FAQ’s

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Commercial Residential

Commercial

Which operator do I need?

Please visit the product selector for sectional doors. Please contact us if the proposed application is unusual.

How do I set the limits?

The Zap commercial operators do not use limits in the conventional sense. Instead they continually self-calibrate.

  • Run the door in the open and close direction making sure that the Opening and Closing lights go out and the ACK light flashes twice as soon as the door reaches the end position.
  • Allow the door to run without using the stop button and after three runs in each direction you should see that the door changes to slow speed at the same point on each run.
  • Allow the door to run without using the stop button and after three runs in each direction you should see that the door changes to slow speed at the same point on each run.

Why does the door stop before it reaches the fully open or fully closed position?

This usually indicates that the door is not running as smoothly as it was.

  • Release the manual override lever and move the door manually from fully closed to fully open and back again.  The door must run freely and be evenly balanced.  Make adjustments to the door hardware until it is well balanced and runs freely.
  • Check to ensure that there are no jolts or irregularities in the operation of the door.  If necessary turn the Close Sensitivity adjuster slightly anti-clockwise to reduce the sensitivity to minor imperfections.
  • If the door is large then you might need to turn the Max Power Clamp slightly anti-clockwise to increase the maximum power available to the motor.
  • Run the door several times after making any adjustments and make sure that the door runs fully in both directions, that the opening and closing lights go out as soon as the door stops moving and that the speed changes from fast to slow at the same point on subsequent runs.

Why does the opening or closing light stay on after the door stops moving?

This usually indicates that the motor pulley is slipping against the V-belt.

  • Check that the manual release lever is tight enough,  it should have compressed the release spring and be tensioning the V-belt when the lever is horizontal.
  • Check that the V-belt doesn’t need replacing.
  • Turn the Max Power Clamp adjuster slightly clockwise to reduce the power if the motor is running on in the fully open position.
  • Turn the Close Sensitivity adjuster slightly clockwise to increase the sensitivity if the motor is running on in the fully closed position.

Why does the door run slowly?

This usually indicates that the motor pulley is slipping against the V-belt.

  • Check that the manual release lever is tight enough, it should have compressed the release spring and be tensioning the V-belt when the lever is horizontal.
  • Check that the V-belt doesn’t need replacing.
  • Turn the Max Power Clamp adjuster slightly clockwise to reduce the power if the motor is running on in the fully open position.
  • Turn the Close Sensitivity adjuster slightly clockwise to increase the sensitivity if the motor is running on in the fully closed position.
  • Run the door up and down several times and make sure that the door speeds up and the speed change points are in the same positions on each run.

Why doesn’t the acknowledge light flash twice when the door stops moving?

This feature was introduced for the series 3 operator, earlier operators do not indicate the fully open and fully closed positions.

If a series 3 operator doesn’t indicate the fully open or fully closed position then it may mean that the V-belt is slipping if the opening or closing light stays on, or alternatively that the door needs to be factory reset and run three times in order to re-establish its position.

What do the LEDs indicate?

1 ACK – Acknowledge light flashes once before opening or closing, flashes twice when the door reaches the fully open position.
2 SFTY – Safety light is on when there is a safety breach or the controller is operating in deadman close mode.
3 PWR – Power light is on when there is mains power and flashing when there is only battery power.
4 CLSNG – Closing light is on when the motor is running in the close direction; It should turn off as soon as the door stops moving.
5 OPNG – Opening light is on when the motor is running in the open direction; It should turn off as soon as the door stops moving.

What do the Close Sensitivity and Max Power Clamp controls do?

What do the Close Sensitivity and Max Power Clamp controls do?

  • The Max Power Clamp adjuster sets a maximum allowed current flow through the motor, this is usually triggered by a steady increase in load when the pusher springs are being compressed or if the door is unbalanced or difficult to move.  The adjuster should be turned anti-clockwise to increase the maximum power.
  • The Close Sensitivity adjuster responds to rapid changes in the load on the motor in either direction, this is usually triggered by a sudden increase in load when the door reaches the ground or strikes an obstruction.  It can also be triggered by damage to the tracks or door.  The adjuster should be turned anti-clockwise to reduce the sensitivity to obstructions.
  • The motor stall sensor detects a current close to the maximum allowed power which has been present for several seconds, this is usually triggered if the door is badly out of balance or if the V-belt is slipping or worn.  This limit is not adjustable.
  • Please see “A graphical look at the power and sensitivity controls on Zap series 3 commercial operators.pdf

How do I do a factory reset?

A factory reset will erase all programmed transmitters, disable the service due reminder and the close delay and re-set the auto-close time and door size to the factory defaults.

  • Press and hold the RESET button.
  • Press and hold the PROGRAM button.
  • Release the RESET button but keep the PROGRAM button pressed.
  • The ACK light will flash once every 4 seconds.
  • For doors under 4.5m high release the PROGRAM button after the first flash of the ACK light.
  • For taller doors, release the PROGRAM button after the second flash of the ACK light – this extends the initial run-time to allow the controller to calibrate to larger doors.
  • The ACK light will flash twice to indicate that the factory reset has been completed.
  • Re-establish the door limits by running the door in the open and close directions until the point at which the speed changes from fast to slow stabilises.

Why does the acknowledge light keep flashing?

The ACK light flashes once every 4 seconds while accessing the various programming modes. If it is flashing at this rate then the PROGRAM, STOP, OPEN or CLOSE buttons may be stuck.
The ACK light flashes once per second for 10 seconds before and during the close cycle if the service due reminder has been triggered.
The ACK light gives flashes of varying lengths for several seconds while it is displaying the operations count.

Why doesn’t the door close straight away?

  • The controller has a soft start which gently accelerates the door up to full speed in order to prevent the cables going slack at the start of the close cycle.  In some cases a loose or incorrectly fitted torque arm bracket can allow the operator to rotate sideways during this soft start which further delays the start of the close.  The operator should not move sideways at all while it is driving the door.
  • There is a programmable close delay which allows a warning to be given before the door starts to close, if this is active then the acknowledge light will flash once at the start of the delay and again at the start of the close.  Please see “How do I change the close delay?

How do I set the auto-close time?

The factory default auto-close time is 15 seconds, it can be set to anything from 3 seconds to 4 minutes. To turn off the auto-close, set DIP switch 4 to OFF.

  • Close the door to the ground and set DIP switch 4 AUTO-CLOSE to ON.
  • Press and hold the PROGRAM button, the ACK light will flash once every 4 seconds.
  • Release the PROGRAM button after the second ACK light flash to start the auto-close programming procedure.
  • Press and release the OPEN button to open the door.
  • Start timing when the door stops in the fully open position.
  • Press and release the CLOSE button after the required auto-close time has elapsed.
  • The ACK light will flash several times and the door will close.
  • Test the auto-close time by opening the door and waiting for it to close, adjust if necessary.

How do I clear the service due reminder?

The case lid buttons can be used to access the operations count and to reset or to disable the service due reminder. An 850 Beeper Module, which beeps every time the ACK light flashes, is available to allow these functions to be used without having to open the control box.

  • Press and hold the STOP and OPEN buttons together.
  • The ACK light will flash (beeper sounds if fitted) once every 4 seconds.
  • Release the STOP and OPEN buttons after the first flash/beep to get the operations count – long flashes/beeps for 1,000’s of operations and short flashes/beeps for 100’s of operations.
  • Release the STOP and OPEN buttons after the second flash/beep to reset and enable the service due reminder – the reminder will add a 10 second pre-close delay after another 19,200 door operations (9,600 cycles) have been completed.
  • Release the STOP and OPEN buttons after the third flash/beep to cancel and disable the service due reminder – the reminder will no longer activate (this is the factory default setting).

How do I change the close delay?

  • Open the door to the fully open position.
  • Press and hold the PROGRAM button, the ACK light will flash once every 4 seconds.
  • Release the PROGRAM button after the third ACK light flash.
  • Press and release the CLOSE button to start the close delay timing.
  • Press and release the CLOSE button after the required close delay time has elapsed.
  • The ACK light will flash twice and the door will close.
  • Test the close delay time by opening the door, pressing the CLOSE button and waiting for it to close, adjust if necessary.

Will the Zap operator fit in the space available?

The control box is 270mm wide by 220mm high by 110mm deep. The operator dimension drawings show the required clearance around the different operators.

Can the Zap operator control a light?

There is a built in light control relay which can drive a 1kW mains load. The relay function is selected via DIP switch 6.

  • DIP switch 6 OFF – the relay comes on for 3 minutes after any door operation. DIP switch 6 ON – the relay is on when the door is open.

How can the Zap operator be interfaced to a dock controller?

The 82-DTLM plug in Dock Traffic Light and Leveller Interlock Module can be used together with the interlock input to provide a Red traffic light output when the door is not fully closed, a Green traffic light output when the door is fully closed, an Interlock output to prevent dock operation until the door is fully open and an Interlock input to prevent door operation unless the leveller is parked / truck latch is engaged.

How do I wire an external radio receiver to a Zap controller?

There is a radio connector one third of the way up on the right hand side of the control panel. The connector provides a 24V supply and a cycle input. Please see detailed instructions for connecting the following devices:

  • Megacode
  • Delta 3
  • 312HM
  • 355LM
  • 365LM
  • 850LM
  • Marantec
  • Blueguard

How far away from the operator can I site the control box?

The control box can be sited at a remote location up to 20m from the operator provided the following conditions are met:

  • The door control position must be located in a location with a clear view of the area both inside and outside the door while the door is closing.
  • The motor cable must be replaced with no more than 20m of 4mm2 core diameter cable to avoid an excessive voltage drop from causing the motor to stall.
  • The photo-eye wiring will need to be extended too but this wiring must not come within 50mm of the motor cables or any mains carrying conductors.

How far away from the control box can I site a remotely wired button station?

A remotely wired button station can be sited up to 20m from the control box provided the wiring is kept away from any mains carrying conductors to avoid electrical interference from causing unreliable operation.

Why is the power light off?

  • The power supply is not on.
  • The main supply fuse has blown.  Isolate the mains power supply, remove the fuse and test it.  The 800 and 8800 controller requires a 6.3A F rated fuse while the 8800-HP has a 10A F rated fuse.
  • The voltage selector switch is not set correctly.  Turn off the mains power supply, set the voltage selector switch to the correct value and turn the mains supply back on.

Residential

Is the 8825-R4 suitable for my door?

The 8825-R4 is suitable for residential doors up to a maximum size of:

  • 26m2 580kg for standard lift and low-headroom doors with drums up to 140mm in diameter.
  • 20m2 435kg for high lift doors with drums up to 190mm in diameter.
  • 13m2 300kg for high lift doors with drums up to 240mm in diameter.
  • 15m2 340kg for vertical lift doors with drums up to 220mm in diameter.

How do I set the limits?

  • Establish the door direction by manually opening the door a few cm and then pressing and releasing the green illuminated button.
  • The opening light should flash while the door tries to open. If the door moves in the wrong direction then slide the DIRECTION dip switch to the other position and try again.
  • Press and hold the PROGRAM button until you hear a beep after about 3 seconds.
  • Release the PROGRAM button to enter calibration mode; the beeper will now sound every second.
  • Press and hold the PROGRAM button to open the door. Release the button when the door stops at the opening end-stop.
  • Press and hold the PROGRAM button to close the door. Release the button when the door reaches the ground.
  • Press and release the green illuminated button to calibrate the door power. The door will open, wait and close at normal speed.
  • Once the door has stopped on the ground, press and release the PROGRAM button to exit the calibration mode.

Please refer to the installation instructions for further information about the installation and calibration processes.

Why does the opening or closing light keep flashing after the door stops moving?

This usually indicates that the motor pulley is slipping against the V-belt.

  • Check that the manual release lever is tight enough, it should have compressed the release spring and be tensioning the V-belt when the lever is horizontal.
  • Check that the V-belt doesn’t need replacing.
  • Re-set the limits but release the PROGRAM button just as the door is about to touch the opening obstruction or the ground. This will reduce the force required to stop the door at the end points.
  • Reduce the tolerance to obstructions. This will reduce the force over the entire door movement:
    • Press and hold the PROGRAM button, the beeper sounds once every 3 seconds.
    • Release the PROGRAM button after the second beep, the beeper sounds every second for 15 seconds.
    • Press and release the green illuminated button after the required number of beeps: 1 beep is very sensitive, 6 beeps is the factory default.

You will need to re-set the limits after reducing the obstruction tolerance in order for the change to take effect.

Why does the door run slowly?

The door can run slowly if the controller has lost track of the door position after a power outage or after the door has been manually moved.  The controller should return to normal operation after running a few times in both directions.  Allow the controller to run without stopping the door with the green illuminated button.  If the door doesn’t start running correctly within 3 opens and 3 closes, then manually close the door to the ground and turn the power off and back on again to reset the controller.

Why doesn’t the door stop moving when it reaches the open position?

The default behaviour for the 8825-R4 is for it to open until it encounters a physical obstruction.  If you want the door to stop before it reaches the physical obstruction then you need to alter the open stopping mode:

  • Press and hold the PROGRAM button, the beeper sounds once every 3 seconds.
  • Release the PROGRAM button after the third beep to toggle the open stopping mode.
  • One long beep indicates that the operator will now stop at a position set during calibration. Two short beeps indicate that the operator will open to a physical end-point.

You will need to re-set the limits after altering the open stopping mode in order for the change to take effect.

What do the LEDs indicate?

LD1 – The closing light flashes when the motor is running in the close direction; It is on if the door is stopped on the ground and off if the door is stopped in any other position.

LD2 SAFETY – The safety light is on when there is a safety breach or the controller is operating in deadman close mode.

LD3 – The opening light flashes when the motor is running in the open direction; It is on if the door is stopped in the fully open position and off if the door is stopped in any other position.

How do I perform a factory reset?

To restore the factory defaults:

  • Turn the power off.
  • Press and hold the PROGRAM button.
  • Turn the power back on and keep the PROGRAM button pressed.
  • The beeper will sound once every 4 seconds.
  • Release the PROGRAM button after the second beep.
  • You will hear a sequence of beeps and see the operator light flash several times to indicate that the factory reset has been completed.

You will need to re-set the limits after performing a factory reset.

Why does the beeper keep sounding?

  • The beeper sounds once every 3 or 4 seconds while accessing the various programming modes. If it is beeping at this rate then the PROGRAM or green illuminated button may be stuck.
  • The beeper sounds once per second for 10 seconds before and during the close cycle if the service due reminder has been triggered.

The beeper sounds intermittently for several seconds while it is displaying the operations count, the serial number or the system status.

Why doesn’t the door close straight away?

The controller has a soft start which gently accelerates the door up to full speed in order to prevent the cables going slack at the start of the close cycle.  The soft start can be shortened if necessary:

  1. Press and hold the PROGRAM button, the beeper sounds once every 3 seconds.
  2. Release the PROGRAM button after the fifth beep, the beeper sounds every second for 10 seconds.
  3. Press and release the green illuminated button after the required number of seconds: The factory default is 4 seconds.
  4. You might need to re-set the limits after altering the soft start.

In some cases a loose or incorrectly fitted torque arm bracket can allow the operator to rotate sideways during this soft start which further delays the start of the close.  The operator should not move sideways at all while it is driving the door.

There is an in-built service due reminder which can be set to introduce a close delay after 20,000 door operations (10,000 door cycles) have been completed.  This is to remind the user that the door needs servicing.  Please see the installation instructions for information on setting, re-setting and disabling the service due reminder.

How do I set the auto-close time?

The factory default auto-close time is 15 seconds, it can be set to anything from 5 to 96 seconds.  To turn off the auto-close, set DIP switch 1 to OFF.

  • Turn off the power and set DIP switch 1 AUTO-CLOSE to ON.
  • Press and hold the green illuminated button and turn the power back on, the beeper will sound once every 4 seconds.
  • Release the PROGRAM button after the first beep to select the auto-close time.
  • The beeper will sound once every second for 96 seconds: Press and release the green illuminated button after the required time.

Note that it is not possible to set the door limits or use the radio to close the door while the auto-close DIP switch is on.

Will the Zap operator fit in the space available?

The control box is 122mm wide by 122mm high by 64mm deep.  The operator can be mounted in any orientation – even inside the cable drums.  It requires: 64mm of jackshaft and 120mm clearance beyond the end of the jackshaft; 70mm clearance on three sides of the jackshaft and 377mm on the fourth side.

Why is the green illuminated button light off?

  • The power supply is not on.
  • The main supply fuse has blown. Isolate the mains power supply, remove the fuse and test it.  The 8825-R4 controller requires a 5A F rated 1¼

Why does the door stop before it reaches the fully open or fully closed position?

This usually indicates that the door is not running as smoothly as it was.

  • Release the manual override lever and move the door manually from fully closed to fully open and back again. The door must run freely and be evenly balanced.  Make adjustments to the door hardware until it is well balanced and runs freely.
  • Check to ensure that there are no jolts or irregularities in the operation of the door. If necessary increase the obstruction tolerance to reduce the sensitivity to minor imperfections.
  • If the door is large then you might need to increase the obstruction tolerance to increase the maximum power available to the motor.
    • Press and hold the PROGRAM button, the beeper sounds once every 3 seconds.
    • Release the PROGRAM button after the second beep, the beeper sounds every second for 15 seconds.
    • Press and release the green illuminated button after the required number of beeps: 6 beeps is the factory default, 15 beeps gives the greatest obstruction tolerance.

You will need to re-set the limits after reducing the obstruction tolerance in order for the change to take effect.

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