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Zap JACKSHAFT MOTOR-CONTROL SYSTEM 815-RL Installation Instructions Manual

Residential garage doors motor-control system
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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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  Summary of Contents for Zap JACKSHAFT MOTOR-CONTROL SYSTEM 815-RL

  • Page 1: Installation Instructions

    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...
  • Page 3 IMPORTANT INSTALLATION INSTRUCTIONS 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.
  • Page 5: Table Of Contents

    Safety circuit and Photo-Eye wiring ... 14/15 Interlock circuit wiring ... 16 Accessory Radio Receiver wiring ... 16 Programming ... 16 Zap Transmitter code programming ... 17 Auto-Close timer programming ... 18 Wiring diagrams ... 19 Fault Finding Guide ... 22...
  • Page 6: Product Overview

    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. CONTROL UNIT model 800-R Integrated Control unit with case mounted control button. This Control unit will...
  • Page 7: Description

    A significant advantage of the Zap drive system with its fast obstruction sensing, is that when an object obstructs the doors travel, the cables should never jump off the cable drums.
  • Page 8: Fitting The Super-Drive

    (Pic 4) Counterbalance springs will weaken over time and the balance can become biased closed. The Zap obstruction sensing system automatically adjusts to Pic 4 changes in door balance over a period of time.
  • Page 9 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 spacer bush, which should pass through the lower slot in the Cover back. (Pic 7) The Cover back will be secured later.
  • Page 10: Fitting The Manual Over-Ride Lever

    The second Allen screw, set at 90 degrees, should then be tightened and secured with the locknut. Now tighten the torque arm screws (Pic 10) Pic 10 FITTING THE MANUAL OVER-RIDE LEVER MECHANISM The position of the cable post should be assessed next.
  • Page 11 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 on the inside of the track or doorframe.
  • Page 12: Fitting The Control Unit

    FITTING THE CONTROL UNIT Check that the control unit voltage, which is shown on the label on the side of the control unit case, is correct for the available single-phase supply voltage. The control unit model number has a suffix, which relates to the supply voltage.
  • Page 13: Fitting The Motor Cover Kit

    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 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.
  • Page 14: Connecting The Mains Power Supply

    Pic 23 CONNECTING THE MAIN A/C SUPPLY The Operator should be installed in accordance with local codes and national electric code. To reduce the risk of electric shock, this equipment has a grounding type plug that has a third (grounding pin). This plug will only fit into a grounding type outlet.
  • Page 15 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...
  • Page 16: Testing The Door Operation

    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 28 of the Acknowledge LED.
  • Page 17: Door Speed Change Point And Limit Of Travel Calibration

    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.
  • Page 18 Pic 35 After the door has stopped in the fully closed position, press the OPEN push button again. When the door has stopped in the open position – press the button to close the door. Complete another door open and close cycle and confirm that when the door has correctly calibrated the door stops and remains stationary in the fully closed position.
  • Page 19: Safety Circuit And Photo-Eye Wiring

    direction may be adjusted with the CLOSE SENSITIVITY preset. (Pic 37) Pic 37 If it is required to increase the obstruction sensitivity, thus reducing the door edge pressure required to activate the control unit obstruction sensing circuit, which causes the door to stop and re-open during the close fast speed cycle, then the CLOSE SENSITIVITY adjuster should be turned further clockwise.
  • Page 20 The 24-volt accessory supply may be used to power other accessories such as an accessory radio receiver (non Zap). (Pic 41) The maximum current should not exceed 200mA. Pic 41 An Over-Load circuit will trip if the accessory load current exceeds 200mA.
  • Page 21: Interlock Circuit Wiring

    The wiring of a non-Zap accessory radio is shown on pages 17 and 18. A Zap radio receiver model 840 may be fitted in the socket marked “ZAP RADIO” at the top left- hand side of the panel. (Pic 47)
  • Page 22: Zap Transmitter Code Programming

    A Zap radio receiver model 840 may be fitted in the socket marked “ZAP RADIO” at the top left hand side of the panel. (Pic 47 page 15) To program a Zap transmitter code into memory: 1.
  • Page 23: Auto-Close Timer Programming

    If it is required to change the programmed delay then repeat the programming sequence. If a Zap Radio Remote Control system is fitted and the Auto-Close function is enabled then operation of the transmitter will only open the door. The door will close after the programmed time delay.
  • Page 24: Wiring Diagrams

    ZAP 800-R CONTROLLER WIRING – PULSE OPERATION WITH LIFT MASTER 412 HM RADIO  ...
  • Page 25 ZAP 800-R – SAFETY WIRING CONNECTIONS – ZAP PHOTO-EYES !      !                                    ...
  • Page 26 ZAP 800-R – SAFETY WIRING CONNECTIONS – NON-ZAP PHOTO EYES !      !      !      """""""""""""""""""""""""""""                  """""""""""""""""""""""""""""""""...
  • Page 27: Fault Finding Guide

    FAULT REASON & REMEDY The door stops just after it has started in the open direction. The closing door stops and reopens before it contacts the ground. FAULT FINDING GUIDE The door movement is stiff due to the door running tight against the door frame in the fully closed position.
  • Page 28 ZAP CONTROLS UK 100 Waterloo Boulevard Anglesey Business Park Cannock Staffordshire WS12 1NR United Kingdom...