and the STOP key.

SERVICE LEVELS
In addition to operating the door, the up (▲), down (▼),
and reset (●) keys are used to navigate through the
control system parameters. See “Navigating Parame-
ters” on page 21.
NOTE: The RESET key also serves as the
ENTER key and the STOP key.

The parameters, beginning on page 28, are grouped

into two service levels.

18
 SYSTEM START-UP—INITIAL START-UP

INITIAL START-UP 3. After the reset (●) key has been pressed one time,
verify the motor rotation by briefly pushing the up
(▲) and down (▼) keys on the control panel.
The door should open with the up (▲) key and
close with the down (▼) key. If the door does not
Initial system start-up is only to occur operate in this manner, reverse two of the motor
once the door and control panel have been wires (not the incoming three-phase supply wires).
properly installed, wired, and all prelimi-
nary door adjustments made. Failure to NOTE: Reversing the incoming supply voltage
follow the instructions as outlined in the lines will not solve the problem if the motor
installation manual that was provided with is running in the wrong direction. The
your door can result in damage to the door motor leads T1 and T2 must be swapped
upon initial system start-up. to change motor rotation. If the motor
rotated incorrectly during the start-up pro-
cess, the limits may need to be reset by
entering P:210 and setting a value of 5.

The RESET key also serves as the

When limits are established the display ENTER key and the STOP key.
will prompt you to push the down key and
begin the auto-calibration process. I:500 4. Now set the door open and close limits according to
messages will appear on the display. This the instructions on the display.
is normal. The I:500 messages should dis- If any error messages are displayed, some of the
appear within 10 complete cycles. Keep required input connections may be missing. Once
hands and equipment away from the door the missing inputs are connected, perform the
until the auto-calibration is complete. open and close limit set-up. Otherwise, refer to
“FAULT CODES” on page 41.
1. Release the brake located on the end of the motor
and manually move the door to the half-open NOTE: When establishing the open- and close-
position. limit positions, refer to the installation
manual that came with your door.
2. Apply power to the control system. During the sys-
tem initialization, the display will indicate that the
door open and close limits must be set by displaying
“! Set Limits !”. (See Figure 24.)
Then the message Push ● [press reset (●) key] When limits are established the display
will appear on the display. will prompt you to push the down key and
begin the auto-calibration process. I:500
messages will appear on the display. This
is normal. The I:500 messages should dis-
appear within 10 complete cycles. Keep
hands and equipment away from the door
! S e t L i m i t s !
until the auto-calibration is complete.
→ ● T o B e g i n
5. Once the limit-setting procedures have been com-
pleted, the door will automatically cycle until the
auto-calibration is complete (typically 5–10 com-
plete cycles). This is done to optimize performance
Figure 24
and will allow the door to run smoothly and effi-
ciently.

The door open and door close limits are to

be set only after verifying that the motor
(door) operates in the proper direction
when the up (▲) and down (▼) keys are
pressed.

19
SYSTEM START-UP—INITIAL START-UP

NOTE: The door will fine-tune the speed setting

based on the programmed limits during
the first several cycles. The informational
messages I:510, I:515, I:520, and I:555
will and may appear during the first 10
cycles of the door operation. This is nor-
mal, as the controller is optimizing the
operational curve of the AC drive and
motor. The door may run erratically during
this process. DO NOT change any speed
or limit parameters during this time. If the
message does not disappear from the dis-
play after 15 cycles, contact Rytec Cus-
tomer Support at 800-628-1909.

6. Set ACL1 and ACL2 timers as required. (See “” on

page 28.)
Clock Setting Procedure
The System 4 control panel has been shipped with the
internal clock set with the date and central time. If your
time zone is different, the clock can be adjusted. To
adjust the clock, see “Navigating Parameters” on
page 21.
Table 1

Parameters

P:C00 = Shows the current date and time the System

4 clock is set to

P:C01 = Adjusts the hour of the clock

P:C02 = Adjusts the minutes of the clock

P:C03 = Adjusts the seconds of the clock

P:C04 = Adjusts the day and month of the clock

P:C06 = Adjusts the year of the clock

P:C07 = Adjusts for daylight saving time

NOTE: See “Clock Parameters” on page 38 for

more information on the clock parameters.

20
 SYSTEM START-UP—ACCESSING PARAMETERS

ACCESSING PARAMETERS
Three-Digit Parameter
NOTE: To access Operator Level and Service Parameter Name or Group Operator Level (O)
Level parameters, the control board ser- Number Service Level 2 (S)
vice switch must be in the ON position.
(See Figure 25.)
P : P o s i t i o n i n g s
2 1 –
0 = 0 9#

Cursor
Scrolling Parameter Parameter Unit
Display Value Status

Figure 27

Figure 28 details password parameter 999 (P.999).

Three-Digit
Parameter
Parameter Operator Level (O)
Service Switch Name or Group
Number Service Level 2 (S)

P : P a s s w o r d
9 9 9
– = 0 0 1 09 #

Cursor
Terminal Terminal Block(s) Parameter Unit
Parameter
Screws Value Status

Figure 28

Navigating Parameters
The following procedure explains how to navigate
A5400016 through the parameters. The procedure is the same
Figure 25 regardless of the service level.

Parameter Messages 1. To navigate the parameters:

A scrolling display on the control panel (as shown in • Simultaneously press and hold the up (▲) and reset
Figure 26) displays all parameter settings when the con- (●) keys for approximately three seconds. The con-
trol system is placed in a service level (Operator Level trol system will enter the Operator Level and display
or Service Level 2). Figure 26 details a the last-saved operator parameter. (To access the
typical parameter. upper service level(s), see “Accessing Service
Level 2” on page 22.)
Three-Digit • Continually press the up (▲) or down (▼) key to
Parameter
Parameter Opertor Level (O) loop through the list of available parameters. Hold-
Name or Group
Number Service Level 2 (S) ing either key speed-scrolls you through the list.
• Press the reset (●) key to access the displayed
parameter. The parameter is accessed when the
P :
= cursor jumps over to the currently saved value for
that parameter. (See Figure 29.)
Parameter • Continually press the up (▲) or down (▼) key to
Value Unit loop through the list of available parameter values.
Read/Write (=) Parameter Holding either key speed-scrolls you through the
Read Only (#) Status list.
Figure 26

For example, Figure 27 details door limit set-up param-

eter 210 (P.210).

21
SYSTEM START-UP—ACCESSING PARAMETERS

• Pressing the enter (●) key saves the displayed

value. Press and hold the enter key until a check- Three-Digit
Parameter
Parameter Operator Level (O)
mark appears to the right of the value you wish to Number
Name or Group
Service Level 2 (S)
enter. (Note: If the enter (●) key is not held down
long enough, the display will return to the previously
saved setting.) A checkmark next to the displayed P : P a s s w o r d O
value indicates the currently saved value. An aster-
isk next to the displayed value indicates a value that
9 9 9
– = – 9 #
0 0 0 0
is not saved. (See Figure 30.)
Cursor
• Pressing and releasing the enter (●) key jumps the Parameter Parameter Unit
cursor back over to the three-digit parameter num- Value Status
ber.
Figure 31
NOTE: The RESET key also serves as the
ENTER key and the STOP key. 3. Enter the password by first pressing the up (▲) or
down (▼) key until the numerical password required
See Table 5 on page 30 for a complete list of for the desired service level is displayed.
parameters available through the Operator Level. (See Figure 32.)

Three-Digit
Parameter
Parameter Operator Level (O)
P : P o s i t i o n i n g s Name or Group
Number Service Level 2 (S)
2 1 0
– = 09 #

P : P a s s w o r d s
Parameter Cursor Position Cursor Position 9 9 9 = 1 09 #
Number when Scrolling Once Parameter
through Parameters Is Accessed
Parameter Value
Figure 29 (Numerical Password Unit
Service Level 2) Parameter
Status
Three-Digit Parameter
Parameter Name or Group Operator Level (O) Figure 32
Number Service Level 2 (S)
4. Press the enter (●) key to accept the password and
enter that particular service level. A checkmark will
P : P o s i t i o n i n g s appear to the right of the value entered. Release the
2 1 0
– = 59 # enter key, then press and release the enter key (●)
once more. The cursor will jump back under the
Cursor three-digit parameter number and a large “S” will
Parameter Unit appear on the display to indicate that Service Level
Parameter
Value
Status 2 is accessed.
Figure 30 NOTE: The RESET key also serves as the
ENTER key and the STOP key.
Accessing Service Level 2
5. Press the up (▲) or down (▼) key to scroll through
1. Access the Operator Level. (See “Navigating
the list of available parameters for that particular
Parameters” on page 21.)
service level. (Only the parameters associated with
2. To access Service Level 2, scroll to password the accessed service level will be available.)
parameter 999 (P.999). Then briefly press and
6. Access a displayed parameter by briefly pressing
release the reset (●) key. The cursor will jump from
the enter (●) key. The parameter is accessed when
the three-digit parameter number over to the param-
the cursor jumps over to the currently saved value
eter value on the display. (See Figure 31.)
for that parameter.

22
 SYSTEM START-UP—SYSTEM RESET (MANUAL RESET)

Setting Door Limits (Open, Intermediate, and Close) SYSTEM RESET (MANUAL RESET)
1. Access parameter P.210. (See “Navigating Param- A system reset is necessary after the control system
eters” on page 21.) displays an error message and the problem resulting in
2. Press the up (▲) or down (▼) key until the desired that error message has been corrected. To reset the
door limit option is displayed. Pressing and holding control system, press and hold the reset (●) key for
the enter (●) key will save the displayed option. approximately three to five seconds. If the display clears
and the message reappears, the problem has not been
NOTE: The RESET key also serves as the corrected and will need further investigation.
ENTER key and the STOP key.
NOTE: The RESET key also serves as the
3. Follow the instructions on the display to set the door ENTER key and the STOP key.
limits.
Once the reset is complete, if the door was is the full-
Setting Automatic Delay Timers open or -closed position prior to the error message, the
1. Access the Operator Level. (See “Navigating display will indicate the door type and cycle count. If the
Parameters” on page 21.) door was in a position other than the full-open or -closed
position, the display will indicate the door is stopped.
2. Press the up (▲) or down (▼) key until the desired
delay timer parameter is displayed (P.010 = ACL1, After the system is reset, the door can be normally oper-
P.011 = ACL3, P.015 = ACL2). ated with the up (▲), down (▼), and reset (●) keys.
Figure 33 shows that auto-close delay timer ACL1 DEFROST SYSTEM
is currently set with an eight (8) second delay. If your door is configured with an optional defrost sys-
tem, the System 4 Drive & Control is designed to oper-
Three-Digit ate and monitor that system.
Parameter
Parameter Operator Level (O)
Name or Group See “” on page 28 for additional information on setting
Number Service Level 2 (S)
the defrost system controls.
WIRELESS REVERSING EDGE
P : A c l 1 O
0 1 –
0 = 8 9# The wireless system has two main assemblies: the
mobile unit located in the bottom bar under the plastic
cover and the stationary antenna located in the head
Cursor assembly. (See Figure 34 and Figure 35.) All mobile
Parameter Unit
Value Parameter units are installed at Rytec prior to shipping. The wire-
Status less antenna may or may not be installed by Rytec prior
to shipping. Some Rytec models require the antenna to
Figure 33
be installed in the field. Please reference the specific
3. With the desired timer parameter displayed, press product installation manual for your model of Rytec
the enter (●) key to access that parameter. The cur- door. The antenna has a tan-colored cable that runs to
sor will jump over to the parameter value. the encoder, which is mounted to the back of the motor,
and a black cable from the encoder that carries the sig-
NOTE: The allowable time delay range for a timer
nals for the reversing edge and the breakaway back to
is 0 to 9999 seconds.
the System 4 control board.
The RESET key also serves as the
ENTER key and the STOP key.

4. Press the up (▲) or down (▼) key to change the

displayed value. Press and hold the enter (●) key to
save the displayed value.

23
SYSTEM START-UP—WIRELESS REVERSING EDGE

NOTE: Clear plastic cover is

shown for sample purposes.

Antenna Prongs Point

Toward the Drum Roll

Mobile Unit

A2500246

Figure 34 Tan Cable

A7700019

Figure 36

Antenna Prongs Point

Toward the Drum Roll

Antenna
Prongs

Drum Roll

A2500247

Figure 35

Attached to the electric motor is a small tan-colored

cable. The tan cable is routed from inside the motor
Line of Sight
assembly, through the front head assembly, and to the
mounting bracket of the front spreader. When the
bracket is installed, the 2-inch prongs from the antenna
will point toward the drum roll and the tan cable should
exit the bottom of the antenna.
(See Figure 36 and Figure 37.)
NOTE: No bends, kinks, or loops are allowed in
Mobile Unit
the tan cable. The antenna is fragile and
should be handled with extreme care.

Any leftover packaging material should be

removed from the antenna prior to installa-
A2500249
tion.
Figure 37

24
 SYSTEM START-UP—WIRELESS REVERSING EDGE

Parameters for Wireless System

Parameters
The control system for the wireless reversing edge has
been programmed at Rytec. However, field adjustments P:F07 = Mobile unit address
may be required. Below is a list of the applicable param-
• Unique to each unit
eters and fault codes associated with the wireless
reversing edge system. • Hexadecimal number located on the transmitter
unit in the bottom bar (See Figure 38.)
NOTE: Do not make any changes to the wireless
system until you have contacted Rytec Cus-
NOTE: Hexadecimal address should be the
tomer Support at 800-628-1909. Access for same value as Parameter P:F07.
programming parameters can be found in
the Rytec System 4 Drive & Control manual
that is shipped with the door in the small
parts carton.

Table 2

Parameters

P:F00 = Activates the wireless system

1 = On, 0 = Off
A2500250
P:F01 = Packet timeout before “edge trip” occurs Figure 38
Adjustment made in milliseconds = 6 ms to 250 ms
IMPORTANT: The hexadecimal number on
NOTE: 50 ms is default. the transmitter unit must be
facing to the left when installed
P:F05 = Channel group
in the bottom bar. When facing
1–10 Factory setting (can only be viewed in parame- the front of the door, the Rytec
ter mode) decal will be seen to the right
of the mobile unit.

After entering the address, it

is necessary to check that the
controller is connected and
working with the selected
mobile unit. Since the number
system is hexadecimal, it is
possible to have letters
included in the mobile unit
address. For example: 1C46,
89D3, and 65B1.

25
SYSTEM START-UP—WIRELESS REVERSING EDGE

Table 4
Parameters

P:F09 = Battery low 3.6 volts Encoder Cable Connections

System 4 Control Panel
When battery voltage drops below the pre-set value
an error will be displayed = F 857 Battery low NOTE: The encoder cable is to be cut to length.
DO NOT leave excessive cable inside
If voltage falls below the preset level, F:857 will be the control panel.
displayed on the screen. The door will remain opera-
tional with the message displayed but the battery will NOTE: Connections below are for the wireless
need to be changed soon. If battery goes completely reversing edge connections only. Refer-
dead, F:856 will appear and the door will not function. ence the electrical schematic that was
New battery is "D" size 3.8 volt Lithium Ion battery. shipped in the control panel for specific
Part number 0011193. connections for your particular door.
NOTE: Figure 39 shows the battery through a Encoder connections may vary
clear cover located in the bottom bar. depending on door models.
Clear cover shown is a sample piece.
Encoder Cable: System 4 Control Board:

NOTE: Battery for wireless reversing edge: Brown (+24 VDC) to terminal #270
blue wire (+), yellow wire (-).
White (Ground) to terminal #277

Green (RS485 b) to terminal #276

Yellow (RS485 a) to terminal #275

Pink (Reversing Edge) to terminal #272

Red (Ajar) to terminal #271

Blue to terminal #273

Gray to terminal #274

A2500246
The encoder cable is vital for proper door operation.
Figure 39
Trim the cable end to expose the drain wire (bare sil-
ver) but do it such a manner as not to damage the
Table 3
drain wire and most importantly the shield.
NOTE: Shield and drain wire should be cap-
Error Codes tured under the P-clip below terminals
270–277. (See Figure 40.)
F 856 = No communication between the stationary
and mobile units for more than ten seconds DO NOT ground to control board or
• Antenna not connected or poorly mounted motor ground.

• Battery is dead
• Mobile unit address is incorrect
• No mobile unit found
• Strong electrical interference in the frequency
range

F 857 = Battery monitoring

• Battery voltage falls below value in P:F08
• New battery is required

26
 SYSTEM START-UP—WIRELESS REVERSING EDGE

A5400031

Figure 40

27
SYSTEM START-UP—WIRELESS REVERSING EDGE

Jumpers on the System 4 Control Panel

The System 4 control panel requires the jumpers located on the control board to be in the following configuration.
NOTE: The configuration of the jumpers should have been done at Rytec prior to shipping. This information is
provided just to confirm the accurate setting of the jumpers. (See Figure 41.)

Reversing Edge Jumper

A5400014

Figure 41

28
 SYSTEM START-UP—WIRELESS REVERSING EDGE

Jumpers on the System 4 Control Panel

Jumper for the reversing edge should be configured for 8.2K ohms.
(See Figure 42.)

1.2K ohm Jumper

8.2K ohm Jumper

A5400018

Figure 42

Please contact Rytec Customer Support at 800-628-1909 if there are any questions or concerns.

29
SYSTEM PARAMETERS—OPERATOR LEVEL PARAMETERS

SYSTEM PARAMETERS
The system parameters are grouped into two levels:
“OPERATOR LEVEL PARAMETERs” below and “SER-
VICE LEVEL 2 PARAMETERS” on page 31.
OPERATOR LEVEL PARAMETERS
Table 5 below lists the parameters available through the
Operator Level. Included in this table is a description of
each parameter and its available range and factory
default setting.
Table 5

Factory
Parameter Range Operator Level Parameters (Password Not Required)
Setting

P.010 0–200 seconds Auto-close delay timer 1 — ACL1 (with activator connected to 10
input 5 — terminals 210 and 212)
0 = Off
Time door remains open after all activation and safeties are
clear

P.011 0–200 seconds Auto-close delay timer 3 — ACL3 (0 = off) 0

The ACL3 timer is available for all doors. The input selected
will need to be programmed to operate through the ACL3
timer.

P.015 0–200 seconds Auto-close delay timer 2 — ACL2 (with activator connected to 5
input 6— terminals 230 and 233)
0 = Off
Time door remains open after all activation and safeties are
clear

P.050 (Defrost 0–3 Heater status 0

System Only) 0: Off
1: On — low heat stage 1 heated blower or – heat lamps
2: On — medium heat stage 1 + 2 heated blower
3: On — high heat stage 1 + 2 + 3 heated blower

P.051 (Defrost 0–1 Heater control (parameter P.050 must be set to on) 0
System Only) 0: Manual
1: Automatic timer

P.055 (Defrost 0–3 Blower control 0

System Only) 0: Off
1: Low-speed
2: High-speed
3: Automatic (blower runs at high speed when door is open)

P.058 (Defrost 5–600 minutes Heater timer on time 30

System Only)

P.059 (Defrost 5–600 minutes Heater timer off time 5

System Only)

P.999 Password (for accessing Service Level 2) is the number 10

Password (for accessing Service Level 1) is the number 5.

30
 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

SERVICE LEVEL 2 PARAMETERS At Service Level 2, the technician will be able to view all
the parameters in the System 4 Control panel. However,
Table 6 below lists some of the parameters available
some parameters (Safety) will require an additional
through Service Level 2. Included in this table is a
Rytec level password to do the changes.
description of each parameter and its available ranges
and factory default settings.
Table 6

Factory
Parameter Range Service Level 2 Parameters
Setting

P.000 Cycles Door cycle counter (read only)

P.001 Cycles Saved door cycle counter

NOTE: This is used to lock in the current door cycle count
for entering Rytec service level passwords. Rytec
level passwords are only available through the
Rytec Customer Support Department at 800-628-
1909.

P.005 Cycles Maintenance counter

NOTE: This indicates the number of cycles remaining
until door maintenance is due. This parameter
works in conjunction with P.970 & P.971. The fac-
tory setting is -1, meaning not turned on. P.005
counts down one cycle from the value in P.971
each time the door operates. For example, if P.971
is set to 100 cycles, each time the door opens
P.005 counts down from 100, 99, 98 etc., until it
reaches 0. P.970 instructs the door what to do
when counter reaches 0. See P.970 for selections.

P.010 0–9999 seconds Auto-close delay timer 1 — ACL1 (with activator connected to 10
input 5 — terminal 210 and 212)
0 = Off

P.011 0–9999 seconds Auto-close delay timer 3 — ACL2 (with activator connected to 10
input 6 — terminal 230 and 233)
0 = Off

P.015 0–200 seconds Auto-close delay timer 2 — ACL2 (with activator connected to 5
input 6 — terminals 230 and 233)
0 = Off
Time door remains open after all activation and safeties are
clear

P.017 0–999 seconds Storage of open commands 0

NOTE: Open commands can be stored with this parame-
ter. If the door is interlocked and when the inter-
lock is released, this timer counts down and
opens the door. To turn off the storage of OPEN
commands change value of P:017 to 0.

31
SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.025 0–20 seconds Pre-warning time before close 3

NOTE: This parameter is used for the yellow flashing
warning lights. Increasing the value will increase
the number of times the yellow LED's flash previ-
ous to closing.

P.026 0–1 Pre-warning time before opening 0

P.050 (Defrost 0–3 Heater status 0

System Only) 0: Off
1: On — low heat stage 1 heated blower or heat lamps
2: On — medium heat stage 1 + 2 heated blower
3: On — high heat stage 1 + 2 + 3 heated blower

P.051 (Defrost 0–1 Heater control (parameter P.050 must be on) 0

System Only) 0: Manual
1: Automatic timer. Timer settings found in parameters P:058
(time heater is ON), and P:059 (time heater is OFF)

P.055 (Defrost 0–3 Blower control 0

System Only) 0: Off
1: Low speed
2: High speed
3: Automatic (blower runs at high speed when door is open)

P.058 (Defrost 5–600 minutes Heater timer on time 30

System Only)

P.059 (Defrost 5–600 minutes Heater timer off time 5

System Only)

P.210 0–5 Limit set-up 0

0: Off
1: Open, close, and partial set-up (partial set using P.244)
2: Open
3: Open and close
4: Partial (P.244 ignored)
5: All (partial set using P.244)

P.221 ± 125 increments Close-limit adjustment 0

(For minor adjustments to the close position of the door. This
adjustment resets to 0 if the limits are reset. 10 increments
equals approximately 1 inch of door travel.)

P.231 ± 60 increments Open-limit adjustment 0

(For minor adjustments to the open position of the door. This
adjustment resets to 0 if the limits are reset. 10 increments
equals approximately 1 inch of door travel.)

P.244 0–3 Partial position 0

0: Parameter off
1: Half-open position
2: Two-thirds-open position
3: Operator-established position

32
 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.630 0–2 Function foil keypad OPEN 2

(Specifies the function (mode) of the OPEN key)
0: No door function
1: Only deadman move during deadman operation
2: Deadman and automatic
NOTE: This parameter is used for security purposes. For
example, if the owner wants to monitor who is
accessing the door via a card swipe, then the UP
arrow on the control panel must be deactivated.
Otherwise, simply pushing the UP arrow will allow
anyone into the room. Changing parameter P:630
to 0 forces entry via the card swipe. The arrow will
remain functional for navigating the parameters
but will not operate the door. The same condition
applies to parameter P:650 for the close key.

P.640 0–2 Function foil keypad STOP 0

(Specifies the function (mode) of the STOP key)
0: No door function during automatic travel
1: After pressing the STOP key, the door is stopped and waits
for any command
2: After pressing the STOP key, the door is stopped and waits
for a keypad command
NOTE: The RESET key also serves as the ENTER key
and the STOP key.

P.650 0–2 Function foil keypad CLOSE 2

(Specifies the function (mode) of the CLOSE key)
0: No door function
1: Only deadman move during deadman operation
2: Deadman and automatic

P.660 0–4 Floor loop detector — channel 1 function 1

20: Deactivated
21: Command forwarding
22: Open command
(Additional settings are also available under this parameter.
Locking, safety, sequence of operation are all available if
needed. Contact Rytec Customer Support to discuss specific
operational sequence. 800-628-1909

P.670 0–4 Floor loop detector — channel 2 function 1

20: Deactivated
21: Command forwarding
22: Open command
(Additional settings are also available under this parameter.
Locking, safety, sequence of operation are all available if
needed. Contact Rytec Customer Support to discuss specific
operational sequence. 800-628-1909

33
SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.683 0–3 Open position — radio channel 1 0

0: Full-open position
1: Partial-open position
2: Partial open when radio is activated one time, full-open
when activated a second time
3: Full-open when radio is activated twice

P.693 0–3 Open position — radio channel 2 0

0: Full-open position
1: Partial-open position
2: Partial-open when radio is activated one time, full-open
when activated a second time
3: Full-open when radio is activated twice

Table 7

Factory
Parameter Range Service Level 2 Parameters
Setting

NOTE: All inputs have the ability to be configured in many different ways. If you are interested in config-
uring an input please contact Rytec Customer Support at 800-628-1909. Please have details available on
what sensor you would like to use and how you would like the sensor to perform.

Contact Rytec Customer Support (800-628-1909) for specific information regarding input configuration. The
Rytec Customer Support group has performed many different input configurations and can help you determine
which configuration is best suited for your environment. Please provide door serial number when contacting
Rytec Customer Support.

P.7x0 The System 4 Drive and Control RY-WI System provides two
NOTE: The “x” in output relays and an expansion board that provides another
P.7x0 represents the
relay number.
six that can be configured a number of different ways.
Example P:710 repre-
sents relay number 1
and P:720 represents
If you are interested in configuring an output relay to perform a
relay number 2 and so specific function, please call Rytec Customer Support at 800-
forth. Up to eight possi-
ble relays can be used.
628-1909. Please be sure to have all operational details prior
to contacting Rytec.

Any and all options are available for the outputs to perform a
variety of operations. The relays can be programmed to per-
form many different scenarios.

34
 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Table 8

Factory
Parameter Range Service Level 2 Parameters
Setting

P.910 0–25 Display mode selection

The following variables are displayed:
0: Control sequence is displayed, i.e. door cycles, door open-
ing, timer, door closing.
1: [Hz] The current travel speed
2: [A] The current motor current
3: [V] The current motor voltage
4: [A] The current DC bus current
5: [V] The current DC bus voltage
6: [°C] The power stage temperature in °Celsius
7: [°F] The power stage temperature in °Fahrenheit
8: [s] The run time of the motor during the last door operation
9: [Increments] The current position
10: [Increments] The position of the reference
11: [Dig] Channel 1 value of the absolute encoder
12: [Dig] Channel 2 value of the absolute encoder
13: [V] Current reference voltage
14: Temperature inside the controller in celsius degrees
15: Temperature inside the controller in fahrenheit degrees
16: Transmission ratio from motor to encoder during opening
17: Transmission ratio from motor to encoder during closing
18: Rotation speed of the motor output shaft
19: Temperature of the encoder
20: Battery voltage of encoder
21: Number of position requisition without answer
22: Number of position requests from the board to the
encoder without an answer from the encoder
23: Wireless reversing edge signal strength during door travel.
Given in a percentage of signal. Percentage should remain
above 90% during travel
24: Numbers of wireless reversing edge errors during the last
door cycle
25: Time of the clock in the controller.
NOTE: Settings 14 and 15 are only available if optional
temperature sensor installed in the controller.

P.920 Error history

(The controller stores the last eight errors in the error history.
The System 4 controller will time stamp the errors with the
date and time the error occurred.)
Error message 1 (most recent error)
Error message 2
Error message 3
Error message 4
Error message 5
Error message 6
Error message 7
Error message 8
Clear the complete error history
Exit the error memory, jump back to parameter

35
SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.940 Volt Input voltage

(The real time voltage the board is receiving. Electrical meters
measure the voltage as an RMS or essentially an average;
therefore, an electrical meter reading may vary by 20 volts or
more. P:940 displays the voltage in real time. If the control
board receives a voltage greater than 10%, its rating error
F:525 will appear until the voltage drops back down within
acceptable range. If this continues, a line reactor will be
needed to prevent the failure. When incoming power is
ungrounded, an isolation transformer may be needed. (Part
number for the Line reactor is 0011748 and the isolation trans-
former is part number 00111101.)

P.980 0–5 Operating mode 0

(This parameter is used to set the operating mode for the con-
troller)
The following modes are possible:
0: Door travels in automatic mode.
1: Door opens in automatic, closes in manual (jog) mode.
2: Door travels in jog mode open and close.
3: Jog mode only (deadman) emergency operation; and no
safety inputs required for deadman operation.

All safety devices and limit switches are ignored.

4: Endurance test with safety devices automatic OPEN and

CLOSE operation. Before each new operation the hold-open
time P.010 is in effect
5: Endurance test without safety devices

All safety devices are ignored.

NOTE: The endurance test setting is lost after turning off

the controller. The controller then reverts to man-
ual mode.

P.985 0–3 Text language 0

0: English text
1: German text
2: Spanish text
3: French text

P.999 Password (for accessing Service Levels 2) is the number 10

P.F00 0–1 Activation of the wireless

(Activate the functions of the wireless in the controller)

36
 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.F01 6–250 Timeout for the wireless 50

milliseconds (This sets the wireless timeout within the controller)
NOTE: If the mobile unit doesn’t send a message within
the specified time, the wireless edge will be seen
as tripped.

P.F05 1–10 Channel group 1

(The channel group of the wireless connection)
Channel is selectable 1–10 find setting with highest percent-
age during door operation. Use P:910 set to 23 to display per-
centage during door travel. Place P:910 back to 0 when
finished testing wireless signal.

P.F07 00000000– Mobile unit address

FFFFFFFF (The address on the mobile unit is used to communicate with
the encoder via the antenna in the head assembly. Each
mobile unit has its own address number.)

Mobile Unit Installed in Bottom Bar

Address

A2500246

Figure 43

NOTE: The mobile address is shown

mounted on the mobile unit.
Mobile
Address

A5500025

Figure 44

37
SYSTEM PARAMETERS—CLOCK PARAMETERS

Factory
Parameter Range Service Level 2 Parameters
Setting

P.F08 0–3.5 Volts Battery voltage warning level

(The warning level for the battery voltage. If the battery voltage
is less than the specified value, an F857 will occur.

CLOCK PARAMETERS password of “10” to enable you to change the clock set-
ting. Table 9 details the parameters used to adjust the
If the clock time needs to be changed to your time zone,
clock setting.
Service Level 2 will be required. P:999 will require a
Table 9

Parameter Range Service Level 2 Parameter

P:C00 Displays the current time and date of the System 4 clock. Clock
is set at Rytec before shipping to current date and central time.

P:C01 0–23 hours Adjusts hours for the current time.

P:C02 0–59 minutes Adjusts minutes for the current time.

P:C03 0–59 seconds Adjusts seconds for the current time

P:C04 0101–1231 Adjusts day and month to current day and month.

P:C06 2000–2099 Adjusts year to current year.

P:C07 0–3 Allows clock to adjust for daylight savings time.

0: Changeover deactivated
1: European Union - Changeover the last Sunday in March from
2:00 a.m. to 3:00 a.m. and last Sunday in October from 3:00 a.m.
to 2:00 a.m.
2: United Kingdom - Changeover on last Sunday in March from
1:00 a.m. to 2:00 a.m. and on the last Sunday in October from
2:00 a.m. to 1:00 a.m.
3: USA/Canada - Changeover on first Sunday in April from 2:00
a.m. to 3:00 a.m. and on last Sunday in October from 3:00 a.m.
to 2:00 a.m.

38
 SYSTEM PARAMETERS—CLOCK INPUT SELECTION

CLOCK INPUT SELECTION times during the day. The four channels allow the poten-
tial of four events to occur each day. If you are interested
The System 4 controller has four clock input channels
in setting the clock for a particular event, contact Rytec
(A, B, C, and D) that can be used to perform special
Customer Support at 800-628-1909. Please have the
timed events. For instance, these inputs can be used to
door serial number and the specific scenario you would
lock a door during specific hours or days of the week, or
like to perform.
open the door during break times or other scheduled
Table 10

Parameter Range Service Level 2 Parameter

P:C0A 0–26 Input channel A. Channel A of the clock with any inverter input.

P:C0B 0–26 Input channel B. Channel B of the clock with any inverter input.

P:C0C 0–26 Input channel C. Channel C of the clock with any inverter input.

P:C0D 0–26 Input channel D. Channel D of the clock with any inverter input.

SWITCHING CLOCK PROGRAMS

Table 11 outlines the parameters used when using the
clock program to perform scheduled events.
Table 11

Parameter Range Service Level 2 Parameter

P:C10 1–50 Choice of switching program. This parameter is used to specify

the program to be used. Works with parameters P:C11 and
P:C19.

P:C11 0–15 Choice of channel. This parameter is used to select the clock
program to be controlled.
0: No channel is activated, deactivated.
1: Channel A
2: Channel B
3: Channel A+B
4: Channel C
5: Channel A+C
6: Channel B+C
7: Channel A+B+C
8: Channel D
9: Channel A+D
10: Channel B+D
11: Channel A+B+D
12: Channel C+D
13: Channel A+C+D
14: Channel B+C+D
15: Channel A+B+C+D

P:C12 0–1 Polarity of channel Parameter shows if the clock program will
switch the selected channel to ON or OFF.
0: Channels will switch OFF
1: Channels will switch ON

39
SYSTEM PARAMETERS—SWITCHING CLOCK PROGRAMS

Parameter Range Service Level 2 Parameter

P:C13 0–9 Day of week. Parameter shows which day the clock program will
be working.

0: Monday to Sunday
1: Sunday
2: Monday
3: Tuesday
4: Wednesday
5: Thursday
6: Friday
7: Saturday
8: Monday to Friday
9: Saturday to Sunday

P:C14 0–23 Hour. Parameter shows which hour the clock program will be
working.

P:C15 0–59 Minutes. Parameter shows which minute the clock program will
be working.

P:C16 0–59 Seconds. Parameter shows which second the clock program will
be working.

P:C17 0–9 Priority of switching program. Parameter defines the priority of

the switching program. 0 lowest priority, 9 highest priority.

P:C18 0101–1231 Date of Start. Parameter shows which day and month the clock
program will be working.

P:C19 0101–1231 End Date. Parameter shows which day and month the clock pro-
gram will end.

P:C1E 0–1 Reset all switching programs. All switching programs will be
deleted and all switching programs will stop.

40
 SYSTEM PARAMETERS—FAULT CODES

FAULT CODES Table 12 below lists the fault codes associated with the
general operation of the door. Included in this table are
GENERAL OPERATION FAULT CODES the available fault codes, a description of each fault
NOTE: If you have an error not listed in the chart code, and the suggested corrective action to clear the
below, contact Rytec Customer Support at fault. (Door is in the error jog only mode.)
800-628-1909.
Table 12

Fault Code
Description Corrective Action
(Displayed Message)

F.000 Door opens past full-open position.

(Beyond Opn) 1. Motor brake faulty or improperly adjusted 1. Repair or adjust motor brake
(beyond open) 2. Door position parameters incorrect 2. Consult factory

F.005 Door closes past full-closed position.

(Beyond Clsd) 1. Motor brake faulty or improperly adjusted 1. Repair or adjust motor brake
(beyond closed) 2. Door position parameters incorrect 2. Consult factory

F.020 Door open run time exceeded.

(Beyond Runt) 1. Blocked door 1. Check mechanical operation of door
(beyond run time) 2. Sluggish motor 2. Check motor. Verify that the motor is
wired to proper voltage. Reference door
electrical schematic for correct motor volt-
age — high or low.
3. Run time set too low 3. Consult factory

F.030 Door travel incomplete (check incoming

(Mtr Stalled) power at L1, L2, and L3 on the control
(motor stalled) board).
1. Blocked door 1. Check mechanical operation of door
2. Jammed motor 2. Check motor and brake
3. Encoder incorrectly installed 3. Check encoder mounting
4. Encoder problem 4. Check encoder operation
5. Low start torque or speed 5. Consult factory
NOTE: Check that cables are cut to
length and that high- and
low-voltage lines are in sep-
arate conduits.

F.031 Door moves in wrong direction.

(Trv Direct) 1. Encoder wired incorrectly 1. Check encoder and encoder connec-
(travel direction) tions.

2. Motor running in wrong direction 2. Check motor rotation. If motor rotation

is incorrect, swap the T1 and T2. The lim-
its will need to be cleared in parameter
210.
NOTE: The controller knows the
motor was rotating back-
wards. You will receive an
encoder fault if limits are not
cleared and reset.

3. Consult factory
3. Motor brake releases early

41
SYSTEM PARAMETERS—DOOR SAFETY/EMERGENCY FAULT CODES

Fault Code
Description Corrective Action
(Displayed Message)

F.060 Bottom bar breakaway input activated, ter- Reassemble bottom bar or repair break-
(Door Ajar) minal 271 away switch. The controller believes the
door was impacted and the panel is out-
side the side columns. Reassemble bot-
tom bar or repair breakway switch.
NOTE: If an error reappears after
resetting the error, it has not
been corrected. If the door
has a coil cord, a wire for the
breakaway circuit may be
broken inside the coil cord.

F.070 Door panel closed past cleaning position. Adjust cleaning position (P.070).
(Clean Pos) 1. Motor brake faulty or improperly adjusted 1. Repair or adjust motor brake
(clean position) 2. Door position parameters incorrect 2. Consult factory

DOOR SAFETY/EMERGENCY FAULT CODES

Table 13 lists the fault codes associated with the door
safety/emergency system. Included in this table are the
available fault codes, a description of each fault, and the
suggested corrective action to clear the fault. (The door
is in the emergency stop mode and will not operate.)
Table 13

Fault Code
Description Corrective Action
(Displayed Message)

F.201 1. Door stopped and does not operate 1. Reset E-Stop 1

(E-Stop 1) 2. Corresponding error message displayed 2. Check jumper terminals 240 and 241
NOTE: Terminals can be used for
emergency stop push button
in place of the jumper. Switch
must be normally closed.

F.211 External Emergency Stop activated.

(E-Stop 2) 1. Door stopped and does not operate 1. Reset E-Stop 2
2. Corresponding error message displayed 2. Check jumper terminals 250 and 251
NOTE: Terminals can be used for
emergency stop push button
in place of the jumper. Switch
must be normally closed.

F.212 External Emergency Stop activated.

(E-Stop 3) 1. Door stopped and does not operate 1. Reset E-Stop 3
2. Corresponding error message displayed 2. Check jumper terminals 260 and 261
NOTE: Terminals can be used for
emergency stop push button
in place of the jumper. Switch
must be normally closed.

42
 SYSTEM PARAMETERS—REVERSING EDGE CIRCUIT FAULT CODES

REVERSING EDGE CIRCUIT FAULT CODES

Table 14 below lists the fault codes associated with the
reversing edge circuit. Included in this table are the
available fault codes, a description of each fault code,
and the suggested corrective action to clear the fault.
(The door is in the error jog only mode.)
Table 14

Fault Code
Description Corrective Action
(Displayed Message)

F.361 Reversing edge tripped.

(Edge Trip) 1. Bottom edge of door made contact with 1. Reset control system
(edge trip) object in door opening
2. Short circuit in reversing edge wiring 2. Check and repair wiring
3. Pressure switch faulty or not adjusted 3. Check and adjust switch
NOTE: Ohm reading on terminals
272 and 283 should read
8.2K or 8200 ohms.

All wireless units use a 8.2K

ohm resistor.

F.363 Reversing edge circuit open. Check all parts of reversing edge circuit
(Edge Open) 1. Reversing edge wiring disconnected including resistor. Make any necessary
2. Reversing edge cable in the bottom bar repairs or adjustments. Verify proper
may be cut or damaged. operation of reversing edge after all
3. Reversing edge resistor is wrong value repairs and adjustments are made. Ohm
or missing reading is ohms at terminals.
NOTE: All resistors are 8.2K ohms.
Terminals 272 and 273.

43
SYSTEM PARAMETERS—DRIVE SYSTEM FAULT CODES (400-LEVEL CODES)

DRIVE SYSTEM FAULT CODES (400-LEVEL CODES)

Table 15 below lists the fault codes associated with the
drive system. Included in this table are the available
fault codes, a description of each fault code, and the
suggested corrective action to clear the fault.
Table 15

Fault Code
Description Corrective Action
(Displayed Message)

F.410 Over current.

(Mtr OC L1) 1. Mechanical problem 1. Check operation of door
(motor over current 2. Motor brake not releasing 2. Check brake
limit 1) 3. Motor nameplate parameters (frequency, 3. Check motor parameter settings and
current, etc.) incorrectly set verify settings match listing on motor
nameplate
4. Motor torque boost incorrectly set 4. Consult factory
NOTE: Parameter P:140 (open boost)
or P:145 (close boost) set too
high.

F.425 High supply voltage.

(Power OV) 1. Incoming voltage too high 1. Check parameter P:940 =
(power over voltage) incoming voltage to control board

F.426 Low supply voltage.

(Power Low) 1. Incoming voltage too low 1. Check parameter P:940 =
(power low) incoming voltage to control board

44
 SYSTEM PARAMETERS—DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)

DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)

Table 16 below lists the fault codes associated with the
drive system. Included in this table are the available
fault codes, a description of each fault code, and the
suggested corrective action to clear the fault.
NOTE: All 500-level codes are warnings indicat-
ing the maximum allowable value has
been exceeded. The door will operate only
in the failure error jog mode.

Table 16

Fault Code
Description Corrective Action
(Displayed Message)

F.510 Over current.

(Mtr OC L2) 1. Mechanical problem 1. Check operation of door
(motor over current 2. Motor brake not releasing 2. Check brake
limit 2) 3. Motor torque boost incorrectly set 3. Consult factory
4. Motor nameplate parameters (frequency,
current, etc.) incorrectly set

F.515 Maximum motor over current.

(Mtr OC Ext) 1. Motor or motor connection problem 1. Check motor: Turn off power, discon-
(motor over current 2. Incorrect motor parameters nect motor leads and ground. Ohm wind-
external) 3. Incorrect motor nameplate parameters ings T1-T2, T2-T3, and T1-T3 readings
should be comparable. Also ohm each
motor lead to ground, motor should not
ohm to ground.
2. Consult factory

F.519 IGBT over current.

(IGBT OC) 1. Faulty motor winding or motor shorted to 1. Check motor: Turn off power, discon-
(insulated gate bipolar ground nect motor leads and ground. Ohm wind-
transistor over current) ings T1-T2, T2-T3, and T1-T3 readings
should be comparable. Also ohm each
motor lead to ground, motor should not
ohm to ground.
2. Incorrect motor parameters 2. Consult factory
3. Incorrect motor nameplate parameters

F.525 High supply voltage (>+10%).

(Power OV) 1. Incoming voltage too high 1. Check incoming voltage, check param-
(power over voltage) eter P:940 = incoming voltage to control
board

DOOR POSITION FAULT CODES should be installed in conduit with low volt-
age wiring.
Table 17 lists the fault codes associated with the posi-
tion of the door. Included in this table are the available The encoder cable must be separated from
fault codes, a description of each fault code, and the the high-voltage wiring. All cables must be
suggested corrective action to clear the fault. cut to length. DO NOT wrap up excess cable
NOTE: The encoder is sensitive to electromag- near the motor or in the control panel.
netic interference (EMI) and many of the
F:700 codes are the result of electromag-
netic interferences. The encoder cable

45
SYSTEM PARAMETERS—DOOR POSITION FAULT CODES

The encoder shield wire must also be

grounded to the P-clip located under the
System 4 board to capture the encoder
cable. DO NOT ground the encoder shield
wire to the ground bus on the System 4
board. (See Figure 45.)

P-clip

A5400018

Figure 45

Table 17

Fault Code
Description Corrective Action
(Displayed Message)

F.700 Door limits not set.

(Pos Sys 1) 1. Set limits 1. Set limit P.210
(position system 1) 2. Possible encoder failure 2. Check encoder

F.752 Data transmission error.

(Protocol 2) 1. Possible electromagnetic interference 1. Shielded cable broken, no longer
(EMI) to control system grounded, or not used where required
2. Encoder problem 2. Check encoder

F.760 Position of door does not correspond to

(Encoder 2) position of encoder.
1. Possible electromagnetic interference 1. Shielded cable broken, no longer
(EMI) to control system grounded, or not used where required
2. Encoder or encoder mounting problem 2. Check encoder
3. Incorrect resolution setting 3. Consult factory

F.762 Limit switches incorrectly set.

1. Limit settings not valid or properly set 1. Limits P.210 reset
2. Open or partial limit settings out of range 2. Reset limits
3. Control system not initialized 3. Consult factory

F.768 The F:768 message appears when the bat- Change battery in the encoder
tery in the encoder needs to be changed

46
 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code
Description Corrective Action
(Displayed Message)

F.770 Overflow from SSI encoder 1. The current position of the door com-
(Protocol 3) pared to the fixed closed position has
Protocol 3 encoder exceed the maximal allowed range of
4095 increments
2. Set P.202 (used resolution of the
encoder) to a higher value and repeat
limit setting
3. Reset P.210—reset limits
NOTE: Fault F:760 may appear.

WIRELESS SYSTEM FAULT CODES

Table 18 below lists the fault codes associated with the
control system. Included in this table are the available
fault codes, a description of each fault code, and the
suggested corrective action to clear the fault.
Table 18

Fault Code
Description Corrective Action
(Displayed Message)

F.856 Wireless communication error between sta- 1. Wrong address parametrized

tionary and mobile unit. 2. Mobile unit broken
3. Battery empty
4. Heavy wireless noise
5. Stationary antenna broken or mounted
wrong

F.857 Battery low. Reversing edge battery needs to be

replaced. Replace with D size lithium ion
battery 3.8 volts (Part number 00111193),

DELAY TIMERS
Table 19 below lists the delay timers associated with the
control system. Included in this table are the available
timers and their descriptions.
Table 19

Delay Timer Description

Acl1 = x Sec Auto close delay timer 1.

(Terminals 210 and 212)

Acl2 = x Sec Auto close delay timer 2.

(Terminals 230 and 233)

Acl3 = x Sec Auto close delay timer 3.

(Can be programmed to any
output)

47
MISCELLANEOUS MESSAGES—DOOR MESSAGES

MISCELLANEOUS MESSAGES SPECIAL STATUS MESSAGES

DOOR MESSAGES Table 21 below lists the special status messages asso-
ciated with the control system. Included in this table are
Table 20 below lists the miscellaneous messages asso- the available displayed messages and a description and
ciated with the control system. Included in this table are definition of each message.
the available displayed messages and a description and
Table 21
definition of each message.
Table 20
Displayed
Description
Message
Displayed
Description
Message Automatic Denotes controller in auto-
matic mode.
Door Held Open Door held open. Input termi-
nal shown in lower right of Jog Mode Denotes controller in jog
display. mode. To enter and exit jog
mode, push stop and down
Door Is Closing Door is closing. arrow simultaneously.
Door Is Open Door open in full-open posi-
tion. DOOR LIMIT MESSAGES
Door Is Opening Door is opening. Table 22 below lists the door limit messages associated
with the control system. Included in this table are the
Door Is Stopped Door is stopped — controller displayed messages and a description of each mes-
waiting for next incoming sage.
command. Table 22
Emergency Jog Door travel possible in jog
mode only — all safety and
limits ignored. Displayed Message Description

Emergency Stop One of the emergency stops ! Set Limits ! Limit set-up initialization.
is activated.
→ ●To Begin Initialize limit setting.
▲
Error Jog ▼ Only Door fault — door travel in jog
→Ú To Closed Pos. Close limit set-up.
mode only.
▲ →Ú To Open Pos. Open limit set-up.
Jog Mode ▼ Manual door operation — jog
mode only. To enter and exit →Ú To Part. Pos. Partial limit set-up.
jog mode, push stop and
down arrow simultaneously. Close Limit Set Close limit setting.

Locked Closed Door locked in closed posi- Hold ● If Ok Save limit setting.
tion. Input terminal shown in
Open Limit Set Open limit setting.
lower right corner of display.
Part. Limit Set Partial limit setting.
Partial Open Door in partial-open
Position position.

Rytec Door Type Cycle count.

Set Limits Start limit set-up procedure.

48
 MISCELLANEOUS MESSAGES—DOOR JOG MESSAGES

DOOR JOG MESSAGES

Displayed Message Description
Table 23 below lists the door jog messages associated
with the control system. Included in this table are the I.160 Close Req. Continuous OPEN still
displayed messages and a description of each mes- (close requested) active.
sage. Close requested however,
Table 23 door is still receiving an
open command. Look for
activator sending open
Displayed Message Description signal(s) request. For
example, a stuck pull cord
Bynd Opn P. Door jogged past full- (not releasing).
(beyond open position) open position.
I.170 Timed Open Forced opening being per-
Jogg. Close Jogging door closed with (timed open) formed. This is performed
(jog close) down (▼) key. with parameter P:018. The
value is in minutes and the
Door Is Opn Door jogged fully open, factory setting is 0. Enter-
(door is open) additional door open ing a value will cause the
travel not possible. door to open when the
time is reached. This fea-
Door Is Cls Door jogged fully closed,
ture is often used in
(door is closed) additional door close
freezer door applications.
travel not possible.
I.199 Counter Err Door cycle counter error.
Jogg. Open Jogging door open with
(counter error)
(jog open) (▲) key.
I.300 Air Locked Locked by another door.
DOOR STATUS MESSAGES (air locked)
Table 24 below lists door status messages associated I.310 Open A12 Door open command
with the control system. Included in this table are the (open A12) initiated to other door in air
displayed messages and a description of each mes- lock.
sage.
I.400 HD Limit Hard door not open.
Table 24
(freezer only) In freezer applications,
Rytec sends additional
switches that turn the
Displayed Message Description defrost heaters OFF if an
insulated door is used on
I.060 Self repair after door ajar
site. The switches acti-
in progress.
vate and deactivate the
I.080 Maintenance required defrost system. The elec-
soon – service counter trical schematic states if
nearly expired. the switches are not used,
jumper wires must be
I.100 Open Spd. Excessive door speed installed for the defrost to
(check open speed) near full-open position. operate. If the jumpers are
Open speed is too high, not installed the informa-
check P:310 opening tional message "I:400 HD
speed in Hertz. Limit" and “I:401 Defrost
Off" will be displayed on
I.150 Close Spd. Excessive door speed
the screen.
(check close speed) near full-closed position.
Closing speed too high,
check P:350 closing
speed in Hertz.

49
MISCELLANEOUS MESSAGES—DOOR STATUS MESSAGES

Displayed Message Description Displayed Message Description

I.401 Defrost Off Defrost deactivated. I.520 Maximum speed during

(freezer only) In freezer applications, automatic limit switch cor-
Rytec sends additional rection is not reached.
switches that turn the
defrost heaters OFF if an I.555 Auto Calibration Limit switches being cor-
insulated door is used on rected.
site. The switches acti-
vate and deactivate the
defrost system. The elec-
trical schematic states if
the switches are not used
jumpers wires must be
installed for the defrost to
operate. If the jumpers
are not installed the infor-
mational message "I:400
HD Limit" and “I:401
Defrost Off" will be dis-
played on the screen.

I.510 Auto Calibration Limit switch correction fin-

ished.
The 500-level messages
appear on the screen after
the door limits have been
set. DO NOT make any
corrections to the speeds
or limits while the 500-
level messages are pres-
ent on the screen.
NOTE: The door may stop
short of the close position
and speed up and slow
down during the 500 mes-
sages, this is normal. Con-
tinue operating the door
until the 500-level mes-
sages leave the screen.
During the 500-level mes-
sages, the controller is
self-learning the optimum
run curve for the door.
After the 500-level mes-
sages leave the screen,
you can then make correc-
tions to the limits if neces-
sary.
This message is for all
500-level messages.

I.515 Auto Calibration Controller is preparing

automatic teach-in of the
limit switches.

50
 MISCELLANEOUS MESSAGES—PROGRAMMABLE TEXT MESSAGES

PROGRAMMABLE TEXT MESSAGES

Table 25 below lists the programmable text messages
associated with the control system. Included in this
table are the available strings and their description.
Table 25

Text Message
Description
Number

1 (Open) Open door.

(Terminals 200 and 201)

2 (Open — ACL1) Open/close with ACL1 timer.

(Terminals 210 and 212)

3 (Open — ACL2) Open/close with ACL2 timer.

(Terminals 230 and 233)

4 (A/A Op — C1) Door open and close.

(Terminals 210 and 211)

5 (Close) Close door.

(Terminals 200 and 202)

6 (Stop) Stop door.

(Normally closed: remove
jumper terminals 200 and
203)

7 (Photoeye — Fr) Front photo eye. (Terminal

222)

8 (Photoeye — Rr) Rear photo eye. (Terminal

232)

9 (Photoeye — Aux) Auxiliary photo eye.

10 (Door Ajar) Breakaway bottom bar

disconnected from side
column. (Terminal 271)

11 (Blower On) Freezer blower on.

12 (Blower High) Freezer blower on high.

13 (Blower Auto) Freezer blower on auto.

14 (Heater St.1) Freezer heater stage 1 or

heat lamps on.

15 (Heater St.2) Freezer heater stage 2 on.

16 (Heater St.3) Freezer heater stage 3 on.

17 (Heater Auto) Freezer heater on auto.

18 (HW Interlock) Freezer hard door interlock.

51
TROUBLESHOOTING—TROUBLESHOOTING WITH STATUS LEDS

TROUBLESHOOTING Table 26

TROUBLESHOOTING WITH STATUS LEDS

If a problem occurs with the control system or the door, Associated LED
LED Group
the controller is configured with various light-emitting Function
diodes (LEDs) that can be helpful when troubleshooting
Emergency Stop NOTE: Reference
the problem. The LEDs are grouped in various functions
Chain LEDs Figure 46 for
and indicators as detailed in Figure 46. Table 26 below
LED Loca-
details the interpretation of each group of LEDs.
tion

1 = E-Stop 1
First External E-Stop
2 = E-Stop 2
Second External E-Stop
24V Short
LED 3 = E-Stop 3
Third External E-Stop

Note: LEDs 1, 2, and 3

must all be on for normal
operation.
Green Input LEDs 4 = breakaway input
Reversing (LEDs on = contact 5 = front photo eyes
Red Edge LEDs connection closed 6 = rear photo eyes
Run LEDs
(Green) LEDs off = contact 7 = alternate action
connection open) activator
8 = auto-close activator 1
Ajar LED
9 = auto-close activator 2
10 = auto-close
activator 2
E-Stop 3 11 = open
E-Stop 2 12 = close
E-Stop 1 13 = stop
Input LEDs
14 = is a programmable
A5400016 input
Figure 46 15 = is a programmable
input

Reversing Edge Normal operation = red is

LEDs (Green and red) OFF and green is ON.
0 ohms (short) = red and
green are both OFF.
Infinite ohms (open) =
both red and green LEDs
are ON.

52
 TROUBLESHOOTING—TROUBLESHOOTING WITH STATUS LEDS

Associated LED
LED Group
Function

24 V Short LED Normal operation = LED off

Red in color
24 V failure = LED on

24 VDC system short

=flashing LED

Note: If the 24 V power

supply is overloaded or
has a defective device
(such as a shorted photo
eye) connected to it, the
power supply will auto-
matically power down for
self-protection.

Run LED There are two green

LEDs.
The left one flashes with
the speed of the door
(power to microboard).
The other flashes at a
constant rate (power to
main board).

53
SPECIFICATIONS—MECHANICAL

SPECIFICATIONS
MECHANICAL

Enclosure Black plastic w/semi-transparent cover window

Dimension L x W x H (approx.) 16 ³/₄ x 8 ¹/₄ x 7 ³/₄ (425 x 210 x 195 mm)
• includes heat sink, brake resistor, and wall brackets
• excludes cable glands, optional switches, and circuit breakers
Materials Polycarbonate Macrolon (no silicone)
Heat Sink Aluminum (natural)

Board Dimension Approx. 10.5 x 8 x 5.5 inches (270 x 200 x 140 mm)

Mounting Brackets Wall brackets integrated in bottom side of enclosure

Vertical installation only

Weight Approx. 11 lb. (5 kg.)

Protection Class/Rating TST FU3R-A: UL Type-4X Standard Enclosure

TST FU3R-AP: open type (Pollution Degree 2 environment only)

Operating Temperature Range: Enclosed type/open type (vertically mounted)

Ambient –4 to 122/149°F (–20 to 50/65°C) at 50% duty cycle of max. motor load
–4 to 113/140°F (–20 to 45/50°C) at 83% duty cycle of max. motor load
–4 to 104/131°F (–20 to 40/55°C) at 100% duty cycle of max. motor load
Storage –13 to 158°F (–25 to 70°C)

Relative Humidity Up to 80% (non-condensing)

Vibration Low vibration installation, e.g. on a concrete wall

Conduit Entry Formed plastic conduit bosses

(appropriately sized holes for conduit must be drilled in boss locations)

Internal Power Consumption Max. 50 W

Fully assembled controller w/o running motor

Approval UL-listed power conversion equipment for US and Canada

Inverter control: UL 508C
24 V power supply output: Class 2

Marks/Stickers TST FU3-AP: UL/UR sticker and serial number

TST FU3P-A: UL sticker, serial number
“WARNING High Voltage” provided by Rytec.

Clock 24-hour real-time clock with integrated gregorian calendar

4-channel electronic timer
Accuracy limit: Max. 5 sec/day over full temperature range

Battery Socket prepared for lithium coin cell CR2032 (3 V)

INPUTS

Power Supply (Line Voltage) Standard 185–500 volt, single- or three-phase

External Fuse: 20 amp, class CC

54
 SPECIFICATIONS—INPUTS

Emergency Stop/Safety Chain All inputs have to be connected potential free

(E-Stop 1, 2, and 3) Contact ratings: 0 to 26 VDC and 10 to 200 mA
< 5V: inactive Jlogical 0
> 7V: active Jlogical 1
Indicated by individual LEDs
When safety chain is interrupted, no movement of the drive is possible, not
even in jog mode.
Factory Setting: Jumpered as in TST FU3P-A

Standard Inputs (IN1–IN10) 24 VDC / typ. 15 mA, max. 26 VDC / 20 mA

Inputs 2 and 3 are dedicated photo All inputs have to be connected potential free or:
eye inputs and require that only spe- < 5V: inactive Jlogical 0
cific photo eye connections are made > 7V: active Jlogical 1
to these two specific inputs. No other Indicated by individual LEDs
electrical connection should be made Min. signal duration for input control commands: > 100 ms
to these two photo eye inputs or
power source.

Input for Safety Edge For electrical safety edges with 1.2K ohm or 8.2K ohm resistance evalua-
tion and for dynamic optical systems. 3 status conditions are indicated by
LEDs: 0 Ohms (short), 1.2/8.2K ohms, Infinte ohms (open).

Keypad 24 VDC/typ. 15 mA
3 Button: Common connected to 24 V, 5-pole connector, ¹/₁₀ reference grid
2 LED Outputs (KP-Out ¹/₂): 24 VDC/max. 20 mA
LED only
Short and overload protection
Mainly prepared for flashing light on keyboard

Inputs INK1 and INK 2 24 VDC/max. 20 mA load

(Alternative: digital control inputs IN11 <5 V: inactiveJlogical 0, >16 V: activeJlogical 1 indicated by individual
and IN12) LEDs
Incremental encoder specification:
• Maximum frequency 1 kHz
• 90° offset between both input signals

Serial Interfaces asynchronous bidirectional serial interface for electronic limit switches,
RS485 A and B wireless safety equipment, and other special equipment from RS485 level,
terminated with 100 ohms

USB Host For USB-Memory stick w/PC compatible file organization (USB profile
“Mass Storage”, Sub Class Code “SCSI Transparent Command Set” (6),
Interface Protocol “Bulk Only Transfer” (5), Logical Unit Number (LUN 0),
no Hubs possible
Connector: Type A
Max. Supply: 100 mA
Max. Cable Length: 7 ft. (2 m)
Alternative USB Device For PC communication with protocol (service only)(Communication
devices simulates virtual serial port)
Connector: Type B
Max. Cable Length: 7 ft. (2 m)

FEIG Interface Bus I TTL communication line

For internal mounted I/O expansion board TST RFUxK only
Max. Distance: 4 in. (10 cm)

55
SPECIFICATIONS—OUTPUTS

FEIG Interface Bus II TTL communication interface to interface converter board TST RFUxCom
for communication with external mounted I/O expansion board TST
RFUxK
Max. Distance: 100 ft. (30 m)

FEIG Interface Bus III TTL communication interface to interface converter board TST RFUxCom
for communication with a second prepared door controller TST FURR
Max. Distance: 100 ft. (30 m)

OUTPUTS

Supply Output I Nominal value: 24 VDC ± 5%

Max. Load: 3.5 A (Includes brake, all plug-in modules, expansion boards, and supply
output II, etc.)
Overload protected by self-resetting semiconductor fuse
Short circuit protected by central switching regulator (switch off the com-
plete control system supply)

Supply Output II (Part of Supply Output For electronic limit switches and safety edge evaluation
I) Nominal value 11.3 V/max. 250 mA
Overload protected, short circuit proof, and self resetting

Motor/Drive Output 3 hp motor (derating for single phase supply)

5 Amps @ 480 V service voltage
10 Amps @ 230 V service voltage
Overload: 20 A for 0.5 seconds (motor overload protection is provided)
Max. Length of Motor Cable: 100 ft. (30 m)
Shielded cable is required; motor lines have to be separated from any
other wires. A separate motor contactor is NOT provided. ATTENTION:
High voltage on output terminals is also possible in E-STOP mode.

Brake Output 24 VDC/2.5A (supplied by internal power)

Electrical switch (e.g, transistor based)
2-pole plugable terminal
Short and overload protected
Prepared for SEW brake BMG4T, 40 Nm, 56 AC/24 DC
Additional noise suppression on electromechanical brake required (e.g, RC)

Auxiliary Relays Outputs Change over contact elements 250 V permitted only when con-
(115 V is more important than pluga- Potential free necting the same phase as the sup-
ble terminals) 250 VAC/¹/₃ hp ply voltage. Contacts used once for
30 VDC/max. 10A/min. 10 mA power switching (>100 mA) can no
Pilot duty B300, R300 longer switch low currents.

Brake Resistance Load Max. 2 hp (1.5 kW) for max. 0.5 seconds
Repetition rate min. every 20 seconds
Brake resistor is mounted on the heat sink

Relay Outputs If inductive loads are switched (e.g, additional relays), there must be
equipped with recovery diodes and appropriate noise suppression means
(e.g, regenerate diodes, varistors, RC elements)
Be careful in switching capacitive loads as they are often in external power
supplies or LED lights

Test Signal Output 24 VDC/min. 10 mA/max. 100 mA

Resistance load only
Short and overload protected
Mainly prepared for test inputs on photo eyes

56
 SPECIFICATIONS—PLUG-IN MODULES (OPTIONAL ITEMS)

PLUG-IN MODULES (OPTIONAL ITEMS)

Plug-In Modules
TST SFSS: 2-channel radio receiver module
TST SUVEK: 2-channel induction loop detector module w/terminals on board (alterna-
tive TST SUKS—second resistor evaluation or other safety equipment)

Expansion Board TST RFUxK

TST RFU3P (Freezer) is NOT provided

Communication Board TST RFUxCOM

Display Direction Board TST RLCCDR-A

Wireless Safety Edge 2.4 to 2.485 GHz, using frequency hopping N.O. (normally open) switch
with 8.2K-ohm resistor located in the door bottom bar

57
SPECIFICATIONS

ABBREVIATIONS
Table 27 below lists the abbreviation of each unit of
measurement referenced throughout the control system
program menu and this manual.
Table 27

Unit Abbreviation

Celsius °C

Counter Cnt

Current (Ampere) A

Cycles Cyc

Digits Dig

Fahrenheit °F

Gigahertz GHz

Hertz (Frequency) Hz

Horsepower HP

Increments Inc

Milliamp mA

MHz Megahertz

Milliseconds Ms

Minute Min

Number #

Percentage %

Seconds Sec

Voltage (Volt) V

Alternating Cur- VAC

rent Voltage

Direct Current VDC

Voltage

58
 SCHEMATICS—GENERAL - INCOMING POWER

SCHEMATICS
GENERAL - INCOMING POWER

NOTE: This schematic is provided for

general information purposes
only. Due to varying require-
ments for individual installations,
another schematic is shipped
with each door and that sche-
matic must be used for that spe-
cific installation.
NOTE: Dashed lines indicate additional
feild wiring may be required.

Incoming Power

A5400025

Figure 47

59
60
A5400026
Front Photo Eye Connections Rear Photo Eye Connections

BLU BLU

BRN BRN PHOTOEYE EMITTER,

PHOTOEYE EMITTER,
REAR. REAR.

BLU BLU

BLK BLK PHOTOEYE RECEIVER

PHOTOEYE RECEIVER
BRN REAR, PNP OUTPUT. BRN REAR, PNP OUTPUT.
GENERAL - ENCODER AND PHOTO EYES

Figure 48
may be required.
additional feild wiring
NOTE: Dashed lines indicate
SCHEMATICS—GENERAL - ENCODER AND PHOTO EYES

24VDC+ 24VDC+
FOR AUXILIARY DEVICE FOR AUXILIARY DEVICE
POWER AND ACTIVATOR POWER AND ACTIVATOR
SIGNAL SOURCE. SIGNAL SOURCE.

ALTERNATE ACTION ACTIVATOR INPUT, PC, PB

ACTIVATOR, PC, PB MOTION, ETC...W/ AUTO
ETC...W/O AUTO CLOSING. CLOSING TIMER 2.
SOURCE, T:210 SOURCE, T:210

ACTIVATOR INPUT, PC, PB

MOTION, ETC...W/ AUTO
CLOSING TIMER 1.
SOURCE, T:210

24VDC- 24VDC-
cific installation.

FOR AUXILIARY FOR AUXILIARY

DEVICE POWER. DEVICE POWER.

Encoder and Bottom Bar Connections Remote Activation Connections

matic must be used for that spe-
only. Due to varying require-
NOTE: This schematic is provided for

with each door and that sche-

another schematic is shipped
ments for individual installations,
general information purposes
 SCHEMATICS—GENERAL - RADIO CONTROL AND E-STOP

GENERAL - RADIO CONTROL AND E-STOP

NOTE: Dashed lines indicate NOTE: This schematic is provided for

additional feild wiring general information purposes
may be required. only. Due to varying require-
ments for individual installations,
another schematic is shipped
with each door and that sche-
matic must be used for that spe-
cific installation.

OPEN INPUT, W/ CLOSING

VIA CLOSE INPUT ONLY
STOP INPUT, JUMPER
MUST BE REMOVED

CLOSE INPUT

Open, Close, Stop Station Connection (Optional)

O,C,S STATION IS UTILIZED.
REMOVE JUMPER WHEN
Radio Control Connections

Remote Emergency Stop Connections (Optional)

REFERENCE SHOWN AT LEFT.
FIELD MOUNTED. SCHEMATIC
EMERGENCY

REMOTE EMERGENCY STOP

STOP

PUSH BUTTON, BY RYTEC,

Loop Detector Connections

A5400027

Figure 49

61
SCHEMATICS—GENERAL - BOTTOM BAR CONNECTIONS

GENERAL - BOTTOM BAR CONNECTIONS

NOTE: Dashed lines indicate NOTE: This schematic is provided for
additional feild wiring general information purposes
may be required. only. Due to varying require-
ments for individual installations,
another schematic is shipped
with each door and that sche-
matic must be used for that spe-
cific installation.

Activation Connections, Motion, PC, PB, Etc.

(Optional Equipment)
Encoder and Bottom Bar Connections

A5400028

Figure 50

62
 SCHEMATICS—GENERAL - CONTROLLER DIMENSIONS

GENERAL - CONTROLLER DIMENSIONS

NOTE: This schematic is provided for

general information purposes
only. Due to varying require-
ments for individual installations,
8.25 another schematic is shipped
with each door and that sche-
matic must be used for that spe-
cific installation.

16.75

A5400011

Figure 51

63
PARTS LIST—PARTS ORDERING INFORMATION

PARTS LIST Substitute Parts

PARTS ORDERING INFORMATION Due to special engineering or product enhancement,

the actual parts used on your control system may be
How to Order Parts different from those shown in this manual.

1. Identify the parts required by referring to the follow- If a part has been improved in design and bears a
ing pages for part numbers and part descriptions. revised part number, the improved part will be substi-
tuted for the original part ordered.
2. To place an order, contact your local Rytec repre-
sentative or the Rytec Customer Support Depart- Return of Parts
ment at: 800-628-1909 or 262-677-2058 (fax). Rytec will not accept the return of any parts unless they
3. To ensure that the correct parts for your controller are accompanied by a Return Merchandise Authoriza-
are shipped, please include the serial number of tion (RMA) form.
your door with the order. Refer to the owner’s man- Before returning any parts, you must first contact the
ual of your door to determine the location of the Rytec Customer Support Department to obtain authori-
serial number plate. The serial number plate is gen- zation and an RMA form.
erally located inside one of the side columns.
NOTE: You must provide the door serial number
(See Figure 52.)
for all control panels and enclosures. The
SERIAL NUMBER(S) door serial number can be found on a
Your DOOR SERIAL NUMBER information can be white decal inside the control panel door.
found in three universal locations. These are at the
inside of either side column (approximately eye level),
on the drive motor, and on the inside door of the System
4 control panel.

IMPORTANT: When installing multiple doors

of the same model but in differ-
ent sizes, verify the serial num-
ber in the control panel with the
one on the door assembly.

Drive/Motor Gearbox

Rytec
System 4
Control
Panel

Left Side
Column
Right Side
Column

A9500221

Figure 52

64
 PARTS LIST—ELECTRICIAN’S QUICK GUIDE

ELECTRICIAN’S QUICK GUIDE 7. The remaining cable for the photo eyes and activa-
tors must also be cut to length and also contain no
The Rytec System 4 controller is a variable frequency
loops or coils.
AC drive. This controller relies on the proper installation
and grounding of wiring and cabling for the controls and 8. All field electrical work must conform to any applica-
motor. THE HIGH AND LOW VOLTAGE MUST BE SEP- ble local or national electric codes.
ARATE. FAILURE TO DO SO WILL VOID THE WAR- 9. All field wiring to be minimum 60° C, 600 V rated
RANTY. A door-specific electrical schematic has been copper stranded type.
shipped inside the System 4 control panel. The electri-
cal schematic in this manual is a general schematic and 10. Use shielded cable where indicated on electrical
only used for reference. Use the schematic provided in drawing.
the control panel for the actual electrical installation.
IMPORTANT: Failure to use shielded cable
NOTE: High voltage is any voltage exceeding 50 may result in improper operation
volts. or premature failure and will
VOID the warranty.

Ferrite core magnets are to be installed on the incoming

L1, L2, and L3 supply voltage wires and also on the T1,
T2, and T3 motor connections. The ferrite core magnets
The System 4 control has a class 2 power
act as a filter for the incoming supply power and voltage
supply. Therefore, no voltage from any
passing to the motor. These filters help to reduce elec-
other source can be introduced to the Sys-
trical noise in the power system. See Figure 13 for
tem 4 controller.
proper installation of the ferrite core magnets.
1. All entries to the control panel must be made NOTE: Failure to install the ferrite core magnets
through the bottom of the control panel. Failure to as illustrated will void the manufacturers
do so will void the warranty. warranty.
IMPORTANT: All conduit entering the control
panel must enter from the bot-
tom of the panel — High voltage
from the bottom left and low volt-
Failure to install the ferrite core magnets will void
age from the bottom right.
the manufacturer’s warranty and potentially cause
Installing conduit through the
irreparable damage to the System 4 control panel.
top or sides of the control panel
will void the warranty.
2. High voltage must run in metallic conduit and enter
the bottom left corner of the control panel.
3. All low voltage wiring is supplied by a class 2 power
supply and should be installed in accordance with
NEC and local electrical codes. Failure to separate
high and low voltage will void the warranty.
4. All cables are to be cut to length. Supply Voltage
Magnet Location
IMPORTANT: Do not bundle or coil excess
cables in the control panel or in
the head assembly of the door.
Green Motor Connection
5. The motor ground (green wire) will terminate to Ground Wire Magnet Location
ground in the control panel. The drain wire (bare sil-
A5400029-30
ver) will also attach to ground.
6. The encoder cable will enter the bottom right of the Figure 53
control panel. The drain wire (bare silver) attaches
under the screw of the P-clip for the encoder cable
(see Figure 45).
NOTE: The encoder cable must be cut to length
and contain no loops or coils.

65
PARTS LIST—CONTROL PANEL — STANDARD PANEL

CONTROL PANEL — STANDARD PANEL

A5400036

Figure 54

ITEM QTY. PART # DESCRIPTION

1 1 Consult Factory System 4 Control Panel

Assembly, 200–500 V
Please provide
door serial number.

66