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Ultimate Products UP-206 - page 1
2 3 1 9 Laure lbroo k Street , Raleigh , NC 27604 Phone (80 0)542-7 221 Fax (919)8 34-4526 UP (6-0043) 4/05 2/08 ...
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Ultimate Products UP-206 - page 2
Air-Powered Door Operator Installation Guide This is an installation guide for the Air-Powered Door Operator . It is a general guideline for a normal installation. If problems arise call (800)542-7221 for specific advice. Necessary tools: Drill and 1/4” bit (to drill mounting holes in operator bracket and door track) 2 vise-grips Set of Allen wre ...
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Ultimate Products UP-206 - page 3
1 Note: Inspect door for smooth rolling and proper balancing before installing A ir Powered Operator. Part 1: BELT INSTALLATION Step 1 Determine which side of door to install the air powered operator. 6” of shaft is required beyond track bracket. Clearance Requirements 8” of side clearance is required to mount operator. ...
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Ultimate Products UP-206 - page 4
2 Step 2 Installing Sprocket Kit Position the 1½” spacer (Part No. SP101) onto the shaft agai ns t the bearing as shown. Next slide the sprocket (Part No. BSP01) against the spacer. Insert key (Part No. K101) of sprocket kit into the keyway of sp rocket and tighten the set screws. Installing Tensio ner Kit Before installing the air cylinder, the ...
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Ultimate Products UP-206 - page 5
3 Installing Tensioner Kit Insert one end of the tensioner rod with holes into round hole of the track bracket. Place 1 washer on each side of bracket and add cotter pins (Part No. DF330) . Place tensioner roller on rod (as shown). End support bracket will be installed after hanging the operator. Proceed to Step 3. ...
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Ultimate Products UP-206 - page 6
4 Step 3 Install speed cont rol kit to the operator. (Part No. TC2002) . Speed Control Kit (Part No. TC2002) Installing Speed Control Kit Before installing t he speed control kit to the operator, place the operator flat on floor with the red plugs facing up. Remove red plugs from the air powered operator. Insert brass elbows (Part No. AP1080B) into ...
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Ultimate Products UP-206 - page 7
5 10 x 24 x 3/8 Machine Screws Speed Control Valve with bracket Step 4 Attaching Belt to Operator NOTE: Remove clamp assembly C L -102 from belt before installing belt onto operator. Operator Belt ...
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Ultimate Products UP-206 - page 8
6 Remove belt roller (Part No. OP01) from center of operator. (roller is attached when operator is shipped from factory) Slide bottom of turnbuckle onto rod closest to the wall leaving ½” of rod above turnbuckle (Part No. CL100) . Tighten bolts of turnbuckle down onto rod and reinstall Belt Roller on operator . NOTE: Turnbuckle will always be in ...
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Ultimate Products UP-206 - page 9
7 Install end support bracket ( Part No. BB103A ) on door shaft. Making sure tensioner rod goes th rough hole of end support bracket. Attach end support bracket to wall before attaching operator to vertical track. Completed Tensioner Kit will be as shown. ...
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Ultimate Products UP-206 - page 10
8 1/4 x 1" Attach top and bottom of the operator to the vertical track with self-tapping screws. ( As seen in figures J and K on pg. 8 ) ...
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Ultimate Products UP-206 - page 11
Item ‘C’ Item B Item ‘A’ CL101 Step 7 Raise door manually to height of desired operation -- For example, if you want door to open 8 feet, raise bottom of door to be 8’ off finished floor. Begin by removing ½” nut from top of turnbuckle – (Item ‘A’) Lower nut (Item 'C') down until desired tightness is achieved. Begin by ...
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Ultimate Products UP-206 - page 12
10 Rod with turnbuckle (Part No. CL100 and CL101) will rise when opening the door Thus after opening door to desired height, the rod closest to the wall will be extended out of the cylinder Now we will attach Part No. ‘C L102’ to the rod that is not extend ed out of the cylinder Your open and close door limits are set. You are now ready for con ...
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Ultimate Products UP-206 - page 13
11 Installation Of Chain Drive ...
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Ultimate Products UP-206 - page 14
12 Part 2: INSTALLING CHAIN DRIVE STEP 1 NOTE: Before begi nning installatio n make sure you have chain roller set-up (Part No. AP1325). Determine which side of the door you are installing the air operator on; you will need at least 6” of shaft beyond track bracket for installing air-powered operator with chain. See Figure A. STEP 2 Position the ...
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Ultimate Products UP-206 - page 15
13 Step 3 Installing Chain Lay air powered operator on floor with red plugs facing up. Remove chain roller ( Part No. AP1325 ) from top of operator See Figures C & D. If you are installing operator on right hand side of door, install turnbuckle of chain on the r od that is closest to the wall. Insert chain around bottom of roller ( Part No. AP1 ...
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Ultimate Products UP-206 - page 16
14 Step 4 Before hanging air-powered operator, install speed control kit ( Part No. TC2002 ). Locate kit with speed control valves, elbows, an d two remaining elbows of sprocket kit. Remove red plugs from air powered operator insert brass elbows See Figure F . Tighten slightly with 9/16 open-end wrench. Attach speed control valve at top of operator ...
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Ultimate Products UP-206 - page 17
15 Step 5 Hang chain of air powered operator around chain sprocket. Align oper ator with vertical track and align sprocket with operator. Tighten all set screws on sprocket and collars of sprocket assembly, add support bracket ( Part No. BB103A ) before attaching operator to vertical track. See Figures I & J . Sprocket Assembly (Part No. SPK100 ...
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Ultimate Products UP-206 - page 18
16 Step 6 Attach operator to vertical track after it is aligned with sprocket and operator hangs straight down using self- taping screws. See Figure K. Tighten chain with turnbuckle. After chain is tight, lock turnbuckle into place with ½” nut on threaded rod. See Figure L . Slide one enclosed clamp assembly Part No. AP1055 so that ¾” of the ...
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Ultimate Products UP-206 - page 19
17 Rod with turnbuckle (Part No. CL100 and CL101) will rise when opening the door Thus after opening door to desired height, the rod closest to the wall will be extended out of the cylinder Now attach Part No. ‘CL102’ to the rod that is not extend ed out of the cylinder Your open and close door limits are set. You are now ready for contro l box ...
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Ultimate Products UP-206 - page 20
Part 3: Install the control A. There are several different control options available for your air-powered operator, depending on how you would like to control your door. Choices are as follows: DC1000: Manual, lever-operated, 3-position air valve. DC4000: 24V Control Box that only works when the electricity is on. It Does NOT HAVE buttons. DC5000: ...
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Ultimate Products UP-206 - page 21
Part 4: Installing Air Lines A. 1. Connect air line at control box. 2 . Connect top port of control box to 90 degree elbow on cylinder closest to wall with airline . (see below) 3. Connect bottom port of control box to elbow on cylinder farthest away from wall. ( See below) B. Install a single 3/8” air line from compressor (or closest air source) ...
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Ultimate Products UP-206 - page 22
Part 5: Testing Operator and Control Box Note: Every Step must be completed before connecting the signal-sending devices. A . Plug the control box into 110V AC outlet. B. Pull up black knob on top of Regulator. Turn knob clockwise to increase air pressure. (See below) Note: Recommended pressure varies between 60-100 PSI C. Press open or close on th ...
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Ultimate Products UP-206 - page 23
Part 6a: U Series Door speed adjustments and fine tuning continued. Note: Only for U series operators B. Door slows too soon when closing Step 1- Speed control valve c loses t to wall controls down. Follow same procedure as Part A, Step 2. C. Door opens slowly and closes rapidly . Step 1- If counter weights are availab le, add more weight if nece s ...
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Ultimate Products UP-206 - page 24
Part 6b: S Series Door adjustments and fine tuning continued Note: Only for S series operators C. Door Slows too Soon When Closing : 1. Locate the airflow control screw on the bottom of the down cylinder (closest to the wall). 2. Turn the airflow control screw one complete turn counter clockwise or until the door operates properly Note: Use caution ...
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Ultimate Products UP-206 - page 25
21 Part 7: Install Signal Senders A. At this point the door , the operator , and the control box should work. The installation of signal senders is complicated and where the most problems gener- ally occur . Be sure to follow these directions carefully . Signal senders include: hose switches, pull cords, electric eyes, magnetic loop detectors, radi ...
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Ultimate Products UP-206 - page 26
22 4. Check the motion of the door . Turn the air pressure to zero and push the controls up and down a few times to expel any air left in the system. Manually raise the door . Go slowly and do no not force the door up -- air is being expelled form the bottom cylinder . If the door moves normally , go to step 5. 5. Loosen the turnbuckle that holds t ...
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Ultimate Products UP-206 - page 27
9 23 Part 9: Automatic Oiler Adjustment A. Using a 10-weight, non-detergent oil, fill the oiler through the top cap (similar to a lawn mower oil cap) or remove the bottom bowl. Do not use antifreeze or heavy weight oil. B. Adjustments to the oil flow are made by turning the cap on top of the oiler . A turn to the (+) direction increases the oil flo ...
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Ultimate Products UP-206 - page 28
24 3. Lower the air pressure: Lower the air pressure to the operator . The door will not operate as quickly and the shock of the immediate reversal of the door won’t loosen the cables. 4. Restrict the air flow: Install a valve in the air line to restrict the airflow . This will slow the reaction time of the door and still maintain the desired air ...
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Ultimate Products UP-206 - page 29
Model DC 5000 Model DC 7000 27 ...
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Model DC 6000 28 ...
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Ultimate Products UP-206 - page 31
Model DC 7000 29 ...
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Ultimate Products UP-206 - page 32
T T y y p p i i c c a a l l C C o o n n t t r r o o l l B B o o x x S S e e t t - - U U p p (DC6000 pictured) APF1450 APF1450 Heavy Duty Filter Part # Description AA1130 Noise Muffler 3/8"x 1/8" Male adapter quick connect (Metal)- used on air filter regulator - PC 3/8 N01 AP1077C 3/8"x 1/8" Male adapter quick connect (Plastic) A ...
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Ultimate Products UP-206 - page 33
Photo Amplifier Wiring Directions 8 7 6 5 4 32 24 21 22 12 1 2 3 9 10 11 34 B 31 11 A 14 Common Open Close 24V Ground Light Transmitter Light Receiver Blcak Shield (To 6) (To 8) (To 5) (To 7) (To 4) (To 10) (Common to 1&2) ZVE1 -- Photo Amplifier Socket Note: The light transmitter is identified by the red and black leads; the light receiver is ...
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Ultimate Products UP-206 - page 34
1 2 3 4 5 6 7 Common Open Close 24V Ground Terminal 2 Terminal1 Terminal 3 Terminal 4 Terminal 5 TIMER Wiring Diagram: Infitec Timer to Control Box TERMINAL STRIP (in control box) Black wire goes to 4 on electric eye amplifier. Red wire goes to open on control box terminal strip. Magnet & L-bracket Lead side of limit switch & bracket Top of ...
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Ultimate Products UP-206 - page 35
Wiring Diagram for Magnetic Loop Sugges ted Ins talla tion of Magnetic Loop Cut one groove and put wires on top of each other starting at the detector . Follow the groove to the rectangle and go around it three times, one on top of the other then back to the detector . Y ou end up with two wires at the detector which go to grey and brown. The loop ...
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Ultimate Products UP-206 - page 36
Wiring Diagram: Finder Timer to Control Box !!DISCONNE CT POWER BEFORE PROC EEDING!! 1. Tim er i s supplied pre-wired t o the accom panying relay and is m ounted on Din R ail. 2. Unplug Photo Am plifier from Amplifier Base. 3. Unclip Amplifier Base from existing Din Rail. 4. Remove existing Din Rail by removing the two screws that attach it to the ...
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Ultimate Products UP-206 - page 37
Operator with Belt 19 Operator with Chain 35 ...
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Ultimate Products UP-206 - page 38
1. retaining rod — 8’ ( AP1354), 10’ (AP1355), 12’ (AP1356), or 14’ (AP1357) 2. tube — anodized steel — 8’ (AP1720), 10’ (AP1721), 12’ (AP1722), or 14’ (AP1723) — non-anodized steel — 8’ (AP1701), 10’ (AP1702), 12’ (AP1703), 14’ (AP1704) 3. “o” ring — AP1004 4. check ball — nickel — AP1064 — stainless s ...
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Ultimate Products UP-206 - page 39
Architectural Guide for Air-Power Operator System Control Box — Power Supply : 1 10V Plug in type. Solenoid valve available in 24V or 1 10V . Always 24V unless specified otherwise. — Model: DC1000: Lever-operated, three-position air valve. DC4000: Control box that only works when the electricity is on (no buttons). DC5000: Control box that only ...
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Ultimate Products UP-206 - page 40
22 — Air Usage: Uses 0.4 cubic feet of air to open and 0.4 cubic feet of air to close. — Air Pressure: Regularly set for 40-90 PSI. — Air Line: 3/8 inch PolyFlow line — Operator Placement: The operator is normally mounted to the side of the track (either side). For extremely cold climates, the operator may be mounted on the horizontal track ...
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Ultimate Products UP-206 - page 41
Maintenance Guide For Air-Powered Operators and Illuminator Doors 23 Superior or Economy Air-Powered Operators Operators with chains 1. At least once every three months, lubricate the chain with a thick, gel-type grease. Do not use spray lubricants. 2. Make sure that the chain is not loose. Tighten the chain using a turnbuckle if needed. Do not ove ...
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Ultimate Products UP-206 - page 42
24 1. Set automatic oiler for one drop of oil for each complete cycle. 2. Keep oil bowl full at all times. 3. If water mixes with the oil, pour the oil out. Drain the air compressor and refill the bowl. Operators without Oiler: 1. Reduce air pressure to zero. 2. Fully extend piston rod out of the cylinder by opening or closing the door . 3. Remove ...
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Ultimate Products UP-206 - page 43
Seal Kit Procedures for Air-Powered Operators Items included in the kit: 6 U-cups 4 Piston Rod Seals 4 O-Rings 2 Breather V ents 2 Check Balls 2 Metering Screws 2 Seal Retainers T ools and materials needed: Rags Lightweight Oil Screwdriver 7/16” and 9/16” Wrenches Vise-grip Lightweight Hammer U-cup Seals 1. Close the door and turn off the air t ...
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Ultimate Products UP-206 - page 44
26 Piston Rod Seals 1. Follow steps 1-5 above. 2. Remove the top cap from the operator by tapping it off and then sliding it off the piston rod. 3. Put the top cap in a vise with the seal retainer facing down. Insert a screwdriver in the middle hole and tap it with a hammer until the seal retainer and two seals come out. 4. Replace the old seals wi ...
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Ultimate Products UP-206 - page 45
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Ultimate Products UP-206 - page 46
Contact us if you have questions about installation or maintenance. T echnical assistance and salespeople are available Monday through Friday between 9 AM and 5 PM, Eastern Standard Time. Ultimate Products is closed for national holidays. 800-542-7221 • 2319 Laurelbrook Street , Raleigh, NC 27604 ...
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