Lift-master FDC User Manual

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Page 1

OWNER’S MANUAL

LISTED DOOR OPERATOR

41B6

LMPLC CONTROL

MODEL FDC

ADVANCED LOGIC

INDUSTRIAL DUTY FIRE DOOR OPERATOR

US PATENT NO. 6,014,307

LMPLC

CONTROL WIRED

B2 Wiring

2 YEAR WARRANTY

Serial #

(located on electrical box cover) Installation Date Wiring Type

NOT FOR RESIDENTIAL USE

Page 2

SPECIFICATIONS

DRIVE SYSTEM

GEAR REDUCERS:....................Helical inline, oil bath

permanently lubricated,

CONTINUOUS POWER RATING:

1/2 HP: ................................175 ft-lbs/sec

1 HP: ................................275 ft-lbs/sec

RATIO:

1/2 Hp:......................................48.8:1

1 Hp:......................................49.8:1

OUTPUT SPEED

1/2 HP: ......................................36 r pm

1 HP: .....................................35 rpm

OUTPUT TORQUE

1/2 HP: ......................................929 in-lbs.

1 HP: .....................................1990 in-lbs.

OUTPUT SHAFT DIA.

1/2 HP: .....................................1”

1 HP: .....................................1-1/4”

OUTPUT SPROCKET

1/2 HP: ......................................#50-14T

1 HP: .....................................#60-14T

MAX. OVERHUNG LOAD: (1”from output bearing face)

1/2 HP: ......................................698 Lbs.

1 HP: .....................................1036 Lbs.

MAX. BACK DRIVING FORCE: (torque)

1/2 HP: .....................................100 in-lbs.

1 HP: .....................................100 in-lbs.

Operators available left hand mount.Must be inverted for right hand mount. Limits and motor direction must be reversed when changing handing.(See Pages 14 - 15)

non-vented.

MOTOR

TYPE:....................................Continuous duty

HORSEPOWER:...................1/2 HP

1 HP

SPEED:.................................1725 RPM

VOLTAGE: .............................115/230 Single phase

230/460 Three Phase

ENCLOSURE:.......................ODP NEMA 56c face mount

ELECTRICAL

TRANSFORMER:...............1PH: 120/240 VAC 24V A C

3PH: 240/480 VAC 24VAC

BATTERY BACKUP: (2) 12VDC 7AH sealed lead

acid batteries

CONTROL STATION:........NEMA 1 three button station.

OPEN/CLOSE/STOP

WIRING TYPE: ...................B2 (Standard)

LIMIT ADJUST:..................Linear driven, fully adjustable

screw type cams.(70 rev. max

@ limit shaft)

DUTY CYCLE:....................25 Reversing cycles per hour

BRAKE: ..............................24VDC electromagnetic disc

THERMAL SENSORS:.............160 deg.F (Open on rise)

(see page 12)

ELECTRICAL ENCLOSURE RA TINGS:motors, electrical enclosure and control station are rated NEMA1

WEIGHTS & DIMENSIONS

ITEM

A B C D E F G H

DIMENSIONS

1/2HP

13.00”

21.00”

16.93”

2.44”

3.35”

4.53”

2.26”

6.67”

8.25”

2.12”

1HP

14.38”

25.73”

16.31”

2.93”

3.94”

5.61”

2.80”

7.22”

7.50”

2.51”

9.57”

HANGING WEIGHT

1/2HP = 80 Lbs. 1HP = 100 Lbs.

Output Sprocket

Center Line

Operator Center Line

MOUNTING DIMENSIONS

1/2HP = 5/16” Mounting Hardware (Typical) 1HP = 3/8” Mounting Hardware (Typical)

17.27”

4.25”

8.50”

Page 3

GENERAL DESCRIPTION

The Fire Door Controller, FDC, is an integrated fire door control system. It is designed to interface with a normally close (NC) or normally open (NO) dr y contact alar m system to control the operation of a fire door. The control station is the standard B2 wiring, momentary contact to open, close and stop, plus wiring for sensing device to reverse and auxiliary devices to open and close with open override.

N OTICE

WARNING

THIS OPERA T OR IS NO T A FIRE ALARM SYSTEM. IT CAN NOT DETECT A FIRE CONDITION.

FUNCTIONAL OPERATION

1. Battery Backup (management system)

The batteries are charged, tested, and monitored automatically by the microprocessor based system. The batteries are tested under load every thirty days, if for any reason the batteries fail this load test, the on board buzzer will sound for 3 seconds of every minute to indicate that the batteries need to be replaced. If the batteries are not replaced within 45 days (from initial test) the door will automatically close, and remain inoperable until the batteries have been replaced. The battery voltage is continuously monitored, if for any reason the voltage drops below 22 VDC (this is the minimum operating voltage for the brake controls) the unit will activate the optional warning signal and automatically close the door.The door will remain inoperable until such time that the batteries come back to charge, or they are replaced.Low batter y condition will be indicated by the on board buzzer sounding 3 seconds out of every minute, and the low battery indicator (located on the key test station) flashing, until the batteries come to the full charge or are replaced.

2. Unit has AC power & no alarm condition:

The B2 control station is used to operate the door electrically. Activation of the safety edge while the door is closing will cause the door to reverse to the full open limit. Activation of the safety edge while the door is opening will NOT effect operation, the door will continue to the open limit. Activating the key-test switch for at least 6 seconds will put the operator in alarm active mode.(see ACTIVE ALARM section for detail operation of alarm active mode)

3. Unit has AC power & active alarm condition (ALARM #1 - smoke alarm etc.):

The unit will activate the OPTIONAL warning signal, the door will automatically close after the preset time delay. (powered down by motor) The time delay is set by means of DIP

switch 1. If the door is in the open position and an alarm condition occurs, the door will automatically close under motor operation. In the event the door should meet an obstruction while closing, it will reverse and return to the full open position, and then start the closing cycle (with delay and warning) again. If the obstruction is not removed, the door will close stopping at the lowest possible position holding the brake for 2 seconds, then releasing the door to Gravity Close (controlled descent). If after the door has finished the cycling mode and the obstruction has been removed, the door will proceed to the floor. In the event of a failure in motor operation, the operator will gravity close.(controlled descent)

Page 4

FUNCTIONAL OPERATION CONTINUED

4. Unit has AC power & active alarm condition (ALARM #2 - Fire Sensor, thermal sensor etc.):

The unit will activate the optional warning signal, the door will automatically close after the preset time delay.

(powered down by motor) The time delay is set by means of DIP switch 1. If the door is in the open position and the alarm condition occurs, the door will automatically close under motor operation. In the event the door should meet an obstruction while closing, the door will stop for 2 sec onds, then release the door to Gravity Close (controlled descent).After the obstruction has been removed, the door will proceed to the floor. In the event of a failure in motor operation, the operator will gravity close (controlled descent) All control station functions will be rendered inactive in this condition. The safety edge will remain active.

5. Unit has No AC power & No active alarm condition:

The Close and Stop buttons of the B2 control station are functional. The door's descending speed is controlled by the integrated braking system. The door will stop if an obstruction is encountered while closing. The Open button is not functional

6. Unit has No AC power & active alarm condition (Alarm #1 or Alarm #2):

The unit will activate the OPTIONAL warning signal, the door will automatically close after the preset time delay. (controlled by integrated braking system) The time delay is set by means of DIP switch 1. If the door encounters an obstruction while closing , the door will stop on the obstruction, and release the brake after (2) seconds.If the obstruction is then removed the unit will perform a controlled drop of the door.(not powered down by the motor)

7. Activation of the internal Thermal Sensor:

Will activate an alarm #2 switch. With AC power present the unit will react as stated in paragraph 4. With No AC power present the unit will react as stated in paragraph 6.

8. Activation of the Key Test Station:

Key must be activated for 6 seconds The unit will activate the OPTIONAL warning signal, the door will automatically close after the preset time delay. (controlled by integrated braking system) The time delay is set by means of DIP switch

1. (to test the signal devices and the delay time) The door will close using gravity close mode (Controlled Descent) in order to test the door balance, descent speed, and the moment of the door. All sensing devices and control devices will be active. (In order to test these devices)

(See page 5 for procedures)

Page 5

DOOR SYSTEM TESTING PROCEDURES

Before beginning any testing, secure the door area, keep unauthorized personnel from entering the area during testing. Be sure ac power is present at the operator. (the green "AC" led will be lighted on the operators control board) and that the batteries are connected and fully charged. (the red "DC" led will NOT be lighted on the operators control board)

1. Begin the test with your door at the full "OPEN" position.

2. Make cer tain dip switch #2 is in the "ON" position "FIREDOOR" mode.

3. If your door is equipped with safety photo eyes, make certain dip switch #4 is in the "ON" position.

Note: If 2 minutes total time elapses from the beginning of step #11and the conclusion of step #15, the unit will automatically exit the "TEST" mode.To re-enter the "TEST" mode repeat step #4, and continue testing.

4.Turn the wall mounted key test switch to the "TEST" position and hold for a minimum of 6 seconds. This action simulates an “ALARM” signal.

5. If dip switch #1 is in the "ON" position, the door should begin to close immediately.If dip switch #1 is in the "OFF" position, the door should begin to close after 10 seconds time has elapsed. (the door will not motor down, it will gravity descend)

6. Using a "stop-watch" verify that your door is closing between 6" and 24" per second. (i.e.. A 10ft high door should close in a time between 5 and 20 seconds.) Your door should now be fully closed.

7. Open the door by depressing the "OPEN" button on the three button control station.

8. Repeat step #4.

9.When the door is approximately 3 to4 feet from the floor, activate the doors safety edge, using a crate, skid or alike.Do not introduce any part of your body to the door system during testing. The door should reverse

to the full open position. Remove the obstruction.

10.The door will begin to close within 1 sec., If dip switch #1 is in the "ON" position. If dip switch # 1 is in the "OFF" position, the door will wait 10 sec. Before beginning to close.The door should fully close to the floor. (the door will not motor down, it will gravity descend)

11. Repeat steps #7 and #8.

12.When the door is approximately ½ way to the floor, interrupt the safety photo eye beam, by blocking with a piece of cardboard or alike. Do not introduce any part of your body to the door system during testing. The

door should reverse to the full open position.Remove the obstruction.

13. Step #10 repeats.

14.When the door is approximately ½ way to the floor, depress and hold the "STOP" button on the three button control station.The door should stop.

15. Release the "STOP" button on the control station. Step #10 repeats.

16. Depress the "OPEN" button on the three button control station. The door should open to the full open position. The unit is now ready to be returned to service.

Page 6

OPERATOR MOUNTING

Before your operator is installed, be sure the door has been properly aligned and is working smoothly. The operator may be wall mounted or mounted on a bracket or shelf. Ref er to the illustr ation and instructions below that suits your application. This motor operator is an integral part of the door system. The motor operator, controls door descent speed under power outage conditions, therefore the motor operator mounting surface is of major importance.The mounting must provide the following:

- All surfaces should be flat, square, and parallel to the door shaft

- The mounting surface must be rigid, and braced off as required

- When wall mounting the motor operator, it should be through bolted to the wall

- All (8) motor operator mounting points MUST be used

- All mounting hardware should be a minimum of grade 5

1a. Bracket or Shelf Mounting

The operator may be mounted either above or below the door shaft. The optimum distance between the door shaft and operator drive shaft is between 12” - 15”. Refer to Figure 1.

NOTE: The door hood, end plates, and mounting bracket must be rigid, and provide adequate structural support.

FIGURE 1

(Right Hand Unit Shown)

1b. Wall Mounting

The operator should generally be installed below the door shaft, and as close to the door as possible.The optimum distance between the door shaft and operator drive shaft is between 12”- 15”. Refer to Figure 2.

Through bolts as required (8 places)

Load spreading plate mounted to wall both sides (supplied by others)

FIGURE 2

(Right Hand Unit Shown)

1c. Place door sprocket on the door shaft. Do not

insert the key at this time.

2. Wrap drive chain around door sprocket and join roller chain ends together with master link. (Link clip should face away from operator.)

3. Raise operator to approximate mounting position and position chain over operator sprocket.

4. Raise or lower operator until the chain is taut (not tight). Make sure the operator output shaft is parallel to door shaft and sprockets are aligned.When in position, secure the operator to wall or mounting bracket.

5. Install all remaining drive keys and set screws. Apply “Loctite-262” or equivalent locking compound to set screws.(Check that all mounting hardware is tight, and the drive chains are taut.

WARNING

THIS FIREDOOR CONTROLLER WILL NONOTT CLOSE A BALANCED DOOR IN THE ABSENCE OF AC POWER.THE DOOR SYSTEM MUST BE ABLE TO GENERATE A MINIMUM BACKDRIVING TORQUE OF 100 IN/LBS.,AT THE OPERATOR OUTPUT SHAFT. STICKING OR BINDING DOORS MUST BE REPAIRED. DOORS, DOOR SPRINGS, BRACKETS AND THEIR HARDWARE MAY BE UNDER EXTREME TENSION AND CAN CAUSE SERIOUS PERSONAL INJURY. CALL A PROFESSIONAL DOOR SERVICEMAN TO MOVE OR ADJUST DOOR SPRINGS OR HARDWARE.

Page 7

ENTRAPMENT PROTECTION ACCESSORIES

SENSING EDGES

All types of sensing edges with an isolated normally open (N.O.) output are compatible with your operator. This includes pneumatic edge. If your door does not have a bottom sensing edge and you wish to purchase one, contact the supplier of your operator.

The operator has been pre-wired to accept connection of a reversing edge device. Connect the normally open contacts to terminals J2-5 and J2-6 on the PCB Board. The auxiliary limit switch will de-activate the safety device during the last few inches of the door's downward travel.

NOTE: F or wiring connections refer to wiring diagram supplied with operator.

Important Notes:

a) Proceed with Limit Switch Adjustments before

making any sensing edge wiring connections to operator as described below.

b) Electrician must hardwire the junction box to the

operator electrical box in accordance with local codes.

TAKE-UP REEL: Take-up reel should be installed 12” above the top of the door.

COIL CORD: Connect operator end of coil cord to junction box (not supplied) fastened to the wall approximately halfway up the door opening.

LIMIT SWITCH ADJUSTMENT

MAKE SURE THE LIMIT NUTS ARE POSITIONED BETWEEN THE LIMIT SWITCH ACTUATORS BEFORE PROCEEDING WITH ADJUSTMENTS. BE CERTAIN THAT DIP SWITCH #2 IS IN THE “OFF”POSITION (CDO MODE) BEFORE MAKING ADJUSTMENTS.

1. To adjust limit nuts depress retaining plate to allow nut to spin freely. After adjustment, release plate and ensure it seats fully in slots of both nuts.

2. To increase door travel, spin nut away from actuator.To decrease door travel, spin limit nut toward actuator.

3. Adjust open limit nut so that door will stop in open position with the bottom of the door even with top of door opening.

4. Repeat Steps 1 and 2 for close cycle. Adjust close limit nut so that actuator is engaged as door fully seats at the floor.

SAFETY

(Aux. Close) Limit Switch

SPARE

Limit Switch

(Shown as LEFT

Hand Unit)

WARNING

TO AVOID SERIOUS PERSONAL INJURY OR DEATH FROM ELECTROCUTION, DISCONNECT ELECTRIC POWER BEFORE MANUALLY MOVING LIMIT NUTS.

If other problems persist, call our toll-free number for assistance - 1-800-528-2806

Actuator

RPM Board

Depress Plate

OPEN Limit Switch

Rotator Cup

CLOSE Limit Switch

Page 8

NOTICE:

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications .Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

INSTALLATION MODE

The motor operator installs as a standard commercial operator with standard wiring functionalty. Once installation is completed and all alarm devices are connected, and tested, the operator is then switched (DIP switch 2) to Fire Door Mode. Upon completion of installation,the units functionality should be chec ked by activ ating the key test station.If for any reason your unit does not respond as described in this manual, check that you have read and followed all installation and operating instructions. If difficulties persist contact the Lift-Master technical hotline.

1-800-528-2806.

WARNING

IT IS THE END USERS SOLE RESPONSIBILITY TO CHECK THAT ALL SYSTEMS ARE INSTALLED AND FUNCTIONAL. THE MOTOR OPERATOR MUST BE SWITCHED TO THE “FIREDOOR” MODE TO ENABLE ALL ALARM, AND WARNING SYSTEMS. DIP SWITCH #2 MUST BE SWITCHED TO THE “ON” POSITION TO ENABLE THE “FIREDOOR” MODE. FAILURE TO DO SO, COULD RESULT IN LOSS OF LIFE AND PROPERTY.

Alarm Inputs:

Alarm Input #1: Used for electronic alarm devices such as smoke detection devices or similar alarm systems.Devices may be N/O or N/C.Switchable using DIP Switch #3.This alarm will activate a motored closure of the door, and all sensing and control devices will remain active. It is imperative that the alarm signal contact is maintained for a time period greater than the alarm delay to close setting.I.E.If dip switch #1 is in the “OFF” position (10 seconds) the alar m system must supply a “DRY” contact signal to ter minals J2-11 & J2-12 for a minimum of 12 seconds.

Alarm Input #2: Used for the ther mal sensors (electronic fusible links) or similar systems. (N.C. state only) This alarm condition will activate a motored closure of the door, and all sensing devices and control stations will be rendered inactive. EXCEPT THE SAFETY EDGE.This alarm will override any other alarm condition or input.

Page 9

INSTALL POWER WIRING & CONTROL STATION

Before installing power wiring or control stations be sure to follow all specifications and warnings described below. Failure to do so may result in severe injury to persons and/or damage to operator.

Do not install any wiring or attempt to run the operator without consulting the wiring diagram. Install the optional Reversing Edge before proceeding with the Control Station installation.

IMPORTANT SAFETY NOTES

WARNING

INSTALL THE CONTROL STATION WHERE THE DOOR IS VISIBLE, BUT AWAY FROM THE DOOR AND ITS HARDWARE. DO NOT INSTALL CONTROL STATION DIRECTLY BENEATH THE OPERATOR. IF CONTROL STATION CANNOT BE INSTALLED WHERE DOOR IS VISIBLE, OR IF ANY DEVICE OTHER THAN THE CONTROL STATION IS USED TO ACTIVATE THE DOOR,

REVERSING EDGE MUST BOTTOM OF THE DOOR.

REVERSING EDGE UNDER THESE CIRCUMSTANCES MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONS TRAPPED BENEATH THE DOOR.

BE INSTALLED ON THE

FAILURE TO INSTALL A

WARNING

TO AVOID DAMAGE TO DOOR AND OPERATOR, MAKE ALL DOOR LOCKS INOPERATIVE. SECURE LOCK(S) IN "OPEN" POSITION.

IF THE DOOR LOCK NEEDS TO REMAIN FUNCTIONAL, INSTALL AN INTERLOCK SWITCH.

WARNING

ANY MAINTENANCE TO THE OPERATOR OR IN THE AREA NEAR THE OPERATOR MUST NOT BE PERFORMED UNTIL DISCONNECTING THE ELECTRICAL POWER AND LOCKING-OUT THE POWER VIA, THE MAIN DISCONNECT SWITCH. UPON COMPLETION

OF MAINTENANCE THE AREA MUST BE CLEARED AND SECURED, AT THAT TIME THE UNIT MAY BE RETURNED TO SERVICE.

WARNING

DISCONNECT POWER AT THE FUSE BOX BEFORE PROCEEDING.

OPERATOR MUST BE PROPERLY GROUNDED AND PERMANENTLY WIRED IN ACCORDANCE WITH LOCAL ELECTRICAL CODES. NOTE: THE OPERATOR SHOULD BE ON A SEPARATE FUSED LINE OF ADEQUATE CAPACITY.

ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED INDIVIDUAL.

IMPORTANT

WARNING

THIS UNIT MUST BE PROPERLY GROUNDED. A GROUND SCREW IS SUPPLIED IN THE ELECTRICAL BOX FOR CONNECTION OF THE POWER SUPPLY GROUND WIRE. FAILURE TO PROPERLY GROUND THIS UNIT COULD RESULT IN ELECTRIC SHOCK AND SERIOUS INJURY.

Page 10

POWER WIRING

POWER WIRING CONNECTIONS

1. Connect power wires to the J1 terminal block located on the Printed Circuit Board (shown below).

2. Be sure to run all power wires through the conduit hole in the electrical box enclosure marked with the label shown below.

GROUND WIRING

1. Connect earth ground to chassis ground screw in the electrical box enclosure marked with the label shown below.

40-10033B

2. Use same conduit entry into the electrical box as the power wiring.

CONTROL STATION WIRING

CONTROL WIRING CONNECTIONS

1. Connect control wires to the J2 terminal block located on the Printed Circuit Board (shown below).

2. Be sure to run all control wires through the conduit hole in the electrical box enclosure marked with the label shown below.

3. Apply power to the operator .Press OPEN push button and observe direction of door travel and then Press the

STOP button.

If door did not move in the correct direction, check for improper wiring at the control station or between operator and control station.(See page 17)

“UL” WARNING

(SEE NOTE)

CONTROL STATION MOUNTING

1. Mount Control Station and Key Test Switch no further than 12” from each other.

2. Mount Control Station and Key Test Switch no further than 12” from the door enclosure.

3. Mount W ARNING NO TICE beside or below the Control Station.

NOTE:

The “UL” Warning label must be read “righside up” from the floor level. Should your operator mounting cause this label to

Control Station

Key Test

Station

be read “upside down”, your accessory kit is supplied with an additional label. Install the new label so that it will be read “rightside up “ from the floor level.

(Left Hand Unit Shown)

4 ft.

(Approximate)

Page 11

OPTIONAL CONTROL SETTINGS

NOTE: All functions are independent of each other and do not require other control settings to be set at any

certain configuration. For dip switch location refer to illustration on next page. All switches are factory preset to the “OFF” position.

SI-1 ALARM DELAY TO CLOSE - Alarm Delay to Close is the time between when the operator first receives an

active alarm signal and the door starts to close. (In Seconds)

SI-4 INFRARED EYES STATE - The operator will support Chamberlain Infrared Eyes when enabled, and

ignore IR inputs when disabled.

ON (0 SECOND DELAY)

1 2 3 4

(10 SECOND DELAY)

OFF

ON (IR'S ENABLED)

1 2 3 4

OFF (IR'S DISABLED)

INSTALLER CONTROL SETTINGS

SI-2 FIRE DOOR MODE/CDO MODE - The operator only monitors alarm inputs when in the Fire Door Mode.

The operator functions as a standard CDO with B2 wiring when in the CDO mode.

SI-3 ALARM STATE - The operator can accept either a normally open or normally closed dry contact alarm

input. DO NOT INDUCE VOLTAGE!

ON (FIRE DOOR MODE)

1 2 3 4

OFF

(CDO MODE)

NOTICE:

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

TERMINAL

BLOCK (J2)

ON (N.C. ALARM)

1 2 3 4

OFF (N.O. ALARM)

DIP SWITCH (S1)

TERMINAL BLOCK (J1)

HEAT SINK

Page 12

3 BUTTON STATION AND SYSTEM TEST

KEY-TEST

IMPORTANT NOTES:

The 3-Button Control Station provided must be connected for operation.

Keyswitch

9 10 11 12

Stop

Open

6 7 8

SENSING DEVICE TO REVERSE OR STOP

Sensing Device

NC Contacts

NO Contacts

ALARM SYSTEM NO OR NC CONTACTS

Must set DIP switch #3

(S1,3) to ON.

Must set DIP switch #3

(S1,3) to OFF.

Low Battery

Indicator

CONTROL CONNECTION DIAGRAM

ELECTRONIC FUSE LINK ARRANGEMENT

SINGLE GANG JUNCTION BOX (2 NOT SUPPLIED)

THERMAL SENSOR (2 SUPPLIED)

A permanent fuse link arrangement shall be set-up for all installations. Use the illustration to the right as a guide.

1. Mount (2) single gang junction boxes (not supplied) on the center line of door (one on each side of the door opening) approximately 6” above door hood. Install (2) thermal sensors (supplied with cover plates and screws) to the junction boxes installed in step #1.

2. Wire sensors in series making required connections to motor operator. (TB1-3, TB1-4) Remove factory supplies “jumper” and wire as shown on page 13. (Alarm input #2)

3. All wiring and conduit should be run in accordance with all state and local electrical codes.

RUN CONDUIT THROUGH WALL

CENTER LINE

OF DOOR

JUNCTION BOX

Page 13

STANDARD POWER & CONTROL CONNECTION DIAGRAMS

LMPLC Board - 230/460V 3PH

(RD)(WH)

LOW BATTERY INDICATOR

13 141516 17 18 19 20 21 22 23

(BR)

ALARM INPUT #1

(DRY CONTACT)

N.O. or N.C .

L1 L2 L3

L1 L2 L3 GND

POWER IN 230/460V 3PH

TB1

123456789101112

IR'S

INTERNAL THERMAL

SENSOR

1 2 3 4 5 6

24 VAC

24 VDC

3 AMP MAX COMBINED

ALARM INPUT#2 (FACTORY JUMPER SUPPLIED)

(FACTORY JUMPER)

KEY-TEST

OPEN

STOP

REVERSE

EDGE

EXTERNAL

THERMAL SENSORS

TB1

13 141516 17 18 19 20 21 22 23

123456789101112

IR'S

INTERNAL THERMAL

SENSOR

1 2 3 4 5 6

24 VAC

24 VDC

3 AMP MAX COMBINED

LMPLC Board - 115/230V 1PH

(RD)(WH)

LOW BATTERY INDICATOR

(BR)

(FACTORY JUMPER)

KEY-TEST

OPEN

STOP

REVERSE

EDGE

EXTERNAL

THERMAL SENSORS

115/230V

ALARM INPUT #1

(DRY CONTACT)

N.O. or N.C .

L1 L2 L3

HOT

POWER IN 115/230V 1PH

115/230V

NEUTRAL

GND

ALARM INPUT#2 (FACTORY JUMPER SUPPLIED)

Page 14

1 PHASE WIRING DIAGRAM

(FDC5011,FDC5021,FDC1011,FDC1021)

INTERNAL MOTOR CONNECTIONS

1892

Notes:

1) See Owner’s Manual for Dip Switch Functions and Programming Procedures

2) TO REVERSE MOTOR DIRECTION: REVERSE PURPLE AND GRAY MOTOR WIRES.

3) CONNECTIONS SHOWN IN DOTTED BOUNDARIES ARE OPTIONAL USER INTERFACE.

OUTPUTS

(K5) LOW BATTERY INDICATOR

(K6) ACC2

(K7) AUDIO

(K8) STROBE

(1 AMP MAX)

ALARM INPUT#2 (FACTORY JUMPER SUPPLIED)

+12 VDC GND

EXTERNAL

THERMAL SENSORS

24 VAC

3 AMP MAX COMBINED

24 VDC

12VDC

BATTERY

DISCONNECT

(RD)

(BK)

(RD)

(YE)

(RD)

(BL)

J14 J15 J13

SAFETY

LIMIT SWITCH

OPEN

LIMIT SWITCH

(WH)

RPM

BOARD

(YE)

(GW)

J3 J4

(RD)

(WH)

RESISTOR

CAPACITOR

(BK)

(WH)

J18 J17J30

BRAKE

COIL

J16 J19 J5

(RD)

(WH/BK)

(YE)

MOTOR

J21

(BL)

(YE)

(OR)

(BL)

J24 J23

(GY)

(PU)

J25

(BL)

J28

J12

13 14 15 16 17 18 19 20 21 22 23 24

J9 J8

123456789101112

(FACTORY JUMPER)

(BK)

(BR)

(BK)

(RD)

INTERNAL THERMAL

SENSOR

(BK)

(WH/BK)

IR'S

(WH)

REVERSE

EDGE

KEY-TEST

OPEN

TB1

6 5 4 3

(BR)

J22

L1 L2 L3

J27 J26

(BK)

OVERLOAD

115V

115V 1PH

POWER IN ONLY

ALARM INPUT#1 (DRY CONTACT ONLY, DO NOT

INDUCE VOLTAGE!)

J20 J29

GND

(SHOWN AS LEFT HAND UNIT)

(BR)

BRIDGE

RECTIFIER

(BR)

STOP

LOW BATTERY INDICATOR

(BR)

(RD)(WH)

TRANSFORMER

SECONDARY

TRANSFORMER

SECONDARY

(WH)

PRIMARY

(BK)

(WH)

PRIMARY

(BK)

Page 15

3 PHASE WIRING DIAGRAM

(FDC5023,FDC5043,FDC1023,FDC1043)

Notes:

1) See Owner’s Manual for Dip Switch Functions and Programming Procedures 2 ) TO REVERSE MOTOR DIRECTION: REVERSE PURPLE AND GRAY MOTOR WIRES.

3) CONNECTIONS SHOWN IN DOTTED BOUNDARIES ARE OPTIONAL USER INTERFACE.

4) INTERNAL MOTOR OVERLOAD ON MODELS UP TO AND INCLUDING 3/4 HP. EXTERNAL OVERLOAD LOCATED IN ELECTRICAL ENCLOSURE FOR 1 HP MODELS.

1893

BATTERY

DISCONNECT

(RD)

OUTPUTS

(K5) LOW BATTERY INDICATOR

12VDC

BATTERY

(K6) ACC2

(K7) AUDIO

(K8) STROBE

(1 AMP MAX)

ALARM INPUT#2 (FACTORY JUMPER SUPPLIED)

+12 VDC GND

EXTERNAL

THERMAL SENSORS

24 VAC

3 AMP MAX COMBINED

24 VDC

(BK)

(BR)

(BK)

(RD)

INTERNAL

THERMAL

SENSOR

TB1

6 5 4 3

(SHOWN AS LEFT HAND) UNIT)

(BK)

(RD)

(YE)

(RD)

(BL)

LIMIT SWITCH LIMIT SWITCH

LIMIT SWITCH

(WH)

SAFETY CLOSE

OPEN

BOARD

(GW)

RPM

(YE)

(RD)

(WH)

J3 J4

J14 J15

J13

J12

13 14 15 16 17 18 19 20 21 22 23 24

J9 J8

123456789101112

(FACTORY JUMPER)

(BK)

REVERSE

EDGE

KEY-TEST

(WH/BK)

(WH)

IR'S

LOW BATTERY

(BR)

BRIDGE

RECTIFIER

INDICATOR

(BR)

(BK)

OPEN

STOP

J18 J17J30

(BL)

RESISTOR CAPACITOR

BRAKE

COIL

(WH)

(BR)

(RD)(WH)

(BR)

(RD)

(WH/BK)

J16 J19 J5

(BK)

J22 J27 J26

(BL)

(BK)

TRANSFORMER

SECONDARY

TRANSFORMER

SECONDARY

INTERNAL MOTOR CONNECTIONS

(YE)

J21 J24 J23

J6 J7

(BK)

J25

J28 J20

(WH)

J29

L1 L2 L3

GND

PRIMARY

(BK)

(WH)

PRIMARY

230/460 3PH

POWER IN

ALARM INPUT#1 (DRY CONTACT ONLY, DO NOT

INDUCE VOLTAGE!)

MOTOR

(PU) (GY)

(BK)

(BR)

MOTOR O/L

OVERLOAD

(1HP & ABOVE)

(BK)

(WH)

(BK)

SEE NOTE 4

95 96 T3

(BK)

Page 16

MAINTENANCE SCHEDULE

Check at the intervals listed in the following chart.

EVERY EVERY EVERY

ITEM PROCEDURE 3 MONTHS 6 MONTHS 12 MONTHS

Drive Chain Check for excessive slack.

Check & adjust as required. Lubricate.*

Sprockets Check set screw tightness

l ll ✔✔

✔✔

Fasteners Check & tighten as required Bearings & Shafts Check for wear & lubricate Functionality Activate Key Test switch (see pg. 4) Monthly or as required by regulatory agency

Gearbox - The gearbox on the motor operator is factory sealed, and non vented, and should not require service for the

life of the operator.

Brake Friction Mater ial - The electromagnetic brake on the motor operator is factory adjusted, and should not require

service for the life of the operator. Should service be required, the entire unit should be replaced.

Use SAE 30 Oil (Never use grease or silicone spray).

✔✔

Repeat ALL procedures.

Do not lubricate motor. Motor bearings are lubricated and sealed at the factory.

Inspect and service whenever a malfunction is observed or suspected.

CAUTION: BEFORE SERVICING, ALWAYS DISCONNECT OPERATOR FROM POWER SUPPLY.

ll ✔✔

MOTOR OPERATOR MAINTENANCE

Operators require practically no special maintenance other than periodic checking to see that mechanical parts where necessary are lubricated and the electrical compartments are clear of dirt.

Service technician should familiarize himself with the proper sequence of operation and all related controls. Power to operator must be disconnected when removing or replacing covers on electrical components, making adjustments, or performing maintenance.

1. Check wire connections for tightness and wire insulation for defects of abrasions.

2. Check to see that all conduit connections are secure.

3. Check wires to safety edge, or infrared safety eyes, if unit is equipped with a safety to reverse feature.

4. Inspect operation of brake.

5. Inspect gearbox for leaks.

6. Inspect roller chain and dr ive sprockets. Align, lubricate the sprockets, and tighten the set screws.

7. Generally inspect the motor mounting, and tighten the fasteners and bracing.

8.Verify that all conduit connections are tight and have no exposed wires.

9. Inspect the electr ical enclosure for debris, arching and moisture. Check for and tighten loose wiring connections.

10.Test motor operation through all control stations.

11. Check limit switch settings.

12. Examine safety edge, coil cord and take-up reel for damage.

13.Test the operation of the safety edge.

14. Check motor amperage draw for a full open and close cycle.Compare readings to those listed on the motor nameplate.

Page 17

MOTOR OPERATOR TROUBLE SHOOTING GUIDE

SYMPTOM

Motor does not run when OPEN or CLOSE button is pushed.

Motor runs but door does not move.

Motor hums but does not run.

Operator runs in wrong direction and limits do not function.

POSSIBLE CAUSE

Circuit breaker tripped or power fuse blown.

Thermal overload tripped. Secondary transformer fuse blown. External interlock open. (if supplied) Sprocket key missing or drive chain bro-

ken. Intermediate shaft or key damaged.

Door jammed. Drive train jammed. Dead phase in 3 phase system. Brake does not release. Open motor winding. On 3 phase operators power supply is out

of phase.

REPAIR

Check circuit breaker, power fuses, safety switch; check cause.

Reset; check cause. Check fuse, check cause. Close interlocks. Check drive train for operation

Close & lock off door, remove motor and inspect; check cause.

Check door.Tr y to operate manually. Check power supply. Check power to brake coil. Check all motor connections. Interchange any 2 wires in 3O

Limit switches do not hold their settings.

Door ‘drifts’when motor shuts off. Operator does not shut off at full

OPEN or at full CLOSE position.

Operator Functions Eratically

Note: All units are checked for proper rotation at factory. Limit switch adjustment instructions in electrical enclosure indicates proper direction of travel for OPEN and CLOSE limit nuts.

Drive chain loose, allows chain to jump sprocket teeth.

Limit nut retainer not engaging slots in limit nuts.

Limit nuts binding on screw threads which allows them to jump position on retainer.

Brake inoperative or worn. Limit nuts not adjusted properly. Sprocket on limit shaft loose or limit drive

chain broken. Defective limit switch Low line voltage

Bad ground “Noise” on electrical line Faulty alarm wiring

Adjust chain to proper tension.

Be sure retainer is in slots of BOTH nuts.

Lubricate screw thread. Limit nuts should turn freely.

Check brake operation. Adjust (see above) Inspect limit chain & sprocket.Adjust chain

tension, replace sprocket & chain if required Operate limit switch manually to determine. Check line voltage at operator. Low voltage,

check cause. Check circuit for high current draws. Eliminate all other units from the circuit. Check ground connections.Check alarm circuits. Simultaneously depress the “OPEN” & “CLOSE” limit switches, this will reset the operator’s microprocessor.

Page 18

REPAIR PARTS KITS – ELECTRICAL BOX

Refer to the parts lists below for replacement kits av ailable f or your oper ator . If optional modifications and/or accessories are included with your operator, certain components may be added or removed from these lists. Individual components of each kit may not be available. Please consult a par ts and ser vice representative regarding availability of individual components. Refer to page 24 for all repair part order ing information.

ELECTRICAL BOX KIT

ITEM PART # DESCRIPTION QTY

E1 E2 E3 E4 E5 E6 E7 E8

E9 E10 E11 E12 E13 E14 E15 E16 E17

E18 E19 E20 E21

K74-16513 10-16156 75-16135 10-16133 10-16157 21-XXXX 25-XXXX 25-3000K 29-NP712 K74-16514 03-8024K 42-106 29-16241 75-13705 K79-13493-1 28-4875-1 28-10219 28-10220 40-10031 40-10032 35-203 29-448

RPM Board Kit Electrical Box Cover Electrical Box Battery Plate Electrical Box Back Plate Transformer (See Variable Chart) Overload (See Variable Chart) Overload Plate (3 Phase Only) Battery, 12V Power Resistor Kit Contactor (Optional) 4 Pole Terminal Block Sensor, Thermostat Standoff Assembly, FDO PCB PCB, LMPLC Assembly Grommet 3/8 x 90 deg. Connector Anti-Short Bushing Label, Power Label, Control Fuse, 3 amp Bridge Rectifier

K72-16327 LIMIT SHAFT ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

09-13701

11-13361

12-10028

13-10024

15-25B22AXX

80-10053

86-RP04-100

87-E-038

Rotator Cup Limit Shaft Flange Bearing Limit Nut Sprocket Washer, Spacer Roll Pin, 1/8” x 1” long E-Ring, 3/8”

1 1 2 2 1 4 1 2

K75-16515 LIMIT SWITCH ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

1 1 1 1 1 2 1 1 2 1

1 1 7 1 1 1 1 2 2 1 1

10-10013

10-12553

10-12806

18-10036

23-10041

31-12542

82-PX04-20

82-PX06-16

84-LH-06

PART # DESCRIPTION QTY

132A2060 40-10231 40-10232 40-10233 40-10234 40-10306 40-12407 40-16070 40-16071 40-16230 40-16238 40-16485 40-16509 40-16601 40-6000 40-65 40-790 40-9054

Depress Plate Nut Plate Switch Backup Plate Spring, Depress Limit Switch Standoff, Switch Screw, #4-40 Pan Head Screw, #6-32 Pan Head Lock Nut, #6-32

K77-16669 LABEL KIT

LABEL, GROUND LABEL, 115V 1 PHASE (115V 1PH ONLY) LABEL, 230V 1 PHASE (230V 1PH ONLY) LABEL, 230V 3 PHASE (230V 3PH ONLY) LABEL, 460V 3 PHASE (460V 3PH ONLY) LABEL, DIRECTION LABEL, (1A-4A) LABEL, (1-12) LABEL, (13-24) LABEL, WIRING DIAGRAM (1PH ONLY) LABEL, WIRING DIAGRAM (3PH ONLY) LABEL, FDC EBOX UL CAUTION LABEL, CLASS 2 CIRCUIT LABEL, E-BOX COVER SW.SETTIGS LABEL, DOOR OPERATOR WARN. SIGN LABEL, DOOR EDGE CAUTION LABEL, RESET LABEL, RATING

1 4 4 2 4 4 8 2 2

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1

Item

P/N

21-16699 21-16698 25-2006 25-2008 25-2010 25-2015 25-4004-K 25-4002-5K

Description

Transformer, 115/230V 75VA 1 Phase Transformer, 230/460V 75VA 3 Phase Overload, 6 Amp Overload, 8 Amp Overload, 10 Amp Overload, 15 Amp Overload, 3.3 - 5.5 Amp Overload, 1.6 - 2.5 Amp

FDC5011

FDC5021

FDC5023

FDC5043

FDC1011

FDC1021

FDC1023

FDC1043

Page 19

ILLUSTRATED PARTS – ELECTRICAL BOX

E15

E11

E12

E14

E10

E17

E21

E13

E17

E18

E19

E20

Page 20

REPAIR PARTS KITS – MODEL FDC

Complete Electrical Box Replacement Kits

To order a complete electrical box replacement kit, add a Kprefix to the model number of your operator. For example:

FDC5011 = K-FDC5011

* Electrical Box Kits include parts K72-16327 and K75-16515

INDIVIDUAL COMPONENTS

ITEM PART # DESCRIPTION QTY

10-16158R 10-16159R

10-16158L 10-16159L

10-16140

10-16160

10-16483

15-16333 15-16244

11-16112

K20-XXXX

28-10219 28-10220

28-12029 28-10220

28-10218

80-16113

82-NH10-04

82-WX10-10T

Frame, Right (1/2HP Operators) Frame, Right (1HP Operators) Frame, Left (1/2HP Operators) Frame, Left (1HP Operators) Bracket, Frame Bracket, Front & Rear Bracket, Lifting Output Sprocket (1/2HP Operators) Output Sprocket (1HP Operators) Extension Shaft Motor Kit (See Motor Kits) Connector, 90 Degree Anti-Short Bushing Connector, Straight Anti-Short Bushing Brake Conduit (1/2HP Operators) Brake Conduit (1HP Operators) Motor Conduit (1/2HP Operators) Motor Conduit (1HP Operators) Step Key Set Screw, #10 Screw, #10-32 x 5/8”

1 1 1 1 4 2 2 1 1 1 1 1 1 1 1

6.5” 8”

13” 14”

1 2

K32-16214 GEAR REDUCER 1/2HP ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

32-16214

82-HN38-20G5

85-LS-38

85-FW-38

Gear Reducer Hex Bolt, 3/8” Lockwasher, 3/8” Flatwasher, 3/8”

1 4 4 4

K32-16234 GEAR REDUCER 1HP ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

32-16234

82-HN38-20G5

85-LS-38

85-FW-38

84-FN38

Gear Reducer Hex Bolt, 3/8” Lockwasher, 3/8” Flatwasher, 3/8” Flange nut, 3/8”

1 4 4 4 4

K08-16114 INTERFACE HOUSING ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

08-16114

82-HN38-16

85-LS-38

Interface Housing Hex Bolt, 3/8” Lockwasher, 3/8”

1 4 4

K75-16512 BRAKE ASSEMBLY KIT

ITEM PART # DESCRIPTION QTY

36-16221

82-SH10-06S

Electromagnetic Brake Socket Head Screw, #10

1 4

MOTOR KITS

K20-1050C2 Models FDC5011, FDC 5021 K20-3050C4 Models FDC5023, FDC5043 K20-1100C2 Models FDC1011, FDC1021 K20-3100C4 Models FDC1023, FDC1043

ACCESSORIES

02-109FDC Key Test Station 1 02-103 3 Button Station 1 74-16685 Thermal Sensor Assembly 2

Page 21

ILLUSTRATED PARTS – MODEL FDC

Page 22

OPERATOR NOTES

Page 23

OPERATOR NOTES

Page 24

HOW TO ORDER REPAIR PARTS

OUR LARGE SERVICE ORGANIZATION

SPANS AMERICA

INSTALLATION AND SERVICE INFORMATION

ARE AVAILABLE 6 DAYS A WEEK

CALL OUR TOLL FREE NUMBER - 1-800-528-2806

HOURS 7:00 TO 3:30 p.m. (Mountain Std.Time)

MONDAY Through SATURDAY

WHEN ORDERING REPAIR PARTS

PLEASE SUPPLY THE FOLLOWING INFORMATION:

PART NUMBER DESCRIPTION MODEL NUMBER

ADDRESS ORDER TO:

THE CHAMBERLAIN GROUP, INC.

Electronic Parts & Service Dept.

2301 N. Forbes Blvd., Suite 104

Tucson, AZ 85745

01-16219D

2000, The Chamberlain Group, Inc.

41B6

LISTED DOOR OPERATOR