Zap Series 3 Technician'S Installation And Service Training Manual Download

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Series 3 Technician’s Installati

on and S

ervice 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

[email protected]

USA Contact

931-510-4432

[email protected]

USA Tech Support 931-510-4432

via telephone or text

Online

www.zap-uk.com

ZAP Controls

Series 3 Technician’s Installation and Service Training Manual

ZAP Controls

Series 3 Te

chnician’s Installa

tion an

d Service Training Manual

Summary of Contents for Series 3

Page 1: ...h Road Cannock Staffordshire England UK Contact 011 44 154 387 9444 sales zap uk com USA Contact 931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online www zap u...

Page 2: ...struction 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 31...

Page 3: ...ramming 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 Troubleshoo...

Page 4: ...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 s...

Page 5: ...ws it is at the limit of travel and to stop If the door is travelling in the open direction prior to the open speed change point and the door meets an obstruction on any part of the door the operator...

Page 6: ...heck that the positioning of the torque arm is correct Figure C If necessary slide the operator off the shaft and adjust the position of the torque arm Reposition operator back onto shaft Note the tor...

Page 7: ...erator back onto shaft Note the torque arm should always be positioned in a horizontal manner never vertically Figure D Secure the torque arm to the track assembly through an existing bolt hole using...

Page 8: ...g inboard of the cable drum With the door in the closed position and the spring tension completely relieved by completely unwinding the torsion springs using the proper tools for accomplishing the tas...

Page 9: ...y be necessary to reach around the cable drum if it is mounted to the outside of the torsion shaft bearing plate To achieve this attach the additional torque arm to the torque arm that is attached to...

Page 10: ...ap america com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com Offset mounting may be achieved in extreme close quarters mounting situations An independently supported solid...

Page 11: ...g around the cable drum to mount to the track assembly developing a separate mounting point for the torque arm altogether If it is required to develop a separate mounting point it is important to note...

Page 12: ...nstalled Figure C Note the flat spot on the bottom of the pulley boss is designed to rest on the door support bracket Tighten set screws being careful not to over torque Figure D Install the door in a...

Page 13: ...use 1 5 6 axles Typically these axles do not extend far enough to allow the installation of a ZAP operator without the addition of a shaft adapter ZAP Controls does not manufacture an adapter to acco...

Page 14: ...take the place of the door spacer that exists between the door and the axle mounting bearing plate Currently the operator is verified as suitable for installation on the US Door Model 502 and Janus 1...

Page 15: ...ble to permit the removal of the operator in the event of the need to replace the operator belt after wearing out without having to disassemble the Bowden cable assembly Figure B If track mounting use...

Page 16: ...A Press down on the over ride lever until the belt feels fully tensioned without locking the lever down Figure B Looking at the handle of the lever as if it were the hand of a clock it should be locat...

Page 17: ...mum of 5 above the ground Do not mount through the back of the controller case by removing the circuit board as this may allow moisture to enter the controller or short circuit the control board if it...

Page 18: ...nsure this is set to the correct voltage prior to turning on power supply Introducing 230VAC while set on 115VAC will damage the board and require the board to be replaced No warranty is available for...

Page 19: ...ease ensure this is set to the correct voltage prior to turning on power supply Introducing 230VAC while set on 115VAC will damage the board and require the board to be replaced No warranty is availab...

Page 20: ...only available as a special order on ZAP 8800 controllers There is no voltage selector switch on 48O 3 phase 8800 Controllers All wiring plugs are removable for easy wiring access with the exception o...

Page 21: ...d knock outs or pre drilled ingress holes are provided on the bottom of the controller for the introduction of conduit and wiring Only use these knock outs for the introduction of wiring into the cont...

Page 22: ...1 44 154 387 9444 sales zap uk com USA Contact 931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com Materials Needed 401002 Photo Cell Tools req...

Page 23: ...ay connector plug from ZAP Controller Safety connection highlighted in red in Figure A Connect wiring together as shown in Figure B Insert safety wires into second terminal from right and secure using...

Page 24: ...open calibration process Figure A Observe that the open LED is illuminated Figure B When the door has reached the fully open position and stopped the open led should turn off immediately If it does no...

Page 25: ...red Small technicians slotted screwdriver Locate the terminals labeled RX Socket indicated Figure B Align the 840 Receiver onto to the 3 pin RX Socket connection Figure C Press into place ensuring tha...

Page 26: ...is illuminated indication the 840 receiver is reading the signal Figure C Hold the transmitter at arms length away from the control box to prevent the signal being transmitted from swamping the receiv...

Page 27: ...a ZAP Controller It is feasible to mount the Linear receiver inside the case lid of the ZAP Controller Ensure it is positioned as shown in Figure A You may secure the receiver in place using double si...

Page 28: ...inside the case lid of the ZAP Controller Ensure it is positioned as shown in Figure A You may secure the receiver in place using double sided tape All wiring for the radio receiver onto the ZAP contr...

Page 29: ...oller It will need to be mounted outside the enclosure of the ZAP controller case All wiring for the radio receiver onto the ZAP control board is connected to the radio wiring connections as indicated...

Page 30: ...2 conductor cable Tools required Small technicians slotted screwdriver Isolate the power supply before wiring any device into a ZAP Controller All wiring for the radio receiver onto the ZAP control b...

Page 31: ...able Tools required Small technicians slotted screwdriver Isolate the power supply before wiring any device into a ZAP Controller All wiring for the radio receiver onto the ZAP control board is connec...

Page 32: ...case through the provided predrilled holes or knockouts on the bottom of the controller and mounting the device to the bottom of the ZAP controller or on an interior or exterior wall Wire the power wi...

Page 33: ...USA Contact 931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com Warning Electrical Shock Hazard To prevent serious injury or death always ensu...

Page 34: ...side of the track After drilling the pilot holes use a 1 4 drill bit to drill the mounting holes from the inside of the track Using the provided flat head screws or track bolts bolt the solenoid bolt...

Page 35: ...hillips Driver bit Appropriate mounting fasteners After properly mounting the 8830 Battery Backup through the corner pillar mounting holes next to the ZAP Controller ensure that you plug the four batt...

Page 36: ...power is disconnected when wiring anything into the ZAP Controller Materials required 82 DTLM 16 20 awg 2 conductor cable Tools required Small technicians screwdriver Isolate the power supply before w...

Page 37: ...oller Materials required 82 DTLM 16 20 awg 2 conductor cable Tools required Small technicians screwdriver Isolate the power supply before wiring any device into a ZAP Controller The 82 DTLM provides a...

Page 38: ...r the red light will close to activate the red light when the door is any position other than fully closed The green light relay will close when the door is the fully open position 24V Traffic Light W...

Page 39: ...lay for the red light will close to activate the red light when the door is any position other than fully closed The green light relay will close when the door is the fully open position 24V Traffic L...

Page 40: ...ock function consult the Dock interlock wiring page for the 82DTLM For driver communication light wiring consult the driver communication light wiring page for the 82DTLM For interlocking 2 doors in t...

Page 41: ...A The ZAP Controller provides a pair of contacts that require a relay on the other end of the wiring be closed to enable operation of the ZAP Controller Figure B The common terminal of the interlock o...

Page 42: ...510 4432 via telephone or text Online www zap uk com Warning Electrical Shock Hazard To prevent serious injury or death always ensure power is disconnected when wiring anything into the ZAP Controller...

Page 43: ...equired 82 TLM 16 20 awg 2 conductor cable Tools required Small technicians screwdriver Isolate the power supply before wiring any device into a ZAP Controller The 82 TLM provides a pair of contacts t...

Page 44: ...contacts that require a relay on the other end of the wiring be closed to enable operation of the ZAP Controller Figure B The common terminal of the interlock on the main ZAP Control Board A Figure B...

Page 45: ...will close when the door is the fully open position 24V Traffic Light Wire the red light wire to the red light connection on DTLM Figure A Wire the traffic light green light wire to the green light c...

Page 46: ...r closed interlock function consult the Door closed interlock wiring page for the 82 TLM For through traffic light wiring consult the through traffic light wiring page for the 82 TLM For interlocking...

Page 47: ...on Isolate the power supply before wiring any device into a ZAP Controller Unplug the case lid plug from TB 3 and remove the red wire from the plug in terminal Using your 4 wire cable insert a wire in...

Page 48: ...eath always ensure power is disconnected when wiring anything into the ZAP Controller Materials Needed 16 20 awg 2 conductor cable Single contact device such as a Single Button wall station microwave...

Page 49: ...0 4432 via telephone or text Online www zap uk com Warning Electrical Shock Hazard To prevent serious injury or death always ensure power is disconnected when wiring anything into the ZAP Controller M...

Page 50: ...0 4432 via telephone or text Online www zap uk com Warning Electrical Shock Hazard To prevent serious injury or death always ensure power is disconnected when wiring anything into the ZAP Controller M...

Page 51: ...ZAP Controller The 871 Interface expansion module is used to facilitate the need for additional wiring space for multiple control wiring functions If an extra Cyclic operation input is required wire...

Page 52: ...o eye Retro reflective photo cells should not be used with the 871 FS as reflective tape is often used on vehicles where this device is employed Wiring the photo cells used with the 871 FS Isolate the...

Page 53: ...tation Module Isolate the power supply before wiring any device into a ZAP Controller Note the positions of the connector plugs on the Auto Lock card Figure A and the 871 Modules Figure B Plug the 871...

Page 54: ...r supply before wiring any device into a ZAP Controller Mount the required photo cells at a position 5 6 above the ground on each side of the opening Terminate the power wire of the photo eye to the 2...

Page 55: ...rious injury or death always ensure power is disconnected when wiring anything into the ZAP Controller Materials Needed 120V Dock Light Isolate the power supply before wiring any device into a ZAP Con...

Page 56: ...Auto Close timer by setting DIP switch No 4 to ON Figure A Press and hold the program button Figure B Release the button after the 2nd flash of the ACK LED or beep if the 850 beeper module is install...

Page 57: ...used to temporally de activate the auto close timer when it is necessary to defeat the auto close timer from timing out and closing the door for one particular cycle This func tion is used for example...

Page 58: ...closure Note To program this function it is necessary to open the case lid of the controller to access the program button and to view the acknowledge light if the beeper module is not installed Figure...

Page 59: ...lled Figure A Start with the door fully closed Press and hold the program button Figure B Release the button after the 5th flash of the ACK LED or beep if the 850 beeper module is installed Figure C N...

Page 60: ...sary to open the case lid of the controller to access the program button and to view the acknowledge light if the beeper module is not installed Figure A ZAP Commercial controllers have the ability to...

Page 61: ...king the number of service due alerts made For example if the door has 50 000 cycle springs installed then on the fifth service due alert it be prudent to replace the torsion springs to prevent the op...

Page 62: ...ations it rolls over to zero If the 850 Beeper module is not employed it will be required to open the case lid of the controller to observe the acknowledge LED See 850 Beeper module installation page...

Page 63: ...nstalled Verify operator is properly installed Verify door balance is correct and spring tension is not too high Verify top section seal is not too tight against header or section too tight against se...

Page 64: ...efore closing 13 External Radio controls or other external device does not function Verify proper operator is installed Verify operator is properly installed Verify Bowden cable is installed properly...

Page 65: ...y that the pulley retaining cir clip is in place or the screw or set screw is tight Inspect the V Belt for signs of excessive wear Replace as necessary Inspect bearings on the pulley for excessive wea...

Page 66: ...controller and verify that the open LED is illuminated while the door is moving Press stop and then close to see if the door travels closed Did the door travel both directions YES NO Inspect all screw...

Page 67: ...fy the power indicator LED is illuminated If not verify power supply Check the mains supply Set your voltmeter to Volts AC Place the red lead in the Left hand LIVE terminal of the green plug Place bla...

Page 68: ...top and common on TB3 Retry Replace the control board if close LED does not illuminate Press the program but once to turn off the close cycle Set your voltmeter to VDC 200 Located TB6 It is the vertic...

Page 69: ...d verify the Close LED is illuminated Check your volt reading It should read opposite or 54VDC of the test of the open cycle test Press the program button again to turn off the open LED If it reads ex...

Page 70: ...urning past the internal stops at these points will break the potentiometer the and require circuit board replacement Use only a small slotted technicians screwdriver no larger than the slot provided...

Page 71: ...931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com To perform a Master reset Locate the program button Figure A Locate the reset button Figur...

Page 72: ...a com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com To perform a Factory reset Disconnect the power supply for 5 minutes Restore power supply Locate the program button Figu...

Page 73: ...B Insert black lead into 0V terminal of TB9 Figure C Place Red lead onto 24V power terminal of TB9 Figure C It should read 31 33VDC If voltage is excessively high or low replace control board If no vo...

Page 74: ...A Check to see if wiring and plug on TB9 is securely connected to TB9 and test If no function completely disconnect device at the plug terminals Using a small technicians screwdriver jump the terminal...

Page 75: ...connected securely Figure A Inspect all wiring for control station and verify there are no loose connections Test by pressing the open button on the ZAP Controller If no function disconnect all wirin...

Page 76: ...ng the pulley lift the pulley bearings and belt from the motor frame Figure C Remove the belt from the pulley Remove the rear bearing this is the bearing facing you as you removed the pulley from the...

Page 77: ...ir of pliers or a 8mm wrench Loosen the nut on the end of the Bowden Cable on the operator head Set the nuts and lock washers in a place where they will not be lost Figure A Ensure you remove the nut...

Page 78: ...and bearing replacement instructions On 8825 Models a snap ring must be removed to remove the drive pulley on the motor Using a pair of snap ring pliers remove the snap ring and put in a place where i...

Page 79: ...ordshire England UK Contact 011 44 154 387 9444 sales zap uk com USA Contact 931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online www zap uk com Series 3 Techn...

Page 80: ...Littleworth Road Cannock Staffordshire England UK Contact 011 44 154 387 9444 sales zap uk com USA Contact 931 510 4432 sales zap america com USA Tech Support 931 510 4432 via telephone or text Online...

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Summary of Contents for Series 3

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