RollSeal RS-500 5K Installation And Operation Manual
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RollSeal RS-500 5K Installation And Operation Manual

Walk-in cooler door
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RS-500 5K Walk-In Cooler Door
Installation and Operation Manual
4801-5164J
1
20 October 2021

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  • Page 1 RS-500 5K Walk-In Cooler Door Installation and Operation Manual 4801-5164J 20 October 2021...

  • Page 2: Table Of Contents

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Table of Contents Section 1: Introduction............................Section 1.1: Definitions of Informational Headings........................... Section 1.2: Scope of Manual................................Section 1.3: Limited Warranty................................Section 1.4: Components..................................Section 1.4.1: RS-500 Walk-In Cooler Door............................. Section 1.4.2: Smart Controller................................
  • Page 3 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Table of Contents (Continued) Section 5: Troubleshooting............................Section 5.1: Emergency Manual Operation............................Section 5.2: P12 Input Status Indicators............................. Section 5.3: Error Codes and Recommended Actions........................Section 5.4: Smart Controller/Smart Switch Error Indicators......................

  • 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 RollSeal RS-500 automated walk-in cooler 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: Components

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 1.4: Components Section 1.4.1: RS-500 Walk-In Cooler Door RS-500 Walk-In Cooler (WIC) automated fabric roll-up doors are designed to separate differing environments. They are used in various applications, including cold storage and environmental rooms. RS-500 WIC doors are manufactured up to 6' W x 9' H, have a maximum speed of 27"...
  • Page 7 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Technical Specifications Power Supply 115VAC; 50/60 Hz; Single-Phase or 230VAC; 50/60 Hz; Single-Phase Temperature Range 32°F to 115°F (0°C to 46°C) Input 10A at 115VAC; Single-Phase or 6A at 230VAC; Single-Phase Operational Power 3A at 115VAC;...

  • Page 8: Section 1.4.2: Smart Controller

    Section 1.4.2: Smart Controller The Smart Controller is manufactured specifically for the RollSeal automated door. Located inside the head unit, it uses internal safety devices, in conjunction with components of the door assembly, to open and close the door automatically. The Smart Controller can also manage the opening and closing speeds of the door, count the number of door cycles, and provide status information for remotely monitoring the door's position.

  • Page 9: Section 1.5: Dimensions

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 1.5: Dimensions 4801-5164J 20 October 2021...

  • Page 10: Section 2: Installation

    Section 2.1: Preliminary Steps 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. Installation Requirements...
  • Page 11 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Standard Diagonal Dimensions for Squaring Opening 6' H 6.5' H 7' H 7.5' H 8' H 8.5' H 9' H 3' W 80-4/8" 85-7/8" 91-3/8" 96-7/8" 102-4/8" 108-1/8" 113-7/8" 3.5' W 83-3/8"...

  • Page 12: Section 2.3: Connect Tracks To Head Unit

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.3: Connect Tracks to Head Unit Remove the cover from the head unit by releasing the two latches at the bottom, removing the Phillips-head screws as needed, then pushing the cover upward. Set the cover aside.

  • Page 13: Section 2.4: Mount Door To Clear Opening

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.4: Mount Door to Clear Opening Ensure the door assembly is lying face-down with the bottoms of the tracks perpendicular to the bottom of the clear opening. Slowly lift the head unit until it is upright.
  • Page 14 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Hex-drive Rivet Self-tapping Screw/Stitch Screw (Metal) Wood Screw (Wood) Hex-drive Rivet Concrete Anchor 4801-5164J 20 October 2021...

  • Page 15: Section 2.5: Install Egress Track System

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.5: Install Egress Track System NOTICE: The left and right egress tracks are not interchangeable. A flange on each track is punched with the door height, followed by either the letter "L" (left) or the letter "R" (right). For example, the image below depicts the left egress track for a 9' door.
  • Page 16 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Track Tab Engaged Open in Slot Track Installed and in Fully Open Position 4801-5164J 20 October 2021...

  • Page 17: Section 2.6: Install Switches And Infrared Safety Beam

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.6: Install Switches and Infrared Safety Beam System Section 2.6.1: Interior Wave Switch Drill a 1" hole in the wall in line with the 1" hole in the back of the right track, approximately 4' above the floor.

  • Page 18: Section 2.6.2: Infrared Safety Beam System And Exterior Smart Switch

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.6.2: Infrared Safety Beam System and Exterior Smart Switch Locate the three-wire harness inside the head unit between the motor and the Smart Controller. Route the harness under the motor, through the grommet on the left end plate, and through the large holes in the braces on the left track, then plug it into the safety beam connector.
  • Page 19 RS-500 5K Walk-In Cooler Door Installation and Operation Manual 20-pin Connector Rear Prewired Switch Harness 4-pin Connector for IR Safety Sensor 4801-5164J 20 October 2021...

  • Page 20: Section 2.7: Connect Power To Door

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.7: Connect Power to Door WARNING Do not turn the power on until the following conditions have been met: • All wire and cable connections are completed. • The voltage selection switch is set to match the required supply voltage.

  • Page 21: Section 2.8: Install Power Disconnect

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.8: Install Power Disconnect Plug the CPC from the disconnect into the receptacle on the right track. The CPC is keyed so it cannot be inserted incorrectly. Once the pins are engaged, push the CPC and twist the outer ring clockwise to lock it in place.

  • Page 22: Section 2.9: Prepare For Operation

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 2.9: Prepare for Operation Apply 115VAC or 230VAC to the Smart Controller (as appropriate), then turn the rocker switch to the On position. Press and hold the Mode button on the Smart Controller for five seconds to engage Program Mode (see Section 3.8.1).

  • Page 23: Section 3: Operation

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3: Operation Section 3.1: Activating Door Section 3.1.1: Switches and Smart Controller The door can be opened and closed using the Smart Switch or the Smart Controller. Press and release the Open or Close button on either the Smart Switch or the Smart Controller to open or close the door, respectively.

  • Page 24: Section 3.2: Egress Track System

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.2: Egress Track System The Egress Track System allows the door to be opened manually from the inside in case of a power outage or other malfunction. The "Emergency Exit" label will face you as you use the system.

  • Page 25: Section 3.3: Home And Auxiliary Safety Sensors; Leading Edge Switch

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.3: Home and Auxiliary Safety Sensors; Leading Edge Switch The home sensor, located inside the controller enclosure, establishes the fully open position of the door, which the encoder uses to generate counts (see Section 3.6) and determine the door's Actual Position (see Section 3.7.1). If the home sensor detects the panel, the corresponding segment on the Display Indicator will be illuminated (see Section 5.2).

  • Page 26: Section 3.4: Infrared Safety Beam

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.4: 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. 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 27: Section 3.5: Power Switch

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.5: Power Switch The power rocker switch is located on the face of the Smart Controller. The switch controls power to both the Smart Controller and the door. Section 3.6: Communication Between Smart Controller and Door The head unit houses an encoder that sends electrical pulses to the Smart Controller when the door is moving and the controller is in the normal operating mode.

  • Page 28: Section 3.7: Smart Controller User Interface

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.7: Smart Controller User Interface Section 3.7.1: 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 the corresponding readings;...

  • Page 29: Section 3.7.2: Display Indicator Readings

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.7.2: Display Indicator Readings In addition to the toggleable readings defined in Section 3.7.1, 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 30 RS-500 5K Walk-In Cooler 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.

  • Page 31: Section 3.8: Configuration

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.8: Configuration Section 3.8.1: 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:...
  • Page 32 RS-500 5K Walk-In Cooler 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.
  • Page 33 RS-500 5K Walk-In Cooler 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 3.8.4), which may be necessary if the limits desynchronize from the encoder. This parameter can be set between one cycle (i.e.
  • Page 34 RS-500 5K Walk-In Cooler Door Installation and Operation Manual P21 - Input Switch Response (Default 0) This parameter can be configured to operate in either of the following modes: - P21 = 0 (Momentary) In this mode, the Open/Close switch can be pressed once and then released to activate the door.
  • Page 35 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.

  • Page 36: Section 3.8.2: Opening And Closing Speeds

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.8.2: Open and Close Speeds The speeds at which the door opens and closes can be adjusted as follows: Press the Mode button until Open Speed is selected. Use the Up and Down arrow buttons to adjust the set a value between 20% and 100%.

  • Page 37: Section 3.8.3: Deceleration Range

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.8.3: 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 3.8.2). 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 3.8.1).

  • Page 38: Section 3.10: Door Activation Inputs

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 3.10: Door Activation Inputs Section 3.10.1: Directional Switch The directional switch input (controlled by program parameter P20; see Section 3.8.1) 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 39: Section 4: Maintenance

    RS-500 5K Walk-In Cooler 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.

  • Page 40: Section 4.2: Component Replacement

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 4.2: Component Replacement Section 4.2.1: Egress Tracks The egress tracks can be removed as follows: Raise the door to the fully open position. Open the head unit cover, then engage the stand.

  • Page 41: Section 4.2.2: Panels

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 4.2.2: Panels The door panels can be removed as follows: Ensure the door is fully closed. Open the head unit cover and engage the stand, or remove the cover entirely for easier access.
  • Page 42 RS-500 5K Walk-In Cooler Door Installation and Operation Manual The new panels can be installed as follows: Unroll the replacement panels. The front and back panels are made of a white anti-static material, whereas the center panel is made of a clear material. The hook-and-loop fastener on the panels must face outward.

  • Page 43: Section 5: Troubleshooting

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 5: Troubleshooting Section 5.1: Emergency Manual Operation If the door loses power while in operation, it must be opened or closed manually. Open the head unit cover, then engage the stand.

  • Page 44: Section 5.2: P12 Input Status Indicators

    RS-500 5K Walk-In Cooler 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.

  • Page 45: Section 5.3: Error Codes And Recommended Actions

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 5.3: Error Codes and Recommended Actions Code Condition Movement Problem Area Recommended Action(s) Opening; Home Sensor Tripped Ensure harness connectors are secured and Home Sensor sensor is not obstructed. Closing; Home Sensor Tripped Opening;...

  • Page 46: Section 5.4: Smart Controller/Smart Switch Error Indicators

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 5.4: Smart Controller/Smart Switch Error Indicators The error indicator LEDs to the left of the Open and Close buttons on the Smart Controller and Smart Switch are used to troubleshoot door issues, display the door's operational status, and warn personnel of door movement.

  • Page 47: Section 5.5: Drive Board Diagnostic Leds

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 5.5: 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).

  • Page 48: Section 5.6: 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. 4801-5164J...

  • Page 49: Section 6: Wiring Diagrams

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 6: Wiring Diagrams Section 6.1: Switch Card and Safety Beams 4801-5164J 20 October 2021...

  • Page 50: Section 6.2: Head Unit

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 6.2: Head Unit 4801-5164J 20 October 2021...

  • Page 51: Section 6.3: Remote Receiver

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 6.3: Remote Receiver 4801-5164J 20 October 2021...

  • Page 52: Section 7: Accessories

    RS-500 5K Walk-In Cooler 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

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 8: Replacement Parts Section 8.1: General 4801-5164J 20 October 2021...
  • Page 54 RS-500 5K Walk-In Cooler Door Installation and Operation Manual Callout Part Number Description Based on Size Head Unit Cover 3001-1570 Leading Edge Switch 0401-17603 Left Top Bar Cover End 1903-6155 Hall Effect Encoder/Harness 3017-5081 1/6 HP Motor 0401-17604 Right Top Bar Cover End...

  • Page 55: Section 8.2: Smart Controller

    RS-500 5K Walk-In Cooler Door Installation and Operation Manual Section 8.2: Smart Controller Callout Part Number Description 1903-6167 Fixed-field Home Sensor/Harness 1903-6141 Auxiliary Safety Sensor/Harness 1903-6146 Audible Alarm Buzzer/Harness 6407-6091 KBVF-22D Drive Board 6407-0617 PCB 201 Assembly 3001-7016 Power Rocker Switch...

  • Page 56: Section 9: Warnings/Avertissements

    RS-500 5K Walk-In Cooler 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.
  • Page 57 RS-500 5K Walk-In Cooler 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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