ZAP 8800 Series 3 Commercial Door Shaft Mounted Motor Operators Instruction Manual

: August 4, 2024
: zap

Table of Contents

ZAP 8800 Series 3 Commercial Door Shaft Mounted Motor Operators
IMPORTANT- SAFETY INSTRUCTIONS
CONTROL UNIT OPERATION
LIGHTING CONTROL
MAINTENANCE SCHEDULE
MORE INFORMATION
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ZAP 8800 Series 3 Commercial Door Shaft Mounted Motor Operators

IMPORTANT- SAFETY INSTRUCTIONS

WARNING: – To reduce the risk of severe injury or death

READ AND FOLLOW ALL INSTRUCTIONS
Never let children operate or play with door controls. Keep the remote control (where provided) away from children.
Personnel should keep away from a door in motion and keep the moving door in sight until it is completely closed or opened. NO ONE SHOULD CROSS THE PATH OF A MOVING DOOR.
Test the door’s safety features at least once a month. After adjusting either the force or the limit of travel, retest the door operator’s safety features.
Failure to adjust the operator properly may cause severe injury or death.
Where possible use the Manual Override Release Lever only when the door is closed. Use caution when using this release when the door is open. Weak or broken springs may cause the door to fall rapidly, causing severe injury or death.

KEEP DOORS PROPERLY OPERATING AND BALANCED. See Door Manufacturer’s Owner’s Manual. An improperly operating or balanced door could cause severe injury or death. Have a trained door systems technician make repairs to cables, spring assemblies, and other hardware.

ZAP MOTOR-CONTROL SYSTEMS FOR COMMERCIAL DOORS
The system includes a model 800 or model 8800 wall-mounting Control Unit with case-mounted control buttons, a Jackshaft Motor Operatr ,and a Manual Override kit.

MOTOR-CONTROL UNITS

MODEL 800
The model 800 Control Unit will power doors up to 12 square metres (130 square feet) in conjunction with the series 800 Motor Operator.

Model 800 Motor Operator

MODEL 8800
The model 8800 Control Unit will power doors up to 26 square meters (280 square feet) in conjunction with a series 8800 Motor Operator.

Model 8800 Motor Operator

MANUAL OVERRIDE RELEASE
The Manual Override drive release mechanism includes a doorframe or track mounted over the centre lever, which is connected to the operator by a Bowden cable. The screw hook on the lever provides adjustment of the V-belt tension.

ZAP COMMERCIAL DOOR MOTOR-CONTROL SYSTEM

Following installation and commissioning by a qualified technician, the power supply should be, when possible, left permanently connected.
If any work is to be carried out on the door or installation then the main power supply should be isolated.

USING YOUR ZAP COMMERCIAL DOOR MOTOR-CONTROL SYSTEM

NOTE: A safety photo-electric sensor may be fitted to operate in conjunction with the control system. If a safety photo-electric sensor is fitted it must be correctly installed and aligned. If it is out of alignment it will prevent the door closing other than by Dead-Man operation (continual depression) of the CLOSE button.

The system may be operated by any of the following items:

Model 800 and 8800 Control Unit push buttons. Operation is as follows: Press and hold either the upper OPEN or lower CLOSE push button until the door starts to move. Note that if a photo-electric sensor has not been installed across the doorway then the close function will only operate in Dead-Man (press and hold to run). The door will stop if the CLOSE button is released.
ZAP Radio Transmitter, if fitted. Operation is as follows: Press and hold the transmitter button until the door starts to move. Note that if a photo-electric sensor has not been installed across the doorway then the door can not be closed by remote control.
Accessory Radio Transmitter (non-ZAP), if fitted. Operation is as follows: Press and hold the transmitter button until the door starts to move. Note that if a photo-electric sensor has not been installed across the doorway then the door can not be closed by remote control.

CONTROL UNIT OPERATION

If the door is open and the CLOSE button is pressed, the door will close.
If it is closed and the OPEN button is pressed it will open.
If the door is opening and the STOP button is pressed it will stop.
If the door is closing and the STOP button is pressed it will stop.
If the door is physically obstructed while it is closing it will stop and reopen.
If the door is physically obstructed while it is opening it will stop.
If the beam from the safety photo-electric sensor (if fitted) is obstructed while it is closing it will stop and reopen.
If the beam from the safety photo-electric sensor (if fitted) is obstructed or damaged while the door is open it will not close other than by Dead-Man operation (continual depression) of the CLOSE push button. In these circumstances, if the CLOSE button is released whilst the door is closing it will stop.
The safety photo-electric sensor operation (if fitted) has no effect on the door when it is opening.

If the safety photo-electric sensor is misaligned, the door will not close from the hand-held transmitter.
However, the door may be closed by pressing and holding the Control Unit case lid push button.

LIGHTING CONTROL

The lighting circuit is wired by a qualified electrician to an external light rated at a maximum of 500 watts and the DOCK LIGHT Dip switch number 6 is set to the OFF position, the light will turn on and remain on for three minutes from the last operation of the door.
The Control Unit may be set by the installer to turn the light on when the door is opened and turn it off when the door is closed instead. This feature is normally used to control a loading bay dock light.

TO OPEN THE DOOR MANUALLY

The door should be fully closed if possible. Pull the Manual Override Release Lever to release the drive and lift the door manually. Press the Manual Override Release Lever down to reengage the drive.
However, if the drive is reengaged with the door in a different position then the door may have to be cycled open and close for at least one complete cycle to enable the controller to synchronize the door position.

CARE OF YOUR ZAP MOTOR-CONTROL SYSTEM

OPERATION DURING COLD WEATHER
During winter if the door reverses off a build-up of snow or ice then the doorway should be cleared to enable the door to close fully.

MAINTENANCE SCHEDULE

Every month check that the closing door reverses when the safety photo- electric sensor beam is interrupted.

Every six months or 2500 operations, whichever is sooner:
Release the Manual Override Release Lever and move the door manually to assess the balance of the door and to check if it is binding.
Check the adjustment of the Manual Override Release Lever tension. The lever should be horizontal when the cable slack is taken up. Once the V-belt is bedded in and the slack is taken up the lever should be slightly lower than horizontal. If the lever tension requires increasing then turn the lever hook screw clockwise to increase the tension.
Check that the door opens and closes fully.
The Motor Operator does not require additional lubrication. Do not grease the door tracks.
If there is any doubt about the correct operation of the door then contact your dealer.

There are no user-accessible adjustments on the controller other than the following case push button programming options:

PROGRAMMING USING THE CASE LID BUTTONS
The following functions may be used providing the Control Unit is fitted with an optional Plug-in Beeper Module.

OPERATIONS COUNTER INTERROGATION
A Door Operations Counter is incorporated. The number of door operations, to the nearest 100 operations, can be checked at any time.

The Door Operations Counter may be checked as follows:

Press and hold the STOP button.
Then press and hold the OPEN button.
Release the buttons after the beep.

The beeper will then indicate the total door operations since the door was installed by sounding long beeps for 1000’s operations and short beeps for 100’s operations.

For example, Two long beeps and three short beeps indicate that the door has completed 2300 operations. If there is no response after releasing the buttons then the door has completed less than 100 operations.

AUTO-CLOSE – STAY OPEN PROGRAMMING
If the Control Unit has been set to Auto-Close and it is required to disable the Auto-Close function for example when it is required to hold the door open on a warm summer’s day, then the Auto-Close can be temporarily disabled by opening the door and waiting for the door to stop in the open position as follows: