Series 3 Technicians Installation and Service Training Manual

1 Series 3 Technician s Installation and Service Training Manual ZAP Series 3 Defy All Other Logic ZAP Controls 100 Waterloo Blvd. Anglesey Business Park, Littleworth Road, Cannock, Staffordshire, England UK Contact 011-44-154-387-9444 USA Contact 931-510-4432 USA Tech Support 931-510-4432 via telephone or text Online DT ZAP Controls Series 3 Technician s Installation and Service Training Manual ZAP Controls Series 3 Technician s Installation and Service Training Manual Series 3 Technician s Installation and Service Training Manual Table of Contents Series 3 Technician s Installation and Service Training Manual Table of Contents ZAP Controls 100 Waterloo Blvd.

2 Anglesey Business Park, Littleworth Road, Cannock, Staffordshire, England UK Contact 011-44-154-387-9444 USA Contact 931-510-4432 USA Tech Support 931-510-4432 via telephone or text Online Commercial operator Standard Mounting on a solid torsion shaft 6 Commercial operator Standard Mounting on a hollow torsion shaft 7 Commercial operator Inverted Mounting 8 Commercial operator Rear Mount Torsion Mounting 9 Commercial operator Offset Mounting 10 Commercial operator Front Mount Low Head Room Torsion Mounting 11 Commercial Dead Axle Sheet Door operator Mounting 12 Commercial Live Axle Sheet Door operator Mounting 13 Commercial Compact Dead Axle Sheet Door operator Mounting 14 Bowden Cable and Over-Ride Lever Mounting 15 Setting Belt

3 Tension with the Over-Ride Lever 16 Controller Case Mounting Instruction 17 115V 1 Phase Wiring Instruction 18 208-230V 1 Phase Wiring Instruction 19 480 3 Phase Wiring Instruction 20 Low Voltage Motor Wiring Instruction 21 401002 Photo Cell Mounting Instruction 22 401002 Photo Cell Wiring Instruction 23 840 Internal Receiver Installation 25 Linear Mega-code / Delta 3 Receiver Installation /Wiring Instruction 27 Chamberlain 355LM Receiver Installation and Wiring Instruction 28 Chamberlain 312HM Receiver Installation and Wiring Instruction 29 Chamberlain 365LM Receiver Installation and Wiring Instruction 30 Marantec External Receiver Installation and Wiring Instruction 31 Blue Guard VK/FE Wiring 32 850 Beeper Module Installation 33 8070 Auto-Lock Installation 34 8830 Battery Backup Installation 35 Truck Restraint Wiring Instruction 36 Dock Leveler Interlock Installation 37 Driver Communication Light Control Installation 38 Slave Relay for 115V Dock leveler control circuit interlock 39 Initial operator Set Up 24 ZAP Radio Transmitter Programming 26 Understanding How ZAP Commercial Operators Work 4-5 822 with Advance Warning of Door Closure 40 Interlocking 2 ZAP Controllers in the door open position 41 82 DTLM to Control Accessory ON/OFF Wiring Instruction 42 Door Closed Interlock 43 Interlocking 2 ZAP Controllers in a Sally Port Configuration 44 Through Traffic Light Control Wiring 45 821 Through Traffic Light Control with Advance Warning of Door Closure 46 Additional 3 Button Wall Station 47 Single Contact Device to Cause Cyclic Operation 48 Wiring a single contact device to cause an open function 49 Wiring a single contact device to cause a close

4 Function 50 871 Interface Expansion Module Installation 51 871 Fire Station Module Installation 52 Series 3 Technician s Installation and Service Training Manual Table of Contents Series 3 Technician s Installation and Service Training Manual Notes ZAP Controls 100 Waterloo Blvd. Anglesey Business Park, Littleworth Road, Cannock, Staffordshire, England UK Contact 011-44-154-387-9444 USA Contact 931-510-4432 USA Tech Support 931-510-4432 via telephone or text Online 872 Adapter Module Installation 53 Photo Cell Installation for Constant Pressure Close / Photo Cell to Stop Upon Obstruction 54 Dock Light Wiring 55 Auto-Close Timer Programming 56 Auto-Close Timer Temporary Defeat 57 Delay Close Programming 58 Part Open Programming 59 Close Slow/ Close Fast Programming 60 Service Due Reminder 61 Operations Counter 62 Basic Troubleshooting Symptom Diagnosis 63-64 Basic Troubleshooting Commercial operator (Motor Head)

5 65 Basic Troubleshooting Commercial operator (Controller) 66 Advanced Troubleshooting Commercial operator (Controller) 67-69 Adjusting Potentiometers 70 Performing a Master Reset 71 Performing a Factory Reset 72 24V Troubleshooting 73 Single Contact Control Device Trouble Shooting 74 Additional 3 Button Station Control Device Trouble Shooting 75 ZAP Motor Assembly Service (Belt and Bearing Replacement) 76 ZAP Motor Assembly Service (Bowden Cable Replacement) 77 ZAP Motor Assembly Service (Motor Replacement) 78 Series 3 Technician s Installation and Service Training Manual Understanding How ZAP Commercial Operators Work Series 3 Technician s Installation and Service Training Manual Understanding How ZAP Commercial Operators Work Series 3 Understanding How ZAP Commercial Operators Work ZAP Series 3 Simply Logical ZAP Controls 100 Waterloo Blvd.

6 Anglesey Business Park, Littleworth Road, Cannock, Staffordshire, England UK Contact 011-44-154-387-9444 USA Contact 931-510-4432 USA Tech Support 931-510-4432 via telephone or text Online Unlike traditional operators, ZAP operators do not have limit assemblies. ZAP operators use a 21st century technology, that uses runtime calibration and current sensing technology to perform the functions of limit assemblies. The limits of the door operator are physical in nature. The floor being the down limit. (Figure A) A physical stop for the upper limit. On standard lift and low headroom doors the physical stop is the track radius as the door can only rise so high into the radius before the torsion shaft would have to counter rotate to allow the door to go higher.

7 (Figure B) On high-lift and vertical lift doors it should be a bumper or pusher spring. (Figure C) The controller monitors the motor load current. It therefore becomes a sensor that automatically detects the door limits as well as obstructions that can occur without the use of an aftermarket safety edge. Because of its unique abilities it can detect an obstructions on any part of the door, not just the leading door edge. Speed Change Point Calibration. Calibration of slow speed change point is needed to determine an approximation of the physical limits. During the initial open calibration cycle, the controller is measuring the run time to the upper limit. Approximately half way through the first open cycle of operation, note that the operator will slow down. This slow down is called a speed change point.

8 After completing the first up cycle, the run time to the upper limit is stored into memory. The same thing occurs on the close calibration cycle. Approximately half way through the first close cycle of operation, the operator will again slow down. After completing the first close cycle, the close run time is stored into memory as well and is compared to the open run time. During the second calibration run, the run times are verified against the first set of run times. If they match, they are stored into memory. It takes 2-3 complete cycles to fully calibrate the run time. Once the operator has fully calibrated the run times, the controller moves the opening speed change point to within seconds of the end of the calibrated open run time. Likewise, the controller moves the closing speed change point to within seconds of the end of it s calibrated run time.

9 This is how the controller knows where the limits are and where to stop. Motor power and sensitivity potentiometer, obstruction sensing, automatic reversing and safety stop. Picture if you will, current flowing to the motor. (Figure D) If you increase power at the power potentiometer you open up the range of power that can be applied to the motor. (Figure E) If you decrease power at the power potentiometer it closes the range of power that can be applied to the motor. (Figure F) Inherent safety functions Stop at limit, safety stop, and automatic reversing The inherent safety and sensitivity function s monitor the system by mirroring the motor current.

10 If the door meets an obstruction in either direction, the current spikes. (Figure F) Continued on next page. Figure C Figure B Figure F Figure D Figure E Figure A Figure F 4 Series 3 Technician s Installation and Service Training Manual Understanding How ZAP Commercial Operators Work Series 3 Technician s Installation and Service Training Manual Understanding How ZAP Commercial Operators Work Series 3 Understanding How ZAP Commercial Operators Work ZAP Series 3 Simply Logical ZAP Controls 100 Waterloo Blvd. Anglesey Business Park, Littleworth Road, Cannock, Staffordshire, England UK Contact 011-44-154-387-9444 USA Contact 931-510-4432 USA Tech Support 931-510-4432 via telephone or text Online If the resistance on the door is significant enough to cause the current demand to spike to the setting of the sensitivity Potentiometer (Figure A), it causes a certain function depending upon the direction of door travel and where the door is in it s cycle of operation.