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Zap 815-RL - page 1
J A CKSHAFT MO T OR-CONTROL SYSTEM FOR RESIDENTIAL GARA GE DOORS Model 815-RL Installation Instructions W ARNING: T o r educe the risk of injur y to persons, use this oper ator onl y with a r esidential sectional door . FOR INST ALLA TION ONL Y BY Q U ALIFIED PERSONNEL ZAP CONTROLS UK 100 W aterloo Boulevard Anglesey Business P ark Cannock Stafford ...
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Zap 815-RL - page 2
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Zap 815-RL - page 3
IMPOR T ANT INST ALLA TION INSTRUCTIONS W ARNING: T o r educe the risk of Injur y or death READ AND FOLLO W ALL INST ALLA TION INSTRUCTIONS Install only on a properly balanced door . An improperly balanced door has the potential to inflict severe injury . Hav e a qualified service person make repairs to cables, spring assemblies, and other hardw ar ...
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Zap 815-RL - page 4
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Zap 815-RL - page 5
CONTENTS Product Overview .............................................................................................. 1 Description ........................................................................................................ 2 Fitting the Super -Dri v e ................................................................................. ...
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Zap 815-RL - page 6
CONTROL UNIT model 800-R Integrated Control unit with case mounted control button. This Control unit will power doors up to 15 square metr es (160 square feet) in conjunction with model 8472 Operator . MANUAL OVER- RIDE model ZA0093 The Manual Over -Ride drive release mechanism includes a Doorframe or track mounted over centre lever , which is conn ...
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Zap 815-RL - page 7
The Zap Controls’ range of Motor -Contr ol Systems for Sectional Doors provides a new concept in safety control and the elimination of the inher ent problems with a number of featur es of existing door Operators. The Zap 815-RL low voltage DC Motor -Control operates without limit switches and without a safety edge. The control unit monitors the m ...
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Zap 815-RL - page 8
3 An optional Beeper model 850 may be fitted to sound at the start of each door movement and provide audible feedback during pr ogramming and door position calibration. PREP ARA TION Ensure that the door is fr ee to move by hand without any stiffness or misalignment of track sections, which may cause the roller wheels to jump over the track joints. ...
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Zap 815-RL - page 9
Next slide the Super -Drive assembly onto the door shaft and select a suitable hole in the torque arm to bolt it to the Super -Drive back plate using the spacer bush, which should pass through the lower slot in the Cover back. (Pic 7) The Cover back will be secured later . The T orque Arm should be approximately at right angles to the Super -Drive ...
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Zap 815-RL - page 10
The second Allen screw , set at 90 degr ees, should then be tightened and secured with the locknut. Now tighten the torque arm scr ews (Pic 10) FITTING THE MANU AL O VER-RIDE LEVER MECHANISM The position of the cable post should be assessed next. The Cable Post, which secures the Bowden cable outer sheath, is fixed to the door track or frame using ...
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Zap 815-RL - page 11
Mark the hole positions for the Manual Over -Ride lever on the door track or frame in a convenient position with the lever held in the horizontal position. Drill two M5 or 7/32nd of an inch size holes. (Pic 13) . Fit the M5 screws pr ovided with the scr ew head on the inside of the track or doorframe. Fit the M5 nuts. Secure the hook in the D-shack ...
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Zap 815-RL - page 12
FITTING THE CONTROL UNIT Check that the control unit voltage, which is shown on the label on the side of the control unit case, is correct for the available single-phase supply voltage. The control unit model number has a suf fix, which relates to the supply voltage. US is 120 volts EU is 220 volts UK is 240 volts The US/120 volt control unit will ...
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Zap 815-RL - page 13
be strapped to the Super -Drive Bowden cable with cable ties to allow both cables to seat neatly in the slot in the bottom of the Motor Cover . (Pic 20) Do not cut or shorten the Motor Cable. Ensure that any unused cable is coiled and secured away from any moving parts, using the cable ties provided. NOTE THA T ALL TERMINALS ARE PLUG-IN FOR EASE OF ...
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Zap 815-RL - page 14
C O NNECTING THE MAIN A/C SUPPL Y The Operator should be installed in accordance with local codes and national electric code. T o reduce the risk of electric shock, this equipment has a grounding type plug that has a thir d (grounding pin). This plug will only fit into a grounding type outlet. If the plug does not fit into the outlet, contact a qua ...
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Zap 815-RL - page 15
7. The new supply wiring should be terminated to the GREEN connector block. The correct locations for the Live, Neutral and Ground wires ar e marked on the panel next to the GREEN socket. The new Black (live) wire should be terminated in the left hand terminal. The White (neutral) wire should be terminated in the center terminal and the Green (gr o ...
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Zap 815-RL - page 16
TESTING THE DOOR OPERA TION When the basic wiring is complete the door operation may be tested. It may be helpful to fit an optional Plug-in Beeper module (part No. 850) (Pic 28) , which sounds in conjunction with flashes of the Acknowledge LED. The beeper will sound at the start of each door movement and provides audible feedback during programmin ...
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Zap 815-RL - page 17
DOOR DIRECTION ASSESMENT The motor direction will depend on which side of the shaft the Operator is mounted. In order to assess the corr ect dir ection of movement of the door first release the Manual Over -Ride Lever and move the door manually to a half open position. Then re-engage the Manual Over -Ride Lever . Momentarily press the Control unit ...
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Zap 815-RL - page 18
After the door has stopped in the fully closed position, press the OPEN push button again. When the door has stopped in the open position – press the button to close the door . Complete another door open and close cycle and confirm that when the door has correctly calibrated the door stops and remains stationary in the fully closed position. Afte ...
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Zap 815-RL - page 19
direction may be adjusted with the CLOSE SENSITIVITY preset. (Pic 37) If it is requir ed to incr ease the obstruction sensitivity , thus reducing the door edge pr essure requir ed to activate the contr ol unit obstruction sensing circuit, which causes the door to stop and re-open during the close fast speed cycle, then the CLOSE SENSITIVITY adjuste ...
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Zap 815-RL - page 20
See the wiring diagrams on pages 19 and 20. If two or more Photo-Eyes, or any other safety devices are fitted then each switching cir cuit should be wired in series. A 24-volt Photo-Eye or other accessory may be powered fr om the 24-volt DC accessory Radio supply terminals at the lower right hand side of the panel. The 24-volt accessory supply may ...
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Zap 815-RL - page 21
If the safety circuit is interrupted whist the door is closing then the door will stop and reopen. If the safety circuit is interrupted whist the door is operating with the Auto-Close timer DIP switch No. 4 set to ON then the timer will reset during each interruption of the safety circuit, whilst the door is open. The Auto-Close function is not ope ...
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Zap 815-RL - page 22
When the program button is pr essed and held, a sequence of flashes of the Acknowledge LED follows at 4-second intervals. If a Bleeper is fitted then the Bleeper will sound with the flashes of the LED. The first flash or bleep indicates the Zap remote control transmitter pr ogram mode. The second flash or bleep indicates the Auto- Close timer progr ...
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Zap 815-RL - page 23
A UT O-CLOSE TIMER PROGRAMMING This function is not available for the North American market. The factory set Auto-Close timer delay is 15 seconds. In order to confirm the operation of the Auto- Close timer first set DIP switch No. 4 to ON. Then press the case push button to open the door . The door will open and re-close after the time delay . The ...
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Zap 815-RL - page 24
19 ; ! " 2 75( 6+( $6( (&(,8(4 9,6+ 6+( " 21 ...
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Zap 815-RL - page 25
20 ZAP 800-R – SAFETY WIRING CONNECTIONS – ZAP PHO T O-EYES ! ! ? ...
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Zap 815-RL - page 26
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Zap 815-RL - page 27
REASON & REMEDY A. The door movement is stiff due to the door running tight against the door frame in the fully closed position. In which case adjust the position of the roller wheel supports to ease the pr essur e of the door against the frame. B. The door is badly out of balance. In which case re-tension the counterbalance springs. C. The doo ...
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Zap 815-RL - page 28
ZAP CONTROLS UK 100 W aterloo Boulevard Anglesey Business P ark Cannock Staffordshire WS12 1NR United Kingdom ...
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