RYTEC Plexline PL5000 Owner's Manual
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RYTEC Plexline PL5000 Owner's Manual

RYTEC Plexline PL5000 Owner's Manual

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R
Y
T
E
C
®
Plexline
Owner's Manual
P.O. Box 403, One Cedar Parkway, Jackson, WI 53037
Phone: 262-677-9046
Fax: 262-677-2058
Rytec Website:
www.rytecdoors.com
Rytec On-line store:
www.rytecparts.com
Rytec E-mail:
helpdesk@rytecdoors.com
Parts E-mail:
parts@rytecdoors.com
[Revision: AA (2017-08-03), R1160103-0, ©Rytec Corporation 2010]

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Summary of Contents for RYTEC Plexline PL5000

  • Page 1 ® Plexline Owner’s Manual P.O. Box 403, One Cedar Parkway, Jackson, WI 53037 Phone: 262-677-9046 Fax: 262-677-2058 Rytec Website: www.rytecdoors.com Rytec On-line store: www.rytecparts.com Rytec E-mail: helpdesk@rytecdoors.com Parts E-mail: parts@rytecdoors.com [Revision: AA (2017-08-03), R1160103-0, ©Rytec Corporation 2010]...
  • Page 3 PLEXLINE PL5000 & PL5500 LIMITED WARRANTY Rytec Corporation (“Seller”), an Illinois corporation with its principal place of business at One Cedar Parkway, PO Box 403, Jackson, WI 53037, warrants to the original registered end-user commercial purchaser (“Buyer”) that the Plexline® PL5000 & PL5500 (“Product”) sold to the Buyer will be free of...
  • Page 4 Limited Warranty Void. This Limited Warranty shall be void in its entirety if: a. The Product is modified in a manner not approved in writing by Seller; or b. Buyer fails to maintain the Product in accordance with instructions contained in the Owner’s Manual for the Product. © Rytec Corporation 12.12.2012...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PAGE INTRODUCTION ..................... 1 HOW TO USE MANUAL ....................1 DOOR SERIAL NUMBER(S) ..................1 GENERAL ARRANGEMENT OF DOOR COMPONENTS ..........1 OPERATION ......................2 OPERATING CONTROL SYSTEM ................2 PHOTO EYES ........................2 BOTTOM BAR ASSEMBLY ..................2 Breakaway Capability ....................2 IMPACT ........................2 REPAIR (RETURN TO OPERATING POSITION) ..........
  • Page 6 PARTS LIST ......................27 PARTS ORDERING INFORMATION ................27 How to Order Parts ....................27 Substitute Parts ...................... 27 Return of Parts ......................27 RYTEC TECHNCIAL KNOWLEDGE CENTER ............27 SIDE COLUMN ......................28 SIDE COLUMN W/BRAKE & COUNTERWEIGHT ............30...
  • Page 7 TABLE OF CONTENTS PAGE SIDE COLUMN – COUNTERWEIGHT ................. 31 REAR SPREADER — BRUSH SEAL ................32 REAR SPREADER — ANTENNA HARDWARE & ENCODER ........33 MOTOR ASSEMBLY ....................34 DRUM ASSEMBLY ...................... 35 BOTTOM BAR ASSEMBLY ..................36 HOOD ASSEMBLY ...................... 38 PHOTO EYES ......................

  • Page 9: Introduction

    & match the serial numbers of UNDERSTAND THE INSTRUCTIONS CONTAINED all the components for each door (i.e. control IN THIS MANUAL. panel, side columns, drive assembly, etc.). If you have any questions contact your Rytec Failure this will void representative or call the Rytec Technical Support manufacturer’s warranty and may lead to...

  • Page 10: Operation

    IMPACT OPERATING CONTROL SYSTEM Plastic tabs mounted at each end of the bottom bar The Plexline door is equipped with the Rytec System pro- vide adequate strength to keep the assembly in 4 Drive & Control, a solid-state, microprocessor- contact with the side columns during normal based control system designed exclusively to operation.

  • Page 11: Reversing Edge

    OPERATION-POWER DRIVE SYSTEM POWER DRIVE SYSTEM Bottom Bar Assembly The Plexline power drive system consists of an electric motor/brake assembly, reduction gear assembly, and encoder. The standard Plexline is equipped with a variable-speed motor. The control system will vary the door speed depending on door position.

  • Page 12: Move The Door Manually

    OPERATION-MOVE THE DOOR MANUALLY Figure 8 Lower Door with Hand Crank MOVE THE DOOR MANUALLY IMPORTANT: The following instructions may also be used in case of a power outage. When the power is If the Plexline has a counterweight, the restored and the disconnect is not door panel will be upward biased.

  • Page 13: Raise Door With Hand Crank

    OPERATION-MOVE THE DOOR MANUALLY 3. Pull down and hold the manual brake release to disengage the brake. Using the crank, hand turn the motor shaft to raise the door to the desired height. (See Figure 9) 4. Let go of the manual brake release to fully Motor Hand engage the brake.

  • Page 14: Raise Door With Manual Brake Release

    PLANNED MAINTENANCE-RECOMMENDED SCHEDULE PLANNED MAINTENANCE RECOMMENDED SCHEDULE Daily Quarterly Motor Hand Damage Inspection Brake Release Door Operation Motor Hand Reversing Edge Inspection Crank Mounting Photo Eye Inspection Location Mounting Hardware Inspection Fabric Inspection Door Limit Inspection Motor Brake Inspection A9800034 Bottom Bar Inspection Figure 10 Kill Switch Inspection...

  • Page 15: Door Operation

    PLANNED MAINTENANCE—DAILY INSPECTION Door Operation Run the door through four or five complete cycles to ensure that the door is operating smoothly and effi- Personnel being used for this inspection ciently and that binding or unusual noises do not should not be in the path of the door panel exist.

  • Page 16: Encoder Hardware

    PLANNED MAINTENANCE-QUARTERLY INSPECTION ENCODER HARDWARE Mounting Hardware Side Mounting Columns Hardware Photo Lower Anchors Middle Anchors Power Drive A9800039, A9800040 System A7500314 Figure 15 Figure 13 BEARING BLOCK HARDWARE SIDE COLUMN HARDWARE Check All Hardware Anchors A9800041 A9800015 Figure 14 Figure 16 Fabric Inspection 1.

  • Page 17: Door Limit Inspection

    Enclosed in A7500195 Wind Rib Figure 18 2. If the reversing edge does not seal properly against the floor, see the Rytec System 4 Drive & Control A9800042 Installation & Owner’s Manual for adjustment Figure 17 procedure. 3. Check the vision panel for clarity. Clean or replace OPEN LIMIT the panel as required.

  • Page 18: Motor Brake Inspection

    PLANNED MAINTENANCE—QUARTERLY INSPECTION To check the kill switch assembly, proceed as follows: 2. If the panel does not stop in the proper location, see the Rytec System 4 Drive & Control Installation & Owner’s Manual for adjustment procedure. Motor Brake Inspection...

  • Page 19: Weather Seal Inspection

    PLANNED MAINTENANCE-QUARTERLY INSPECTION Weather Seal Inspection HEADER ASSEMBLY Inspect the header weather seal for wear or damage. (See Figure 24) Replace if necessary. (See “BRUSH and WEATHER SEAL(S)” on page 24) Grease Fitting Flanged Bearing Assembly A9800015 Figure 22 2. Motor Gearbox Assembly: The motor gearbox is filled with synthetic oil, which does not need to be changed but should be checked regularly for proper oil level.

  • Page 20: Electrical Connection Inspection

    ADJUSTMENTS DOOR OPEN- AND CLOSE-LIMIT POSITIONS See the Rytec System 4 Drive & Control Installation & Owner’s Manual for the proper procedure for adjusting 3 in. the open and close door limits. The open- and close-limit door positions are detailed below.

  • Page 21: Pneumatic Reversing Edge Switch Adjustment

    ADJUSTMENTS-PNEUMATIC REVERSING EDGE SWITCH ADJUSTMENT PNEUMATIC REVERSING EDGE SWITCH 3. The air bleed has been set at the factory and ADJUSTMENT should not require adjustment. To check the air bleed, turn the air bleed adjustment screws, located on the front and back of the switch, fully clockwise but do not overtighten.

  • Page 22: Pneumatic Kill Switch Adjustment

    ADJUSTMENTS-PNEUMATIC KILL SWITCH ADJUSTMENT the same side as the door motor. (See Figure 32) Reversing Remove Edge Switch Wires and (On Side Resistor to Opposite Test and Door Motor) Adjust Switch Access Cover Resistor Bottom Sensitivity Assembly A9800046 Adjustment Screw Figure 32 A7500317 Kill Switch Air Bleed Check...

  • Page 23: Photo Eye Adjustment

    Plexline door. If less sensitivity is required, 3. Adjust the photo eyes on the rear side of the door contact the Rytec Technical Support Department at as required, depending on the type of mounting 800-628-1909 before any adjustments are made.

  • Page 24: Replacement Procedures

    REPLACEMENT PROCEDURES-COUNTERWEIGHT STRAP Dust Cover All retaining nuts and air gap must be equally set throughout the entire circumference of the brake, or the parts will wear unevenly. Dust Cover Retaining Bolts A7500245 Figure 37 Feeler Gauge 3. Remove sealing band. (See Figure 38 ) Checking Brake Air Gap A7700048...
  • Page 25 REPLACEMENT PROCEDURES-COUNTERWEIGHT STRAP 4. Remove side column cover. (See Figure 41) IMPORTANT: When unwinding the counter- weight strap, keep track of how NOTE: The door many times the strap is wrapped panel has been Idler around the counterweight strap removed for clarity. Pulley spool.

  • Page 26: Idler Pulley

    REPLACEMENT PROCEDURES—IDLER PULLEY IDLER PULLEY If you have any questions, con- tact your Rytec representative or call the Rytec Technical Support Department 800-628-1909. Always refer to the serial number of the door when calling the rep- There is potential for damage to the prod-...

  • Page 27: Non-Drive Bearing

    REPLACEMENT PROCEDURES—NON-DRIVE BEARING 5. Lift and support the counterweight. NOTE: The counterweight should be supported high enough in the side column for the The disconnect must be in the OFF posi- strap to clear the idler pulley. tion and properly locked and tagged 6.

  • Page 28: Motor/Gearbox

    REPLACEMENT PROCEDURES—MOTOR/GEARBOX NOTE: If you have any questions, contact your Rytec representative or call the Rytec Technical Support Department at 800- 628-1909. If the procedure is not followed as described, the potential for damage to the 8. Prior to bearing installation, use emery cloth to...
  • Page 29 REPLACEMENT PROCEDURES-MOTOR/GEARBOX NOTE: The counterweights should be blocked high enough for the strap to clear the idler pulley in the head. Side Column Cover Hood Piece End Cap Assembly A9800047 Figure 50 A9800034 4. Remove encoder assembly from the gearbox. Figure 52 (See Figure 51) 7.
  • Page 30 Replace as necessary. (See Figure 55) 16. Inspect shaft end for any wear and tear. NOTE: If you have any questions, contact your Rytec representative or call the Rytec Technical Support Department at 800- 628-1909. 17. Prior to installation use emery cloth to clean shaft end.
  • Page 31 REPLACEMENT PROCEDURES-MOTOR/GEARBOX NOTE: The motor/gearbox assembly is extremely Motor Mounting heavy. The use of a mechanical lift or Bracket another co-worker would be required for this procedure. 20. Using the lift, raise the door panel assembly back into position above the side columns. 21.

  • Page 32: Brush And Weather Seal(S)

    REPLACEMENT PROCEDURES—BRUSH AND WEATHER SEAL(S) NOTE: When the motor/gearbox is replaced, the encoder must be removed. Most likely the Counterweight encoder position will change, and when Capscrews Strap power is reapplied, the control system will not recognize the original position. The limits will have to be reset.

  • Page 33: Side Column And Cover

    REPLACEMENT PROCEDURES-BRUSH AND WEATHER SEAL(S) 5. Install the new seal in reverse order of removal. Bottom Bar Assembly 6. Install the hood pieces. 7. Restore power to the door and return door back to service. Side Column and Cover There is potential for damage to the product Side Column or property damage, if the procedure is not Assembly...

  • Page 34: Wear Strip(S)

    REPLACEMENT PROCEDURES-WEAR STRIP(S) NOTE: The above illustration shows the front side Bottom Bar of the door. Left and right are determined Assembly when viewing the front side of the door. 6. Install the new seal in the same manner as the old one was removed.

  • Page 35: Parts List

    PARTS LIST—PARTS ORDERING INFORMATION PARTS LIST Return of Parts Rytec will not accept the return of any parts unless PARTS ORDERING INFORMATION they are accompanied by a Return Merchandise How to Order Parts Authorization (RMA) form. 1. Identify the parts required by referring to the...

  • Page 36: Side Column

    PARTS LIST—SIDE COLUMN SIDE COLUMN Screw, 3/8-16 x 1.25 Weldment, Side Column, LH HHCS, SS Part #R1160011-1 Part #RS550014 Weldment, Side Column, RH Part #R1160011-2 Nut, 3/8-16 Serr. Flg. Hex Lock, SS Washer, Flat, 3/8, SS Part #S553229 Part #RS021035 Assembly, Idler Pulley, Part #R1160039- Req’d.
  • Page 37 PARTS LIST—SIDE COLUMN SIDE COLUMN Screw, #8 x 1-½” Lng, Phil Flat Hd, Sheet Mtl, SS Part #S021801 (Use w/ WeatherSeal) Weatherseal, 1-⅜” Wht Part #R0007744 Side Column Assy. with Counterweight Option Screw, #8 x 1-½” Lng, Phil Flat Hd, Sheet Mtl, SS Part #S021801 (Use w/ WeatherSeal) Set Screw, M6-1.0 x...

  • Page 38: Side Column W/Brake & Counterweight

    PARTS LIST—SIDE COLUMN W/BRAKE & COUNTERWEIGHT SIDE COLUMN W/BRAKE & COUNTERWEIGHT Bolt, 3/8-16 x 2.00, SS Part #RS021641 Washer, Split Lock, 3/8, SS Part #RS554225 Washer, Flat, 3/8, SS Part #RS021035 Clamp Plate, Counterweight Part #RS703418 ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 39: Side Column - Counterweight

    PARTS LIST— COUNTERWEIGHT SIDE COLUMN – COUNTERWEIGHT ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 40: Rear Spreader - Brush Seal

    PARTS LIST—REAR SPREADER — BRUSH SEAL — REAR SPREADER BRUSH SEAL Reference Part #R1160096-0 ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 41: Rear Spreader - Antenna Hardware & Encoder

    PARTS LIST—REAR SPREADER — ANTENNA HARDWARE & ENCODER REAR SPREADER — ANTENNA HARDWARE & ENCODER Antenna, Part of Wireless Encoder, Part #R00142058 Not sold Separately. Ratchet Fastener, Black Screw, #10-24 x ½”, SS P/N #R5550264-0 Part #RS550317 ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 42: Motor Assembly

    PARTS LIST—MOTOR ASSEMBLY MOTOR ASSEMBLY ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 43: Drum Assembly

    PARTS LIST – DRUM ASSEMBLY DRUM ASSEMBLY Nut, 3/8-16 Serr Flg, SS, Washer, Flat, 3/8, SS, Part #RS553229 Part #RS021035 Assy, Drum/Pnl/Mtr, Non-Counterweighted Part #R1160033-1X (Shown) Bearing Assembly, Part #RS0704145 Screw, 3/8-16 x 1-1/4”Lng, SS Part #RS550014...

  • Page 44: Bottom Bar Assembly

    PARTS LIST—BOTTOM BAR ASSEMBLY BOTTOM BAR ASSEMBLY Bottom Bar Assembly Requires Door serial # to order. LH Drive Reference Assemblies #R1160142-1 or #R1160249-1 (SS) RH Drive Reference Assemblies #R1160142-2 or #R1160249-2 (SS). ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...
  • Page 45 PARTS LIST—BOTTOM BAR ASSEMBLY BOTTOM BAR ASSEMBLY Washer, #8 Split Lock Part #R5550045-0Z01 Screw, PPMS #6-32 x ⅜” Lng Part #R5550045-0Z01 Battery Holder, “D” Cell Part #R00111192 Cover, Bottom Bar Part #R1060061-0Z01 Potted Mobile Unit (Ref) Part #R1210463-0 Battery, Wireless “D” w/ Tabs Screw, ¼-20 x ⅜”...

  • Page 46: Hood Assembly

    PARTS LIST—HOOD ASSEMBLY HOOD ASSEMBLY ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 47: Photo Eyes

    PARTS LIST— PHOTO EYES PHOTO EYES ALWAYS INCLUDE SERIAL NUMBER OF DOOR WHEN PLACING ORDER Due to product enhancement, the actual parts on your door may be different from those shown in this manual...

  • Page 48: Common Spare Parts

    PARTS LIST – Common Spare Parts COMMON SPARE PARTS R0211397 Air Pressure Switch R00111193 Battery Wireless R0012242 Falcon Motion Detector R0012867 IS40 Motion/Presence sensor R0012145 BEA Universal Remote R0012210 Pull Cord/Wall Switch R00121002 Pushbutton, Black Mushroom R1160153-0 Photo Eye, Telco SMT3000C SG T3, Transmitter R1160145-0 Photo Eye Telco SMR3215 SG T3, Receiver R1160059-0A00 Photo Eye, Cable 10 Meters Long R1160059-0B00 Photo Eye, Cable 15 Meters Long...
  • Page 49 NOTES...
  • Page 50 NOTES...

This manual is also suitable for:

Plexline pl5500

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