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JACKSHAFT
MOTOR-CONTROL
SYSTEM
FOR
RESIDENTIAL GARAGE DOORS
Model 815-RL
Installation Instructions
WARNING: To reduce the risk of injury to
persons, use this operator only with a
residential sectional door.
FOR INSTALLATION ONLY BY
QUALIFIED PERSONNEL
ZAP CONTROLS UK
100 Waterloo Boulevard
Anglesey Business Park
Cannock
Staffordshire WS12 1NR
United Kingdom
August 2006
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IMPORTANT INSTALLATION INSTRUCTIONS WARNING: To reduce the risk of Injury or death READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS Install only on a properly balanced door. An improperly balanced door has the potential to inflict severe injury. Have a qualified service person make repairs to cables, spring assemblies, and other hardware before installing the opener. Remove all ropes and remove, or make inoperative, all locks connected to the garage door before installing opener. Where possible, i
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CONTENTS Product Overview .............................................................................................. 1 Description ........................................................................................................ 2 Fitting the Super-Drive ....................................................................................... 3 Fitting the Manual Over-Ride lever .................................................................... 5 Fitting the Control unit .............
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ZAP SUPER-DRIVE MOTOR-CONTROL SYSTEM FOR SECTIONAL DOORS The system includes model 800-R wall-mounting Control unit, Super-Drive jackshaft Operator, Motor Cover kit and Manual Over-Ride kit. PRODUCT OVERVIEW CONTROL UNIT JACKSHAFT model 800-R SUPER-DRIVE Integrated Control unit OPERATOR with case mounted model 8472 control button. This The Super-Drive Control unit will Operator incorporates power doors up to 15 a V-belt drive with a square metres (160 Bowden cable v-belt square feet) in tension
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JACKSHAFT MOTOR-CONTROL SYSTEM FOR RESIDENTIAL GARAGE DOORS Model 815-RL Installation Instructions The Zap Controls’ range of Motor-Control Systems It is preferable to set the overhead track angle at for Sectional Doors provides a new concept in a gradient above horizontal to increase the safety control and the elimination of the inherent influence of gravity on the initial movement of the problems with a number of features of existing door in the close direction. If there is any door Operators.
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Pic 4 changes in door balance over a period of time. However springs should be checked and adjusted on each service visit at least once per year or 1500 door cycles, whichever is the sooner. FITTING THE SUPER-DRIVE OPERATOR The Super-Drive Jackshaft Operator kit includes an Pic 3 anti-torque arm, which prevents the operator An optional Beeper model 850 may be fitted to rotating and which is bolted to the Super-Drive sound at the start of each door movement and back plate using the motor cover ba
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Align the Super-Drive keyway with the door shaft keyway and fit the key supplied with the package. Ensure that the two Allen screws are firmly tight and then tighten the lock nuts. (Pic 8) Pic 6 Next slide the Super-Drive assembly onto the door shaft and select a suitable hole in the torque arm to bolt it to the Super-Drive back plate using the Pic 8 spacer bush, which should pass through the lower If there is no keyway one wall of a hollow door shaft slot in the Cover back. (Pic 7) The Cover ba
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The second Allen screw, set at 90 degrees, should When fitting the Manual Over-Ride lever it is then be tightened and secured with the locknut. preferable to position the lever relative to the Now tighten the torque arm screws (Pic 10) position of the end of the inner cable of the Bowden cable with the lever in the horizontal position. When fitting the Over-Ride Lever ensure that the lever is horizontal when the cable tension is taken up. It is important that sufficient tension is achieved to en
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Mark the hole positions for the Manual Over-Ride lever on the door track or frame in a convenient position with the lever held in the horizontal position. Drill two M5 or 7/32nd of an inch size holes. (Pic 13). Pic 13 Fit the M5 screws provided with the screw head Pic 15 on the inside of the track or doorframe. Fit the M5 nuts. When the lever tension is correct push the lever completely down to tension the V-Belt drive. Secure the hook in the D-shackle of the over-ride (Pic 16) cable. (Pic 14
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The control unit lid can be temporarily secured to FITTING THE CONTROL UNIT the case side screw positions to prevent it hanging Check that the control unit voltage, which is by the cables during the setting up process. shown on the label on the side of the control unit (Pic 18) case, is correct for the available single-phase supply voltage. The control unit model number has a suffix, which relates to the supply voltage. US is 120 volts EU is 220 volts UK is 240 volts The US/120 volt control uni
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be strapped to the Super-Drive Bowden cable with cable ties to allow both cables to seat neatly in the slot in the bottom of the Motor Cover. (Pic 20) Pic 21 The upper two pegs in the top edge of the cover back are next located in the two holes in the top edge of the cover front. (Pic 22). Pic 20 Do not cut or shorten the Motor Cable. Ensure that any unused cable is coiled and secured away from any moving parts, using the cable ties provided. NOTE THAT ALL TERMINALS ARE PLUG-IN FOR EASE OF WIRIN
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Pic 24 DO NOT PLUG THE POWER PLUG INTO THE SOCKET YET. Please ensure that any unused cable is coiled and secured using cable clips or cable ties provided. Pic 23 If the Control unit is to be wired permanently into the house wiring circuit, then the main 120 volt CONNECTING THE MAIN A/C (Europe: 220 volt, UK 240 volt) supply lead, with SUPPLY plug attached, should be removed from the Control unit case as follows: The Operator should be installed in accordance with local codes and national electr
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7. The new supply wiring should be terminated to the GREEN connector block. The correct locations for the Live, Neutral and Ground wires are marked on the panel next to the GREEN socket. The new Black (live) wire should be terminated in the left hand terminal. The White (neutral) wire should be terminated in the center terminal and the Green (ground) wire should be terminated in the right hand terminal. (See Pic 24, previous page). Note that alternative wire colors apply to UK and Europe. If th
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TESTING THE DOOR OPERATION When the basic wiring is complete the door operation may be tested. It may be helpful to fit an optional Plug-in Beeper module (part No. 850) (Pic 28), which sounds in conjunction with flashes Pic 30 SW1 SAFETY MODE OFF/N/C Pic 28 SW2 STANDARD SAFETY OFF SW3 12V PHOTO-EYE OFF of the Acknowledge LED. The beeper will sound at SW4 AUTO-CLOSE OFF (NOT USED) the start of each door movement and provides SW5 INTERLOCK OVER-RIDE ON audible feedback during programming and door
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DOOR DIRECTION ASSESMENT The motor direction will depend on which side of the shaft the Operator is mounted. In order to assess the correct direction of movement of the door first release the Manual Over-Ride Lever and move the door manually to a half open position. Then re-engage the Manual Over-Ride Lever. Momentarily press the Control Pic 32 unit case lid button. The door should initially run in the OPEN direction and is confirmed by the illumination of the OPENING LED at the top right hand s
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a build up of snow and ice or other surface material or subsidence of the ground surface. If the fully closed position varies significantly over a period of time it may be preferable to complete a new CALIBRATION RESET. If the door is subsequently moved by hand during a power supply failure the speed change points will be automatically re-established following confirmation of the ground position after a complete door cycle Pic 35 in both the open and close directions. After the door has stopped
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direction may be adjusted with the CLOSE SENSITIVITY preset. (Pic 37) Pic 39 If either of the preset controls is adjusted, the compression of the door edge seal will be affected and thus the position of the fully closed door may be different to the calibrated reference. In which Pic 37 case it may be necessary to complete a new If it is required to increase the obstruction Calibration Reset procedure. sensitivity, thus reducing the door edge pressure required to activate the control unit obstruc
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See the wiring diagrams on pages 19 and 20. 12 VOLT TWO WIRE PHOTO-EYE WIRING If two or more Photo-Eyes, or any other safety A 12 volt two wire Photo-Eye may be wired to the devices are fitted then each switching circuit terminals marked at the top of the panel. (Pic 43). should be wired in series. DIP switch No. 3 should be set to the ON position. Wiring diagrams for various types of photo-eye A 24-volt Photo-Eye or other accessory may be units are shown on pages 19 and 20. powered from the 24-
