RollSeal RS-500M Installation And Operation Manual
Intrinsically safe barrier door
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Summary of Contents for RollSeal RS-500M
- Page 1 RS-500M/RS-600M Intrinsically Safe Barrier Door Installation and Operation Manual 4801-9003B 8 September 2021...
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Page 2: Table Of Contents
Section 1.1: Definitions of Informational Headings........................... Section 1.2: Scope of Manual................................Section 1.3: Limited Warranty................................Section 1.4: Component Overviews..............................Section 1.4.1: RS-500M/RS-600M ISB Door............................. Section 1.4.2: SC-325M/SC-650M ISB Smart Controller.......................... Section 1.5: Specifications................................... Section 1.6: Dimensions and Installation Requirements........................Section 1.6.1: RS-500M ISB Door................................ - Page 3 Intrinsically Safe Barrier Door Installation and Operation Manual Table of Contents (Continued) Section 5: Troubleshooting............................Section 5.1: Manual Operation Via Crank Handle..........................Section 5.2: P12 Input Status Indicators............................. Section 5.3: Error Codes and Recommended Actions........................Section 5.4: Drive Board Diagnostic LEDs............................Section 5.4.1: Door Idle....................................
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Page 4: Section 1: Introduction
NOTICE: This heading draws attention to specific information. Section 1.2: Scope of Manual NOTICE: This document is subject to change without notice. The latest version is maintained at rollseal.net/rollseal-technicals/. This manual describes the following aspects of the RS-500M ISB/RS-600M ISB automated door: Installation of the door and its components. -
Page 5: Section 1.3: Limited Warranty
No entity has the authority to bind RollSeal to any representation or warranty other than this Limited Warranty. RollSeal shall not be liable for any damages or losses resulting from any application of the Product or caused by any defect, failure, or malfunction of the Product. -
Page 6: Section 1.4: Component Overviews
The RollSeal Intrinsically Safe Barrier (ISB) automated fabric roll-up door is designed to separate differing environments. It is used in Class I Division 2 applications, including industrial finishing. The RS-500M ISB door is manufactured up to 12' W x 12' H, and has a maximum speed of 18"... -
Page 7: Section 1.6: Dimensions And Installation Requirements
Intrinsically Safe Barrier Door Installation and Operation Manual Section 1.6: Dimensions and Installation Requirements Section 1.6.1: RS-500M ISB Door Installation Specifications Door Size Personnel Equipment Tools Time - Forklift Up to 6' W x 9' H ~ 4 Hours - Glasses... -
Page 8: Section 1.6.2: Rs-600M Isb Door
Intrinsically Safe Barrier Door Installation and Operation Manual Section 1.6.2: RS-600M ISB Door Installation Specifications Door Size Personnel Equipment Tools Time Up to 8’ W x 8’ H Ladder ~ 2 Hours 12' W x 12' H - Glasses - Standard Hand Tools - Gloves - Ladder 16' W x 16' H... -
Page 9: Section 1.6.3: Sc-325M Isb/Sc-650M Isb Smart Controller
Intrinsically Safe Barrier Door Installation and Operation Manual Section 1.6.3: SC-325M ISB/SC-650M ISB Smart Controller 4801-9003B 8 September 2021... -
Page 10: Section 2: Installation
Read this manual in its entirety before beginning the procedure. Inspect the contents of the shipping crate for damaged, loose, or missing components. If any components are damaged, loose, or missing, contact your RollSeal distributor immediately. Section 2.2: Adjust Framing and/or Clear Opening Using the appropriate diagram in Section 1.6, determine the required width and height of the clear opening. -
Page 11: Section 2.3: Assemble Tracks (If Over 13' Tall)
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.3: Assemble Tracks (if Over 13' Tall) Tracks taller than 13' must be spliced together as follows: Arrange the top and bottom tracks as shown. Slide the bottom track into the top track so they butt together on the splice bracket and the splice plate. Bolt the tracks together. -
Page 12: Section 2.4: Connect Tracks To Head Unit
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.4: Connect Tracks to Head Unit Each end of the head unit has a U-shaped plate that fits the corresponding track. The plate has four bolt holes (two on the outside and two on the inside) that match the bolt holes in the tracks. -
Page 13: Section 2.5: Mount Door To Clear Opening
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.5: Mount Door to Clear Opening Center the door assembly in front of the clear opening. Align the bottom of each track with the corresponding framing member or post. Ensure the assembly is square and level. Position all workers, forklifts, etc. -
Page 14: Section 2.6: Mount Smart Controller
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.6: Mount Smart Controller Using four screws, mount the Smart Controller next to the top-right corner of the door, at least 3' from the clear opening. Ensure the Smart Controller is not connected to power and the electrical disconnect next to the controller is turned off. Plug the circular plastic connectors (CPCs) from the AC and DC harnesses (located at the bottom of the enclosure on the right side of the head unit) into the receptacles on the bottom of the controller. -
Page 15: Section 2.7: Switches
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.7: Switches NOTICE: RollSeal recommends using a prewired activation switch kit. Open and close signals are wired through intrinsically safe barriers. Other activation devices should be wired through these channels unless classified for use in the operating environment. -
Page 16: Section 2.8: Connect Infrared Safety Beam System
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.8: Connect Infrared Safety Beam System The tracks house an infrared emitter and receiver. If the infrared beam is interrupted (e.g. by a person or a forklift) while closing, the door will stop and reverse to the fully open position. See Section 3.3 for details. The emitter and receiver are set up as follows: Access the electrical enclosure: - If the motor is mounted at the top-right corner of the head unit, locate the enclosure mounted near the motor. - Page 17 Intrinsically Safe Barrier Door Installation and Operation Manual 4801-9003B 8 September 2021...
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Page 18: Section 2.9: Power
Contact RollSeal for details. • The SC-325M ISB Smart Controller and the corresponding RS-500M ISB door can use either a 115VAC or 230VAC power supply. However, the voltage switch is preset to 230VAC, so it must be toggled manually for 115VAC operation. -
Page 19: Section 2.10: Motor Crank Handle
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.10: Motor Crank Handle The motor crank handle is used to manually operate the door in the event of power failure (see Section 5.1). It is installed as follows: - Insert the handle into the two pre-installed mounts on the bottom of the left track. The handle should snap into place. 4801-9003B 8 September 2021... -
Page 20: Section 2.11: Prepare For Operation
Intrinsically Safe Barrier Door Installation and Operation Manual Section 2.11: Prepare for Operation Perform the following steps before operating the door: Apply power to the Smart Controller (see Section 2.9), then turn the disconnect to the On position. Press and hold the Mode button on the Smart Controller for five seconds to engage Program Mode (see Section 3.7.1). "P1"... -
Page 21: Section 3: Operation
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3: Operation Section 3.1: External Switch and Smart Controller The door can be opened and closed using the external switch (during normal operation) or the Smart Controller (if necessary). Press and release the Open or Close button to open or close the door, respectively. If an error prevents the door from functioning, press and hold the button to engage a constant-pressure override. -
Page 22: Section 3.2: Home And Leading Edge Switch
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.2: Home and Leading Edge Switches Two switches are located inside the head unit. The home switch establishes the fully open position of the door, which the encoder uses to generate counts (see Section 3.5) and determine the door's Actual Position (see Section 3.6.1). -
Page 23: Section 3.3: Infrared Safety Beam
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.3: Infrared Safety Beam The infrared emitter installed near the bottom of the door produces a constant, invisible beam that is ordinarily intercepted by the receiver on the opposite track. If this beam is interrupted (e.g. by a person or a forklift) while the door is closing, the door will stop and reverse to the fully open position. -
Page 24: Section 3.6: Smart Controller User Interface
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.6: Smart Controller User Interface Section 3.6.1: Overview The user interface is used to view information and settings on the Smart Controller. It consists of the Display Indicator; four LEDs labeled with their corresponding readings; the Up and Down directional arrows; and the Mode button. Only one reading is shown on the Display Indicator at a time. -
Page 25: Section 3.6.2: Display Indicator Readings
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.6.2: Display Indicator Readings In addition to the toggleable readings defined in Section 3.6.1, the Display Indicator sometimes shows other values that represent the Smart Controller's status. Software Version and Model Number When the Smart Controller is powered on, the Display Indicator flashes the current software version and the model number for approximately two seconds. - Page 26 Intrinsically Safe Barrier Door Installation and Operation Manual Assumed Position When the Smart Controller is powered on, after the software version and model number disappear, the Display Indicator alternates between the Actual Position reading and the Unknown Position notification until the door is activated. This indicates the Smart Controller has assumed the current position of the door.
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Page 27: Section 3.7: Configuration
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.7: Configuration Section 3.7.1: Program Mode Settings defined when the Smart Controller is installed or adjusted are known as program parameters. Each program parameter is assigned a code by which it is identified on the Display Indicator: Program Parameters P1: Close Time Delay P11: Service Reminder... - Page 28 Intrinsically Safe Barrier Door Installation and Operation Manual P4 - Warning Output Function (Default 0; J12-AUX #1 on PCB 201) This parameter can be configured to operate in one of five modes. NOTICE: When P4 is set to 1 or 2, the input's functions are reconfigured for interlock operation and cannot be used normally. - P4 = 0 (Door Movement/Door About to Close) This configures the Warning Output to indicate door movement or warn that the door is about to close.
- Page 29 Intrinsically Safe Barrier Door Installation and Operation Manual P7 - Refresh Door Limits (Default 25) This parameter allows the user to set the number of open and close cycles that must be performed before the door refreshes the Open and Closed Limits (see Section 3.7.4), which may be necessary if the limits desynchronize from the encoder. This parameter can be set between one cycle (i.e.
- Page 30 This parameter determines the period of time (measured in minutes) the J13-AUX #2 relay remains on should the application require it to be switched on and off; P26 dictates the off time. Contact RollSeal Technical Support if this is necessary.
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Page 31: Section 3.7.2: Open And Close Speeds
Intrinsically Safe Barrier Door Installation and Operation Manual PS1 - Change Program Limits This parameter can be set to either "Yes" or "No". To change the Open Limit (PS2) or the Closed Limit (PS3), set this parameter to "Yes", then press the Mode button. To exit Program Mode while this parameter is selected, set PS1 to "No", then press the Mode button;... -
Page 32: Section 3.7.3: Deceleration Range
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.7.3: Deceleration Range The Deceleration Range is the rate at which the door slows down as it approaches the Open Limit or the Closed Limit. The Smart Controller sets the minimum Deceleration Range automatically based on the Open Speed and Close Speed (see Section 3.7.2). The user can increase the time it takes for the door to decelerate by increasing program parameter P3 from the default value of 0 (see Section 3.7.1). -
Page 33: Section 3.9: Door Activation Inputs
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.9: Door Activation Inputs Section 3.9.1: Directional Switch The directional switch input (controlled by program parameter P20; see Section 3.7.1) is primarily used with a three-position directional switch that opens, stops, or closes the door when the corresponding button is pressed. However, the Smart Controller can be programmed to hold the door in the fully open, stopped, or fully closed position when the corresponding button is pressed and held. -
Page 34: Section 3.10: Relay Outputs
Intrinsically Safe Barrier Door Installation and Operation Manual Section 3.10: Relay Outputs The Smart Controller has two relay outputs for internal and external communication, which are controlled by Program Parameters P4 (AUX #1) and P24 (AUX #2), respectively. See Section 3.7.1 for details. Door Open Signal To report a door open signal, use AUX #1 with P4 set to 3. -
Page 35: Section 4: Maintenance
Intrinsically Safe Barrier Door Installation and Operation Manual Section 4: Maintenance Section 4.1: Cleaning and Adjustment Section 4.1.1: Cleaning Panels and (if Present) Window The door panels (and the window, if present) can be cleaned by gently wiping any soiled areas with a cloth and mildly soapy water. Rinse the area with water to remove the solution, then immediately dry the panels using a separate cloth. -
Page 36: Section 4.1.2: Adjusting Panels And Tension Pipes
Intrinsically Safe Barrier Door Installation and Operation Manual Section 4.1.2: Adjusting Panels and Tension Pipes The tension pipes must remain in close proximity to one another (between 1/4" and 1/2") during normal operation. If the tension pipes are too far apart, they will not repel each other, causing poor contact with the floating seal. If the tension pipes touch one another, the panel material will flow unevenly and become wrinkled. -
Page 37: Section 4.2: Component Replacement
Intrinsically Safe Barrier Door Installation and Operation Manual Section 4.2: Component Replacement Section 4.2.1: Panels The door panels can be removed as follows: Engage Jog Mode (Section 3.8), then lower the door until the center panel drive pipe attachment point is visible through the access panel. - Page 38 Intrinsically Safe Barrier Door Installation and Operation Manual 4801-9003B 8 September 2021...
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Page 39: Section 4.2.2: Hook-And-Loop Seal
Intrinsically Safe Barrier Door Installation and Operation Manual Section 4.2.2: Hook-and-Loop Seal The hook-and-loop seal can be replaced as follows: Turn off power to the Smart Controller. Raise the door to its upper limit. Remove the PEM plate nuts from the side of one of the tracks. Remove the PEM plates and the seal assemblies from the tracks. -
Page 40: Section 5: Troubleshooting
Intrinsically Safe Barrier Door Installation and Operation Manual Section 5: Troubleshooting Section 5.1: Manual Operation Via Crank Handle If the door loses power while in operation, it must be opened or closed manually. If the door is open, it can be closed by flipping the lever at the bottom of the motor downward to release the brake. CAUTION: The door will drop as soon as the brake is released. -
Page 41: Section 5.2: P12 Input Status Indicators
Intrinsically Safe Barrier Door Installation and Operation Manual Section 5.2: P12 Input Status Indicators This program parameter is used to service and troubleshoot the door. The inputs are represented by LED segments on the Display Indicator. If an LED segment is on, the corresponding switch is closed. If the segment is off, the switch is open. Important P12 status indicators are as follows: For the door to close, the Primary Safety and Leading Edge segments must be off. -
Page 42: Section 5.3: Error Codes And Recommended Actions
Intrinsically Safe Barrier Door Installation and Operation Manual Section 5.3: Error Codes and Recommended Actions Code Condition Movement Problem Area Recommended Action(s) Opening; Home Switch Tripped Check wiring. Ensure home switch is fully Home Switch pressed. Closing; Home Switch Tripped Opening;... -
Page 43: Section 5.4: Drive Board Diagnostic Leds
Intrinsically Safe Barrier Door Installation and Operation Manual Section 5.4: Drive Board Diagnostic LEDs The drive's condition is indicated by a pair of LEDs (Power ["PWR"] and Status ["ST"]) on the drive board. The LEDs may remain solid, flash slowly (on one second; off one second), or flash quickly (on 0.25 seconds; off 0.25 seconds). Section 5.4.1: Door Idle Power LED Status LED... -
Page 44: Section 5.5: Testing Brake Relay
Press and immediately release the button near the bottom right of the board. Listen for a clicking sound coming from the brake, and watch for the panel to drop, to verify the relay is functioning properly. If the conditions in Step 3 are not met, contact RollSeal Technical Support. 4801-9003B... -
Page 45: Section 6: Diagrams
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6: Diagrams Section 6.1: Door Internal Wiring 4801-9003B 8 September 2021... -
Page 46: Section 6.2: Smart Controller
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2: Smart Controller Section 6.2.1: Layout 4801-9003B 8 September 2021... -
Page 47: Section 6.2.2: Internal Wiring
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2.2: Internal Wiring 4801-9003B 8 September 2021... -
Page 48: Section 6.2.3: Interlocking Two Doors
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2.3: Interlocking Two Doors 4801-9003B 8 September 2021... -
Page 49: Section 6.2.4: Connecting Two-Button Switches
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2.4: Connecting Two-Button Switches NOTICE: RollSeal recommends using a prewired activation switch kit. Open and close signals are wired through intrinsically safe barriers. Other activation devices should be wired through these channels unless classified for use in the operating environment. -
Page 50: Section 6.2.5: Connecting Other Switches
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2.5: Connecting Other Switches NOTICE: RollSeal recommends using a prewired activation switch kit. Open and close signals are wired through intrinsically safe barriers. Other activation devices should be wired through these channels unless classified for use in the operating environment. -
Page 51: Section 6.2.6: Connecting Remote Receiver
Intrinsically Safe Barrier Door Installation and Operation Manual Section 6.2.6: Connecting Remote Receiver 4801-9003B 8 September 2021... -
Page 52: Section 7: Accessories
Intrinsically Safe Barrier Door Installation and Operation Manual Section 7: Accessories Section 7.1: Passive Infrared Motion Sensor The Passive Infrared Motion Sensor requires both heat and motion to activate the switch, eliminating the false triggers that commonly affect motion-only sensors. The sensor has a small footprint and can be mounted in multiple locations on and around the door. -
Page 53: Section 8: Replacement Parts
Intrinsically Safe Barrier Door Installation and Operation Manual Section 8: Replacement Parts Section 8.1: General 4801-9003B 8 September 2021... - Page 54 Intrinsically Safe Barrier Door Installation and Operation Manual Callout Part Number Description Based on Size Gear Motor 1903-3109 Leading Edge Switch/Harness 1903-3125 Home Switch/Harness 6540-0089 Hall Effect Encoder Based on Size Smart Controller (See Section 8.2 for sub-assemblies.) 6450-9007 Infrared Safety Beam Emitter/Receiver Based on Size Floating Seal Based on Size...
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Page 55: Section 8.2: Smart Controller
Intrinsically Safe Barrier Door Installation and Operation Manual Section 8.2: Smart Controller Callout Part Number Description 6407-0615 Door Control Board 6407-6086 Drive Board 6407-6088 Brake Module (if Equipped) 3001-7018 Disconnect Switch 6407-1724 PCB 207 3015-3102 Two-Channel Intrinsic Barrier Assembly 1903-6146 Audible Alarm Buzzer/Harness 4801-9003B 8 September 2021... -
Page 56: Section 9: Warnings/Avertissements
Intrinsically Safe Barrier Door Installation and Operation Manual Section 9: Warnings/Avertissements WARNING/AVERTISSEMENT All wiring must be in accordance with national electrical codes as well as any applicable local codes. Tout le câblage doit être conforme aux codes électriques nationaux ainsi qu'à tous les codes locaux applicables. WARNING/AVERTISSEMENT The drive is intended for incorporation into electrical control systems or machines. - Page 57 Intrinsically Safe Barrier Door Installation and Operation Manual WARNING/AVERTISSEMENT The door assembly contains dangerous rotating machinery! Keep hands, clothing, etc. clear during operation. Do not operate the door unless all guards and covers are in place. Le système contient des machines tournantes dangereuses! Gardez les mains, les vêtements, etc. dégagés pendant le fonctionnement.
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