M4000 Installation Manual

Model 4000 | Installation Manual Perimeter Fire Curtains

287 N. Maple Grove. Boise, ID

83704

P. (800) 574-0330 F. (208)

639-7851

i f @ k d

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Table of Contents Section 1: System Overview ................................................................................................................................. 4

1.1 – Major Components ................................................................................................................................. 4

1.2 – Changing System Settings ...................................................................................................................... 6

1.3 – System Orientation ................................................................................................................................. 7

1.4 – Site Verification ...................................................................................................................................... 7

1.5 – Checklist ................................................................................................................................................. 8

Section 2: Main Controller Installation and Conduit Routing ............................................................................ 9 2.1 – Installing the Main Controller .............................................................................................................. 10

Section 3: Housing............................................................................................................................................... 11 Assembling the Housing Sections ..................................................................................................................... 11

3.1 – Drive Motors......................................................................................................................................... 11

3.2 – Optional Satellite Controllers & Junction Boxes ................................................................................. 13

Installing the Housing Sections ......................................................................................................................... 14

3.3 – Installing Housing Top Sections........................................................................................................... 14

3.4 – Motor and Controller Cabling .............................................................................................................. 16

Section 4: Drive System ...................................................................................................................................... 17 Assemble the Drive System .............................................................................................................................. 17

4.1 – Bevel Gear Assemblies ......................................................................................................................... 17

4.2 – U-Joints ................................................................................................................................................. 18

4.3 – Drive Shafts .......................................................................................................................................... 19

4.4 – Additional Drive Shafts ........................................................................................................................ 19

4.5 – Up Limit Switch ................................................................................................................................... 20

Section 5: Electrical Connections ....................................................................................................................... 22 5.1 – 120VAC Connections ........................................................................................................................... 22

5.2 – Main Controller Cables ........................................................................................................................ 23

5.3 – Initiating Device Circuit ....................................................................................................................... 24

5.4 – Optional Keyed Test Deploy Switch .................................................................................................... 24

5.5 – Optional Door Activation Switches ...................................................................................................... 25

5.6 – Satellite Controller Chain Cables ......................................................................................................... 25

5.7 – Main Controller Settings ...................................................................................................................... 26

5.8 – Wiring Diagram .................................................................................................................................... 27

Section 6: Curtain System .................................................................................................................................. 28 Test the Drive System ....................................................................................................................................... 28

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6.1 – Test the Motors ..................................................................................................................................... 28

6.2 – Drive Chain........................................................................................................................................... 28

6.3 – Testing the Drive Line .......................................................................................................................... 29

Assemble the Curtain System ........................................................................................................................... 30

6.4 – Attach the Metal Tape .......................................................................................................................... 30

6.5 – Curtain Tray .......................................................................................................................................... 32

6.6 – Setting Tape Tension & Levelling The Curtain Tray ........................................................................... 34

6.7 – Adjusting the Up Limit Switch ............................................................................................................. 36

6.8 – Layout the Curtain ................................................................................................................................ 38

6.9 – Assemble the Curtain ............................................................................................................................ 38

6.10 – Optional Guide Pins ........................................................................................................................... 40

6.11 – Attaching Curtain to Housing ............................................................................................................. 40

6.12 – Attaching Curtain to Curtain Tray ...................................................................................................... 42

Installing Curtain System Components ............................................................................................................. 43

6.13 – Installing Optional Side Guides .......................................................................................................... 43

6.14 – Attaching Covers ................................................................................................................................ 44

6.15 – Install the batteries .............................................................................................................................. 44

6.16 – Retaining Clips ................................................................................................................................... 45

Section 7: System Testing .................................................................................................................................. 46 7.1 – Calibration Sequence ............................................................................................................................ 46

7.2 – Test Optional Keyed Switch ................................................................................................................. 47

7.3 – Test Optional Door Activation Switches .............................................................................................. 47

7.4 – Sewing Curtain Sections ....................................................................................................................... 48

Section 8: Troubleshooting ................................................................................................................................. 49 Appendix ............................................................................................................................................................... 51

A1 – Contact Smoke Guard .............................................................................................................................. 51

A2 – M4000 Installation Checklist ................................................................................................................... 52

Section 2: Control System ................................................................................................................................. 52

Section 3: Housing ............................................................................................................................................ 52

Section 4: Drive System .................................................................................................................................... 53

Section 6: Curtain .............................................................................................................................................. 54

Section 7: System Testing ................................................................................................................................. 55

A3 – Glossary .................................................................................................................................................... 56

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Section 1: System Overview The Model 4000 Perimeter Fire Curtain (M4000) is a motorized smoke and fire protection system housed in the ceiling of a building. The system uses one or more motors to lower a specialized curtain around a strategic location. When not in use the M4000 is retracted into a housing unit which maintains the aesthetic of the facility it is installed in. NOTE: Each M4000 is specific to its installation site. This guide provides general installation steps for components. Your installation may require some or all of these steps.

1.1 – Major Components Figure 1 - The Model 4000 Perimeter Fire Curtain with optional Side Guides.

A – M4000 Housing: The Housing contains all of the motors, drive shafts, pulley systems and the

Curtain for the M4000. B – Optional Side Guides: Some units may include the optional Side Guides, which guide the

Curtain on rails. C – Curtain: The curtain is made from specialized fabric and designed to withstand fire and smoke. D – Curtain Tray: The Curtain Tray lowers and raises the Curtain. When not in use the Curtain

Tray has aesthetically pleasing exterior paneling. E – Metal Tape: The Metal Tape is used to lower the Curtain from the Housing.

D

A

B C E

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Main Controller The Main Controller serves as housing for batteries, control switches, status LEDs and system control switches which can be used to put the unit into different operating modes. In the event the unit has additional Satellite Controllers and other hardware, the Main Controller serves as the hub for the entire system.

A – Low Voltage Power Block: The low voltage power block is the terminal location for most of the systems on the M4000 including optional features.

B – High Voltage Power Block: The high voltage power block is the main input point for the

M4000 power system. C – PCA: The Printed Circuit Assembly (PCA) controls the normal operation of the M4000. The

PCA is also the location of the configuration switches which are used to change the system from Armed to Jog Mode. The control switches used to jog the system are also located by the PCA.

D – Status LEDs and Test Switch: The status LEDs indicate normal operation and errors on the

M4000. These lights can be used for troubleshooting the system and verifying certain conditions. The system test microswitch is also found on the LED board.

E – Batteries: The batteries provide emergency power to the M4000, enabling it to deploy in the

event of primary power loss.

Figure 2 – (Left) The M4000 Main Controller seen with outer cover. (Right) The interior of the Main Controller.

A B

C

D

E

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1.2 – Changing System Settings Over the course of the installation it will be necessary to change the operating mode of the M4000. The unit can operate in two modes:

Jog Mode: Enables the use of the control buttons to jog the system up and down at will. Armed: The normal setting for the curtain after it has been installed. This is also the mode used for

testing. The operating modes can be altered by changing settings on the DIP switch on the system PCA. Additional DIP switch settings as well as settings for Satellite Controllers can be found in Section 5.

Step 1 – Power off the Main Controller and disconnect the battery. Step 2 – To change system settings, move the #6 DIP switch.

o UP for Armed. o DOWN for Jog Mode.

Step 3 – Wait 3 seconds to allow the system to restart. Then power on the Main Controller and re-connect the

battery. WARNING: Be sure the Main Controller is powered down before changing DIP switch settings.

Figure 3 – The #6 DIP switch is used to change between operating modes on the M4000.

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1.3 – System Orientation The M4000 is installed to a Header at the installation site. Although the unit will be oriented with its top plate anchored to the Header. Illustrations in this guide will present the M4000 in the position it will be in for its final installation.

1.4 – Site Verification Prior to installing the M4000 it is critical that certain requirements are met at the work site. This will ensure safe and successful installation of the M4000. Electrical:

Point to point wiring from the location of the M4000 to its Main Controller must be in place before the system can be installed. Work with your electrical contractor to verify that the required circuit is in place for installation. Consult the Installation Layout Sheets (ILS) located in the shipping manifest as well as Section 2 and Section 5. for more information on wiring.

Work Site: Measure mounting surfaces and correct framing and finishing variances prior to installing the M4000. Consult your architectural diagrams and make any alterations before installing the unit. Because each M4000 unit is unique to its installation site, only your Installation Layout Sheets and architectural documents will apply to your installation.

Materials: Check that all components for the M4000 are ready for installation. Use your bill of materials shipped with the product to verify your parts list. Because each M4000 unit is unique to its installation site, only your Installation Layout Sheets and bill of materials will apply to your installation.

Top

Bottom

Front / Office side

Back / Atrium side

Figure 4 – The M4000 seen from the side. The front of the system houses the motors and other components.

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Staging: Using the Installation Layout Sheets included with your unit, stage components on the floor around the worksite to ensure each section of your unit has all the parts necessary for installation. Each section is numbered and depending on what length and how many corners, each section may require additional motors and Satellite Controllers. Stage components in a manner that is appropriate for your worksite.

NOTE: The motors and controls are generally meant to service a 9’ section. Long sides may require more than one motor and additional hardware. There should be approximately one motor for every 20’ of section.

1.5 – Checklist To help keep track of the installation process and ensure that the M4000 is correctly installed, utilize the check boxes that verify certain critical steps have been completed. A full checklist sheet is available in the appendix.

This is an example of how checklist items will appear throughout the installation.

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Section 2: Main Controller Installation and Conduit Routing It is strongly recommended to maintain easy access and a line of sight from the control system to the M4000 Curtain. Remote installations make communication difficult during installation and servicing. An optimal location to place the Main Controller is above removable ceiling tiles adjacent to the Curtain. WARNING: The Main Controller must be within 30 conduit feet of the unit.

NOTE: This product is intended to be installed in accordance with the National Electric Code NFPA

80, National Alarm Code NFPA 80 and within the limits of the authority having jurisdiction.

Consult with site GC/electrician to identify Main Controller location. Reference your Installation Layout Sheets to determine conduit routing paths. Requirements: Main Controller must be within 30 conduit feet of the Main Junction Box mounting location. 1” conduit is routed between the Main Controller low voltage compartment and Main Junction

Box. ½” conduit is routed to Main Controller high voltage compartment to supply 120VAC. A 120VAC service disconnect is required at the Main Controller.

NOTE: Only low voltage DC is run between the Main Controller and Main Junction Box.

Consult with site GC/electrician to coordinate additional power drops around perimeter of curtain housing (not required for single motor system). Reference your Installation Layout Sheets to determine conduit routing paths and number of circuits. Requirements: ½” conduit is required at each High Voltage Junction Box location on the curtain housing

to supply 120VAC. A 120VAC service disconnect is required at each High Voltage Junction Box location.

Consult with site GC/electrician to coordinate routing of conduit between Main Controller low voltage compartment and initiating device (smoke detector or fire alarm). Requirements: ½” conduit is required between initiating device and Main Controller low voltage

compartment. Two 18 or 20 AWG stranded wires labeled 14 and 15 between initiating device and Main

Controller low voltage compartment.

NOTE: Wires 14 and 15 are connected to the Normally Open contacts of the initiating device in parallel with the Smoke Guard EOL-Diode.

Consult with site GC/electrician to identify optional Wall Switch and/or Door Activation Switches. Reference your Installation Layout Sheets to determine conduit routing paths and number of circuits. Requirements: ½” conduit is required between Wall Switch box and Main Controller low voltage

compartment. Two 18 or 20 AWG stranded wires labeled 16 and 17 between Wall Switch box and

Main Controller low voltage compartment.

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½” conduit is required between Door Activation Switch box(es) and Main Controller low voltage compartment.

Two 18 or 20 AWG stranded wires for each switch between Wall Switch box and Main Controller low voltage compartment. First switch labeled 11 and 13, second switch labeled 12 and 13.

2.1 – Installing the Main Controller Step 1 – Using the Installation Layout Sheets

included with your unit, mark the target conduit locations on the wall. (junction boxes, service disconnect, Main Controller, Housing locations.)

NOTE: Some installations may require additional

components. Step 2 – Mount the Main Controller in an easily

accessible location within 30 conduit feet of the primary motor.

Step 3 – Mount the service disconnect next to the

Main Controller. Step 4 – Supply the Installation Layout Sheets to the

electrical contractor for conduit installation. Install the Main Controller.

The control system is now installed. Verify correct installation by checking all installation checklist items.

STOP

Figure 5 – The mounting points seen on the side of the Main Controller.

16”

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Section 3: Housing The Housing of the M4000 contains the motors, drive shafts and other components which enable the Model 4000 to operate. These components are mounted to the housing structure and the housing is then attached to the worksite. Installation requirements may vary depending on your worksite. NOTE: The Housing should be assembled prior to mounting the unit to the header.

Layout all Housing sections under the installation site according to the Installation Layout Sheets shipped with the unit. Mark Housing outer alignment lines on mounting surface.

Assembling the Housing Sections

3.1 – Drive Motors The curtains of the M4000 are raised and lowered using a system of drive shafts and motors. These steps will show you how to install a motor in your system.

Step 1 – Locate the motor mounting hole on the support bracket. Step 2 – Insert the motor into the 2” holes on the support brackets as seen in Figure 6. Ensure that the motor is

mounted so that the motor drive shaft is on the same side as the pulley on the top of the housing.

Figure 6 – A housing section highlighting the motor mounting points viewed if the unit was installed in the ceiling. During assembly you may have the hardware oriented differently than in this illustration. Be sure to verify what orientation you are working from to avoid assembly errors.

M5-12mm holes

Motor mounting holes

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Step 3 – Use hand tools to secure the motor by fastening the four, M5-12mm bolts located around the motor mounting hole as seen in Figure 6.

WARNING: Motor components are fragile. Using an impact hammer, or other power tool, may damage to

components.

Step 3 – Attach drive sprocket to the motor drive shaft. Position the sprocket so it is evenly spaced on the motor drive shaft, and tighten with set screw.

Attach motors with supplied hardware according to Installation Layout Sheets.

Attach drive sprocket. Ensure sprocket is evenly spaced on the motor drive shaft and tighten set screws.

Step 4 – Loosen all rotating plates on the support brackets and rotate them down so the drive shaft can be

placed in the Housing later in the installation. See Figure 8 for the location of the rotating plate bolt.

Figure 7 – An example of a correctly installed motor and drive sprocket. Note that the drive sprocket will always need to be able to line up with the drive shafts later in the installation.

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3.2 – Optional Satellite Controllers & Junction Boxes Some installations will require additional motors, junction boxes and Satellite Controllers to operate properly. Reference your Installation Layout Sheets to determine if these steps apply to your installation. These steps will show you how to install additional components to your M4000 system. If these steps do not apply to your installation, proceed to Section 3.3. For more information on Satellite Control wiring see Section 5.

NOTE: Every system will include one Main Junction Box. Step 1 – Attach Satellite Controllers to the Housing using the included hardware. See Figure 10 for attachment

locations Step 2 – Attach additional junction boxes using the included hardware. See Figure 10 for attachment locations.

Rotating plate

Figure 9 – (Left) A Satellite Controller. (Center) A Main Junction Box. (Right) A High Voltage Junction Box.

Figure 8 – (Left) The rotating plate on the support bracket can be moved by loosening the indicated bolt. (Right) The drive shaft fits into the support bracket behind the rotating plate.

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(If applicable) Install Satellite Controllers and junction boxes.

Installing the Housing Sections

3.3 – Installing Housing Top Sections WARNING: Large 9’ sections may require 3 or more people for installation. Additional people may be needed

to hold the Housing while it is temporarily anchored. WARNING: Do not lift the Housing sections by the motor. Each section of Housing has oversized ½” pre-drilled holes for initial anchors which will hold the Housing until the permanent anchors can be installed. At this point, adjustments to the alignment of the housing sections can be made if necessary. The Housing can then be permanently attached by inserting anchors through the smaller ¼” pre-drilled holes on the Housing sections see Figure 11 for location details.

Figure 11 – Initial and permanent anchor points on the top plate of the Housing as seen from the bottom.

Initial anchor points

Permanent anchor points

Figure 10 – Mounting locations for additional hardware as seen from the front of the unit.

High Voltage Junction Box Secondary High Voltage Junction Box

Main Junction Box

Satellite Controller

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Step 1 – Layout all the Housing sections under the installation site according to the Installation Layout Sheets shipped with your unit.

Step 2 – Use chalk or other erasable writing tool to mark where the outside of the Housing will align on the

header. Step 3 – For systems installed into a pocket, install the back cover and front cover plates prior to anchoring the

header. NOTE: It may be necessary to pre-install the outer covers of the top plates in instances where the front side of

the unit is exposed due to the ceiling soffit. For information on the outer covers see Section 6.14. Step 4 – Position a section against the header so that the front side faces away from the area the Curtain is

meant to contain. NOTE: For systems in an L or U shape, start installation at one end and work toward the other. Step 5 – Apply the #8 or #10 initial anchors through the ½” pre-drilled holes using the supplied oversized

washers. Step 6 – Apply initial anchors to all other sections.

Install all initial anchors through pre-drilled ½” holes.

Step 7 – Make any necessary adjustments to ensure the Housing sections line up properly.

Align all Housing sections.

Step 8 – Once sections are properly aligned, install the permanent #12 anchors through the ¼” pre-drilled holes. WARNING: The requirements for your anchors may differ from this guide. Consult your architectural

drawings to verify the requirements for your anchors. Install all permanent #12 anchors through pre-drilled ¼” holes.

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3.4 – Motor and Controller Cabling Step 1 – Feed motor and controller cables through the large

grommet holes on the Housing assembly as seen in Figure 12.

Step 2 – Plug wiring harnesses into controllers so that all

hardware is connected. Step 3 – Secure motor and controller cabling with zip ties

and clip wires into cable mounts so that there is 2” of clearance from the cables to the bottom edge of the Housing.

NOTE: Maintaining 2” of clearance between cables and the

bottom of the M4000 will help avoid accidental damage when the cover pieces are installed later.

Step 4 – Ensure all electronics are connected.

Route cables and feed through the large grommet holes on the support brackets. Secure with zip ties and ensure there is 2” of clearance above the bottom edge of the Housing. Ensure all systems are linked by cabling, and that harnesses are plugged in.

Figure 12 – The grommets are located on the support brackets of the Housing assemblies.

Grommet hole

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Section 4: Drive System The drive system is made up of separate sections. The number of sections varies depending on the length of the system. Each section contains drive shafts which serve as spools for the Metal Tape which raises and lowers the Curtain. Sections meeting at corners are coupled with a U-joint assembly or bevel gear assembly depending on the angle of the corner. The drive system also includes components which aid in system calibration such as the Up Limit Switch. NOTE: Following assembly of all components, the drive system will be tested to ensure proper operation.

Following a successful test of the drive line, all fasteners will be tightened on all assembled components. For more information on the drive line testing see Section 6.1.

Assemble the Drive System

4.1 – Bevel Gear Assemblies Bevel gear assemblies are used to connect M4000 sections that meet at a 90° angle. For all other angles a U-Joint is used. Reference your Installation Layout Sheets to determine if these steps apply to your installation. These steps will show you how to install additional components to your M4000 system. If these steps do not apply to your installation, proceed to Section 4.3. Step 1 – Layout bevel gear assemblies in the corner sections of the Housing top plates. Refer to your

Installation Layout Sheets to verify the correct location. Step 2 – Square the bevel gear to the Housing.

Square the bevel gear.

Step 3 – Secure bevel gear to Housing through pre-

drilled mounting holes on the top plate. Secure the bevel gear to the Housing.

NOTE: Not all corner sections have rotating plates to

secure drive shafts. Refer to your layout sheets to verify the components of your installation.

Step 4 – Install and tighten both ¼-20 bolts at the bevel gear shaft. See Figure 13 for an illustration of a bevel

gear shaft. Step 5 – Complete installation of drive shafts at the bevel gear assemblies until all drive shafts are fastened.

Bevel gear shaft

Figure 13 – A bevel gear assembly showing the four mounting points on top of the assembly and gear shafts.

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4.2 – U-Joints If your M4000 uses U-Joints, this step will serve as the first step in Drive Shaft installation as this step requires the U-Joint be connected to drive shafts. Connect drive shafts to the U-joint prior to installation. You can learn more about installing drive shafts in Section 4.3. Step 1 – Layout U-joint sections around the installation where appropriate. Refer to your Installation Layout

Sheets to verify the correct location. U-joints may be accompanied by short sections of drive shaft. Step 2 – Connect drive shaft sections to either side of the U-joint at the U-joint coupler. Figure 14 – The U-Joint is pictured from above with a section of drive shaft. Note the thrust bearing assembly clamped down around the bracket.

Attach U-joints to drive shafts. Install U-joint section with drive shafts into Housing and tighten collar clamps.

Step 3 – Secure drive shaft sections into the Housing by closing the rotating plate over the shafts. Step 4 – Tighten the collar clamps around the thrust bearings on the U-joint support bracket. NOTE: The U-joint attaches to non-coupler ends of the drive shaft. Depending on your installation it may not

be necessary to install short drive shafts. Refer to your layout sheets to verify the requirements for your installation.

U-joint Thrust bearing assembly U-joint coupler

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4.3 – Drive Shafts When installing drive shafts to an M4000 with a bevel gear, it is best to attach the drive shafts to the bevel gear assembly first and work the shaft into the support brackets. Step 1 – Using your Installation Layout Sheets, locate all drive shafts, couplers, chains and other hardware.

Layout the materials under the worksite. Step 4 – Place the drive shafts into the support brackets Step 5 – Tighten all rotating plates on the support brackets to secure the drive shafts.

Install drive shafts. Tighten all rotating plates to secure drive shafts.

4.4 – Additional Drive Shafts Step 1 – Install additional drive shafts by connecting neighboring shafts at the end by a coupler. See Figure 15

for an illustration of the coupler. Step 2 – Bolt shafts together at the coupler with ¼-20 bolts. Keep the bolts as close to the center of the ¼-20

slots as possible. Step 3 – Secure additional drive shafts by tightening all rotating plates on the support brackets. Step 4 – If the section of drive shaft has a motor, align the sprocket on the drive shaft with the motor sprocket

as seen in Figure 16. Step 5 – Verify the drive shaft can rotate freely in the support bracket by rotating it with your hand.

Coupler Non-coupler end

¼-20 bolt hole

Figure 15 – A short drive shaft section with a coupler to connect to other components.

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Verify drive shafts are secure and can rotate freely by hand. Verify sprockets on motors and drive shafts are aligned.

4.5 – Up Limit Switch The Up Limit Switch is the sensor that alerts the M4000 when the Curtain is raised to its maximum level. The Up Limit Switch is installed as a part of an assembly and attached to a support bracket on the Housing.

Step 1 – Attach the Up Limit Switch assembly to the same support bracket as the primary motor. See Figure 17 for more information on the mounting point.

Figure 16 – The motor sprocket and drive shaft sprocket in proper alignment seen from below

Figure 17 – (Left) the Up Limit Switch assembly and components. (Right) the Up Limit Switch mounting slots on the support bracket.

Up Limit Switch mounting slots

Normally Open

Tang

Common

Primary motor

Critical alignment

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Step 2 – Connect the cable from the to the primary motor connector Common and Normally Open tabs on the Up Limit Switch.

NOTE: The Up Limit Switch can be adjusted by moving the assembly forward or backward along the slots on

the support bracket. Later on in the installation it may be necessary to adjust the Up Limit Switch in order to achieve the desired interaction between the Up Limit Switch and the Up Limit Bracket. The Up Limit Bracket will be installed in Section 6.5. Verify the Up Limit Switch assembly is fastened to the same support bracket as the primary motor. Connect the Up Limit Switch to the primary motor.

Step 3 – Attach the Curtain Deflector to the support bracket using two 1/8” rivets. The Curtain Deflector should

be on the opposite side of the Up Limit Switch. See Figure 18 for an illustration of the Curtain Deflector.

Verify Curtain Deflector is secure to support bracket.

Figure 18 – (Left) The Curtain Deflector mounting points. (Right) The Curtain Deflector installed to the support bracket.

Curtain Deflector mounts Curtain Deflector

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Section 5: Electrical Connections This section covers the installation of electrical cables and components of both single motor and multi-motor M4000 systems. Depending on your installation, some steps may not apply.

NOTE: This product is intended to be installed in accordance with the National Electric Code NFPA

80, National Alarm Code NFPA 80 and within the limits of the authority having jurisdiction.

5.1 – 120VAC Connections

Step 1 – Install the supplied AC Chain cables within the housing. The free end of each cable is fed into a High Voltage Junction Box and the power connectors mate with either one, two or three Satellite Controllers.

NOTE: Due to the unique configuration of each M4000 system the AC Chain cables will be uniquely

designed. Reference your Installation Layout Sheets to determine the installation location of each supplied cable.

Step 2 – Ensure 120VAC wiring has been installed at the Main Controller high voltage compartment

and that the service disconnect is open.

Step 3 – Ensure 120VAC wiring has been installed and terminated at each High Voltage Junction Box (if applicable) and that service disconnect is open.

Single Motor Schematic

Figure 19 – The single motor schematic for the M4000.

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Multi Motor Schematic

Figure 20 – The multi motor schematic for the M4000.

5.2 – Main Controller Cables Step 1 – From the Main Junction Box pull free the end of Main Motor Cable and COM Cable to Main


Step 2 – At the Main Controller low voltage compartment connect each wire of Cable as follows:

Wire Terminal Description

1 (RED) 1. MOTOR +

2 (BLK) 2. MOTOR –

3 (RED) 3. +24 VDC

4 (BLK) 4. COMMON

5 (WHT) 5. BRAKE

6 (GRN) 6. SENSOR POWER

7 (ORG) 7. SENSOR SIGNAL

8 (BLU) 8. UP LIMIT

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NOTE: Exercise care in making all terminations. Incorrect wiring can lead to permanent damage. NOTE: At this point ensure that a jumper wire is installed between terminal “9. EDGE SENSOR” and

ground. If the system is supplied with an optional Super Sensor system this jumper will be removed at the time of installation. Installation of the Super Sensor system should occur after the procedures of this document are complete. Its installation is covered in a separate document.

Step 3 – Connect COM Cable to PCA connector J23: Step 4 – At the Main Junction Box connect Main Motor Cable

connector to the junction box connector and connect COM Cable to the junction box coupler.

5.3 – Initiating Device Circuit Step 1 – Ensure that wires 14 and 15 have been installed at the Normally Open contacts of the initiating

device. The Smoke Guard EOL-Diode should be connected in parallel with these contacts, order of diode wires does not matter.

Step 2 – At the Main Controller low voltage compartment connect wires as follows:

NOTE: If it is not possible to perform this step at this time connect the Smoke Guard EOL-Diode directly into terminals 14 and 15 to avoid system fault during subsequent testing.

5.4 – Optional Keyed Test Deploy Switch Step 1 – Ensure that wires 16 and 17 have been installed at the remote key-switch, order of wires does

not matter.

Step 2 – At the Main Controller low voltage compartment connect wires as follows:


14 14. SMOKE DET/FIRE ALARM +

15 15. SMOKE DET/FIRE ALARM -


16 16. WALL SWITCH +

17 17. WALL SWITCH -

Figure 21 – Controller PCA J23 identification.

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NOTE: If it is not possible to perform this step at this time it can be performed prior to final system testing described in Section 7.

5.5 – Optional Door Activation Switches Step 1 – Ensure that wires 11, 12 and 13 have been installed at the normally open contacts of the remote

door activation switches.

Step 2 – At the Main Controller low voltage compartment connect wires as follows: NOTE: If it is not possible to perform this step at this time it can be performed prior to final system

testing described in Section 7.

5.6 – Satellite Controller Chain Cables Step 1 – Ensure that the power connector of each AC Chain cable is connector to Satellite

Controller J4.

Step 2 – Connect a Motor Extension Cable between each Satellite Controller and motor.

NOTE: It is critical that a Motor Extension Cable is installed between controller and motor even if the motor is close enough to controller to plug directly into controller.

Step 3 – Route the Satellite COM cables through the housing. Reference your Installation Layout Sheets to

determine the installation location of each supplied cable. Begin at the Main Junction Box, noting the polarity of the connector that mates with the J2 COM OUT connector. The other end of the cable mates with J2 COM IN of the first Satellite Controller. Continue in this manner with remaining controllers.

Step 4 – Install Satellite Terminator at J3 COM OUT of the last Satellite Controller in the chain.


11 11. DOOR ACTIVATION 1

12 12. DOOR ACTIVATION 2

13 13. GROUND

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5.7 – Main Controller Settings Step 1 – To ensure proper operation, verify that the configuration DIP switches on the Main Controller

PCA match the settings in the figures below. The current limit trip jumper (J18) should be set for 25A power in the configuration shown in the figures below.

Single Motor Configuration for Main Controller

Figure 22 – DIP switch settings for single motor configurations in the Main Controller. Multi Motor Configuration for Main Controller

Figure 23 – DIP switch settings for multi motor configurations in the Main Controller.

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5.8 – Wiring Diagram

At this point, the M4000 is ready for testing and power can be connected to the system. Check that no steps have been missed to ensure smooth operation of the drive system.

STOP

Figure 24 – Reference wiring diagram for a typical 4-motor M4000 system.

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Section 6: Curtain System The Curtain is made up of separate sections. The number of sections varies depending on the length of the system. The Curtain is made from special materials to contain fire and smoke. Depending on your system, the Curtain will also serve as the mounting point for the Side Guide pins. NOTE: The Curtain will be sewn together in Section 7.3. It is left unsewn throughout its installation to allow

adjustments to be made.

WARNING: The Curtain is made from specialized fire-resistant materials and has sharp edges. Use caution to avoid being cut while handling the Curtain material.

Test the Drive System

6.1 – Test the Motors Prior to connecting the motors to the drive system, it is critical to test the motors are moving in the same direction. Step 1 – Using the controls, jog the motors and observe which direction they rotate in. Ensure all motors are

rotating in the same direction, at the same speed. Adjust any motors that are not rotating in the correct direction.

Motors are rotating in the same direction.

6.2 – Drive Chain Step 1 – Wrap the chain around the sprockets on the motor and the aligned drive shaft. Install the master link

into place. Step 2 – Secure the chain tensioner into the slot on the support bracket near the bottom of the chain as

illustrated in Figure 26.

Figure 25 – An image of the Curtain in a fully installed M4000.

29

Step 3 – Adjust the tensioner until the top chain has no more than 1/8” of slack.

The chain should not be loose around the sprockets. Check for debris that may get caught in the chain during installation.

Inspect chain is installed securely around both sprockets. Tension chain so that the slack on the top of the chain does not exceed 1/8”.

6.3 – Testing the Drive Line Step 1 – Inspect the drive line to verify the entire system is connected. Step 2 – Using the controls, jog the motors and observe how the drive system operates. Ensure all drive shafts

are rotating in the same direction, at the same speed, and that no parts are moving out of place, catching or slipping.

Step 3 – If the drive shafts spin properly with the motors and the system appears to be functioning properly,

tighten bolts on all connected components. If the drive system does not function properly, review Section 4 to identify if any steps were

missed and that all components are assembled correctly. The drive line must function properly prior to Curtain installation.

All drive shafts rotate in the same direction when jogged.

Figure 26 – The motor sprocket and drive shaft sprocket seen in a cross-section image of the Housing. Note the installed chain tensioner below the chain and between the sprockets.

Chain

30

Assemble the Curtain System

6.4 – Attach the Metal Tape The Curtain of the M4000 is raised and lowered by metal tape supplied by Smoke Guard. Lengths of tape are shipped specialized for your system. When raised, the metal tape is spooled on the pulleys on the drive shafts. Some lengths of tape extend over the top of the curtain so it can be raised and lowered evenly from both sides.

Figure 28 – (Left) The Metal Tape’s concave side must be facing the reels. The spring coil can be loosened with the hose clamp in order to get the metal tang through the loop on the tape. (Right) Rotate the tape over the top of the reel two turns while applying tension.

Figure 27 – (Left) The completed M4000 with the Metal Tape visible on the Front side. (Right) The routing of the Metal Tape from the drive system is shown from the side of the unit.

A B

Crimp spring here

Direction of rotation

31

Step 1 – Starting at one end of the unit, route the looped side of the Metal Tape around the top of the reel. The concave side of the tape should be facing down on the reel.

Step 2 – Insert the loop on the Metal Tape into the slot on the reel with the spring coil going through it. Step 3 – Insert the end of the spring coil through the loop on the Metal Tape. NOTE: Ends of the springs may need to be

cut down to avoid interference with other components. If necessary, use a grinder to cut down the springs.

Step 4 – Apply tension to the Metal Tape

and rotate the reel two turns to wrap the tape over the top of the reel as illustrated in Figure 28.

Step 5 – Ensure the Metal Tape is centered

on the reel. Step 6 – Align the Metal Tape so that it is

centered between the reel and the pulleys as illustrated in Figure 29. Tape will alternate what side it is suspended from based on the pulley configuration in the Housing.

Step 7 – Use the Swage Tool provided by Smoke Guard to crimp a bead on the spring on either side of the tape

reel to prevent it from sliding off. (Pliers do not provide an adequate bead and the reels may fall off.) NOTE: The Metal Tape should run over the top of the pulleys Step 8 – Tighten the hose clamp on the spring coil and allow the Metal Tape to hang free from the Housing. WARNING: Do not allow the Metal Tape to get kinked. This may damage the Metal Tape. Step 9 – Repeat for all reels throughout the unit.

Metal Tape is properly attached and tensioned to the reels. All reels have Metal Tape installed. Ensure all tape is centered on reels and aligned correctly between pulleys.

Figure 29 – A diagram of the alignment for alternating Metal Tape reels along the drive shafts.

32

All springs are crimped.

6.5 – Curtain Tray The Curtain Tray refers to the pans which are suspended from the Metal Tape. When the Curtain is deployed, the Curtain Tray is the only part to make contact with the ground. When fully retracted the Curtain Tray is flush with the M4000 Housing as well as the ceiling, or other features of the installation site. Smoke Guard ships the corner sections of the Curtain Tray as an assembly, however, some adjustments may need to be made before the sections are fully secured. Step 1 – Layout the Curtain Tray sections under the worksite. Ensure the Curtain Tray sections are oriented in

the correct direction. All front sides will have a smaller 1 ½” gap at the edges of the pan. Step 2 – Using the supplied #25 Torx head screws and section joiners, connect the end flanges of the Curtain

Trays. Line up the gaps on the ends of the pan sections as seen in Figure 31.

1 ½” gap front side 2 ½” gap

back side

Figure 30 – This image shows the difference in gap size on the front and back side of the Curtain Tray.

33

Step 3 – Attach the Up Limit Bracket to the Curtain Tray aligning it so that it is directly under the Up Limit Switch as illustrated in Figure 32.

NOTE: The Up Limit Bracket

will be mounted to a point on the backside of the Curtain Tray with two horizontal slots. This location should be directly below the Up Limit Switch intalled in the Housing.

Step 4 – Insert the free hanging ends of the Metal Tape through the Tape Clamps located on the inside edge of

the Curtain Tray as illustrated in Figure 32.

WARNING: Ensure the Metal Tape is flat and does not warp, twist or kink. Step 5 – Pull the Metal Tape taut and lightly tighten the screws on the tape lamps. The screws should be tight

enough to hold the tape but loose enough to make adjustments later. Step 6 – Cut the excess tape so that it is the width of the Curtain Tray and does not extend beyond the Curtain

Tray.

Figure 32 – (Left) Up Limit Bracket installed on the Curtain Tray. (Right) Metal Tape inserted through a tape clamp on the Curtain Tray.

Figure 31 – The curtain tray connected using section joiners and aligning the gaps on the correct side.

34

All Curtain Tray sections are aligned and joined correctly. Up Limit Bracket is installed. Metal Tape is secured in the tape clamps.

6.6 – Setting Tape Tension & Levelling The Curtain Tray Step 1 – Ensure the Curtain Tray sections are flush with the floor. This should be the position the pans are in

when the Curtain is fully deployed. Step 2 – Gently pull the Metal Tape by the excess on the Curtain Tray to apply tension to the tape. When you

have the desired tension, tighten the two screws on the tape clamp incrementally until they are hand-tight.

NOTE: The proper tension in the tape should be strong enough to be felt in the tape but not strong enough to

lift the Curtain Tray. WARNING: Do not use power tools on the tape clamp screws. These components are fragile and power tools

may damage the tape clamps. Step 3 – Repeat Step 2 until every length of tape in the system is tensioned and the Curtain Tray is level.

Figure 33 – This image highlights the adjustment bolts used to center the Curtain Tray under the Housing.

35

NOTE: If the tape clamps are twisted, this can put a curve in the Metal Tape. If this occurs, a scraping noise may be heard when the Curtain is raised.

Step 4 – Raise the Curtain Tray 1’ to 3’ so a laser level can be used to level the Curtain Tray. Step 5 – Using a level as your guide, fine tune the tension in the lengths of Metal Tape so the Curtain Tray is

level. NOTE: If the floor is uneven or if the front side tape clamp screws are not accessible due to obstacles, use a

scale and laser level to adjust the Curtain Tray flat. Step 6 – Once all lengths of Metal Tape are tensioned, use the controls to raise the Curtain Tray within 2” of the

Housing. Step 7 – Inspect the Curtain Tray to ensure no section sags or rises more than 1” from the other sections. Step 8 – Center the Curtain Tray underneath the Housing. If the Curtain Tray is not centered, adjust the bolts in

the corner section of the Curtain Tray to center it. Step 9 – Adjust the Curtain Tray sections until there is an approximately ¼” gap on all sides. Step 10 – Make any adjustments where needed. NOTE: If your unit has optional Side Guides, the edges of the unit should still have ¼” gap.

All metal tape has proper tension to the Curtain Tray. All Curtain Tray sections are level. All adjustment screws and tape clamps are tightened.

36

6.7 – Adjusting the Up Limit Switch NOTE: These steps may require two or more people. Step 1 – Test the Up Limit Switch by pressing the switch and listening for a click at the Main Controller.

If no click is heard, check the wiring between the primary motor plug and the terminal block at the Main Controller.

If a click is heard proceed to Step 2.

Step 2 – Using the controls, raise the Curtain Tray within 2” of the Housing and check that the Up Limit Bracket on the Curtain Tray is aligned with the tang on the Up Limit Switch as seen in Figure 32.

Step 3 – Use the bolts on the Up Limit Switch assembly and Up Limit Bracket assemblies to align the

components so that they interact correctly. Step 4 – Using the controls, raise the Curtain Tray into the Housing until it stops. NOTE: When the Main Controller is in Jog Mode the yellow LED will illuminate when the Up Limit Switch is

triggered. Step 5 – If the Curtain Tray is not seated at the Up Limit Switch, bend the Up Limit Switch tang gently so that

it lines up with the Up Limit Bracket as seen in Figure 34.

Figure 34 – The Up Limit Bracket resting just under the Up Limit Switch tang.

Up Limit Bracket

Up Limit Switch tang

37

Step 6 – If the Curtain Tray is fully seated, check to verify the Up Limit Switch has been triggered. If the Curtain Tray is seated correctly it will trigger the Up Limit Switch when it is fully raised into the Housing. Bend the tang on the Up Limit Switch so that the switch is only activated when the Curtain Tray

is fully raised into the Housing. This may require you to bend the tang up or down to meet the Up Limit Switch as seen in Figure 35.

NOTE: Ensure the Up Limit Switch tang cannot bind or fall off. Further adjustments to the position of the Up Limit Switch can be made by adjusting the bolts that hold the Up Limit Switch assembly to the support bracket.

Step 7 – Raise and lower the Curtain Tray several times to verify the alignment and seating of the Curtain Tray

into the Housing.

Verify the Curtain Tray has been properly aligned and seated into the Housing. Ensure the Up Limit Switch and Up Limit Switch Bracket are properly configured.

Bent Up Limit Switch tang

Figure 35 – An example of the Up Limit Switch tang being bent to accommodate the Up Limit Bracket.

38

6.8 – Layout the Curtain Step 1 – Using your Installation Layout Sheets, locate all curtain sections, special thread and other hardware.

Layout the materials under the worksite. WARNING: Do not slice the curtain when removing it from packaging. Step 2 – Carefully weave the Curtain sections through the tape onto the Curtain Tray Step 3 – Lay the Curtain sections so they overlap 4” at the seams.

Place the Curtain sections on the Curtain Tray and overlap the edges with at least 4” of overlap.

6.9 – Assemble the Curtain The Curtain is supported by a series of metal bars which provide structure to the Curtain. The bars are threaded throughout the interior of the curtain through pockets. Step 1 – Slide the aluminum bars into every pocket of the Curtain except the top and bottom pockets. Overlap NOTE: It may be necessary to cut the aluminum bars to match the length of the Curtain. Stay 1” away from the

ends of the Curtain.

Figure 36 – (Left) The three types of metal bar used in the Curtain of the M4000. (Right) a photo of a pocket which the bars are installed into.

Steel bar (Top pocket)

Aluminum bar (Center pockets)

Steel rod (Bottom pocket)

39

Install all aluminum bars into the Curtain.

Step 2 – Starting at one end

of the unit, measure the seam on the back side of the pocket on top of the Curtain sections. Do not include overlap in this measurement.

Step 3 – Cut the steel bar

with holes to the length of the seam measured in Step 1.

Step 4 – Slide the bar inside

the pocket, then drill holes through the screen, bar and back out the other side.

Step 5 – Drill a hole no larger than ¼” approximately 2” from each edge of the steel bar. Step 6 – Mark the Curtain at each hole on the steel bar. Step 7 – Repeat for all Curtain sections.

Measure all steel bars to fit the Curtain.

Step 8 – Slide the steel bar into the top pocket so that the holes, and the marks on the Curtain, align.

Install all steel bars into the Curtain.

Figure 37 – The aluminum bars in the Curtain as seen from the top, should alternate in length at overlapping corners as you install them in the pockets on the Curtain.

40

6.10 – Optional Guide Pins Some installations will include the optional Side Guides. The guide pins are a critical component of the Side Guides. Reference your Installation Layout Sheets to determine if these steps apply to your installation. These steps will show you how to install additional components to your M4000 system. If these steps do not apply to your installation, proceed to Section 6.11. Step 1 – Using the controls, lower the

Curtain Tray to a height that makes access to the Curtain easy.

Step 2 – Insert the flat end of the guide pins into the pockets of the Curtain with the aluminum bars. Ensure the pin and the aluminum bar have 4” of overlap in the pocket and the guide pins extrude at least 2” from the Curtain.

Step 3 – Repeat until all guide pins are

installed. Step 4 – Install the Curtain Tray Pin using

the supplied threaded studs as seen in Figure 38.

Insert guide pins into all of the Curtain pockets allowing 4” of

overlap between the pins and the metal bars and allowing the guide pins to extrude at least 2”. Attach the bottom guide pins.

6.11 – Attaching Curtain to Housing NOTE: Review Section 6.9 for information on correct metal bar installation. Step 1 – Using the controls, raise the Curtain Tray within 2’ of the Housing. Step 2 – Lift the top pocket of the Curtain to the Hat Channel of the Housing as seen in Figure 40.

Figure 38 – A side profile of a guide pin showing the flat portion and rounded portion which will extrude from the Curtain.

Figure 39 – The Curtain Tray guide pin shown here attached to the Curtain Tray.

Inside Curtain pocket

Extruding 2”

41

Step 3 – Using the supplied self-drilling screws, drill through the

marked point on the Curtain to attach the Curtain to the Hat Channel.

NOTE: The screw should go through the Curtain and steel bar when

attaching to the Hat Channel. Step 12 – Inspect the steel bar for sagging. If you encounter any

sagging sections of steel bar, apply additional screws. You can drill a self-drilling screw through the Curtain and steel bar without disassembling the Curtain or pre-drilling a hole.

Step 13 – As you install the next section of Curtain, overlap the sections

so that unsewn flaps are wrapped around sewn seams where they meet. There should be 4” of overlap between the Curtain sections as seen in Figure 41.

Step 14 – Repeat for all sections until the Curtain is screwed to the Hat

Channel and the adjacent sections are interlaced.

Screw the Curtain to the Hat Channel. Inspect the top bar and address any sagging you may find.

Figure 41 – Overlapping curtain sections.

Hat channel

Curtain

Steel bar

Figure 40 – This illustration shows how the curtain, steel bar and Hat Channel are all connected.

42

6.12 – Attaching Curtain to Curtain Tray NOTE: At this point in the installation, only the bottom pocket of the Curtain should be empty. All others

should have a metal bar inserted into them. Step 1 – Insert the round steel rod into the bottom pocket of the Curtain. Cut the rod to fit the length of the

Curtain if necessary. Step 2 – Starting at one end of the unit with a 4” filler clamping plate, place the clamping plate over the top of

the round steel bar in the bottom pocket of the Curtain. Press the Curtain against the inside edge of the clamping plate.

WARNING: Use only clamping plates with a Smoke Guard certification sticker. Step 4 – Continue clamping down the Curtain until the entire length of the Curtain is clamped down.

Insert the steel rod into the bottom pocket. Clamp down the entire length of the Curtain under the clamping plate.

Figure 42 – The steel rod is inserted into the bottom pocket of the Curtain and then clamped under the clamping plate on the Curtain Tray.

#2 Philips screws

Clamping plate Steel rod

43

Installing Curtain System Components

6.13 – Installing Optional Side Guides Some installations will include the optional Side Guides. Reference your Installation Layout Sheets to determine if these steps apply to your installation. These steps will show you how to install additional components to your M4000 system. If these steps do not apply to your installation, proceed to Section 6.14. Step 1 – Using the controls, raise the Curtain all the way into the Housing. NOTE: The Side Guide wall pockets should be completed prior to installation of the Side Guides. Step 2 – The Side Guides come in a single assembly, set the side guide assembly into the channel. Ensure the

front of the railing is facing the correct direction as seen in Figure 43. Step 3 – A gap at the top of the Side Guide assembly allows enough room to work the guide pins inside.

Starting with the pins at the top of the Curtain, work the pins into the channel inside the Side Guide assembly.

Step 4 – When the guide pins are inserted into the Side Guide assembly, temporarily secure the Side Guide to

the wall. Step 5 – Plumb and secure the front side of the Side Guide assembly to the wall using the supplied anchors. Step 6 – Using the controls, raise and lower the Curtain to check the pins do not catch at any point along the

guides and the Curtain moves smoothly.

Insert all guide pins into the Side Guide assembly.

Railing

Guide pins

Front

Figure 43 – The guide pins installed into the Side Guide assembly as seen from the top.

44

Anchor the Side Guide assembly into the wall.

6.14 – Attaching Covers The M4000 is closed off with covers on the front, bottom and back depending on the specific installation. These panels close off the interior workings of the unit and are screwed on to the Housing. When panels meet one another they are connected with a flat section joiner. Step 1 – Fully deploy the Curtain. Step 2 – Using your Installation Layout Sheets, determine the

configuration of your covers and layout the components under the worksite.

Step 3 – Starting from one side, bolt covers to the Housing. Use

section joiners to connect covers as necessary as seen in Figure 44.

Step 4 – Continue attaching covers until the entire unit is covered

as required by your layout sheet.

Attach all necessary covers to the Housing.

6.15 – Install the batteries Step 1 – Remove the battery brackets in the Main Controller and

insert the batteries. Step 2 – Clamp the batteries into place by replacing the battery brackets. Step 3 – Connect the battery terminals to the 24VDC terminal on the low power block of the Main Controller.

Install batteries.

Section joiner

Front cover

Figure 44 – Cover sections will overlap with section joiners to completely cover the unit.

45

6.16 – Retaining Clips Following the complete assembly and installation of the M4000 it may be necessary to leave the system without power while work continues around the worksite. To prevent the Curtain from falling due to gravity, special retaining clips can be used to hold the Curtain Tray in the Housing until power is applied. This will allow work to continue around the WARNING: It is critical that the M4000 is in Jog Mode when the retaining clips are in use. If the Curtain

deploys while the retaining clips are installed, the Metal Tape can become unraveled. Step 1 – With the Curtain fully retracted, install the retaining clips through the gaps located where the Metal

Tape is lowered between the Curtain Tray and the Housing. Step 2 – Install clips in every gap around the

M4000. Step 3 – Disconnect the 120VAC power and

the batteries to allow the system to drop onto the retaining clips. The system can now be left

without power.

Step 4 – To remove the clips, set the system to Jog Mode and raise the Curtain Tray off the retaining clips.

Step 5 – With the Curtain Tray raised, remove

the retaining clips.

The Curtain is now installed. Verify correct installation by checking all installation checklist items.

STOP

Figure 45 – This illustration shows how the retaining clip rests in between the Curtain Tray and the Housing. The retaining clips are magnetic to help keep them in place.

46

Section 7: System Testing

7.1 – Calibration Sequence Step 1 – Temporarily install the End of Line Diode provided by Smoke Guard to the initiating device. NOTE: The End of Line Diode will be removed and reinstalled later however it is not critical that it be

removed following this step. Step 2 – Using the controls, jog the Curtain Tray until it rests on the ground. Step 3 – Jog the Curtain up slightly to take out any slack in the Metal Tape. NOTE: During the installation process the Main Controller was placed in Jog Mode. To calibrate the system,

the Main Controller will be set to Armed. Step 4 – Power off the Main Controller and disconnect the batteries. Step 5 – On the system circuit board, move the #6 DIP switch into the UP position. Step 6 – Power on the Main Controller and press the microswitch in the lower right corner of the Main

Controller once. This must be done within 5 seconds of powering on the Main Controller. The Curtain will slowly retract to a seated position in the Housing or until the Up Limit Switch is

triggered.

Figure 46 – DIP switch #6 is used to change between Armed and Jog Mode.

47

Step 7 – Verify the calibration state of the unit. If the unit beeps once and displays a green LED at the Main Controller, proceed to Section 7.2. If there is no beep and the Main Controller displays a red or yellow LED, proceed to Section 8 to

troubleshoot the error. Successfully calibrate the M4000.

7.2 – Test Optional Keyed Switch Once the system is successfully calibrated and running smoothly, it must be switched to Armed. On systems with an optional Keyed Switch, this must be tested to ensure normal operation. Step 1 – With the system set to Armed and fully retracted, test the Keyed Switch by setting the key to the Test

Position. The Curtain should deploy normally.

Step 2 – Turn the key to the Off Position.

The Curtain should retract normally and return to Armed indicated by a green LED on the Main Controller.

Test the optional Keyed Switch.

7.3 – Test Optional Door Activation Switches Step 1 – With the system set to Armed and fully retracted, press the test microswitch on the Main Controller. Step 2 – When the Curtain is fully deployed, press a door activation switch.

The Curtain should retract to its standard 7’ egress height.

Test the optional Door Activation Switches.

48

7.4 – Sewing Curtain Sections NOTE: The curtain has been left unsewn to allow for adjustments. Make any final adjustments prior to sewing

the Curtain sections together. Ensure you have 4” of overlap between the sections of the Curtain before you begin sewing.

Step 1 – Cut a length of specialized thread approximately 6’ long. Thread it through the 4” upholstery needle. Step 2 – Starting at the top of the Curtain, thread the needle through both layers of overlapping Curtain and

back through forming a 1” loop. Thread the needle again forming a second 2” loop. And then, leaving approximately ¼” gap, alternate between 1” and 2” loops as illustrated in Figure 47.

Step 3 – Repeat the pattern in Step 2 until you have sewn down the full length of the Curtain. Step 4 – Make a second row of stitches repeating the pattern made in Step 2.

Sew two seams down the entire length of the Curtain over the 4” overlap at the edges.

The system is now calibrated and tested. The M4000 is now fully installed. This concludes the installation process.

STOP

Figure 47 – (Left) A fully sewn curtain with two sets of stitching. (Right) The alternating 1” and 2” pattern used to sew the Curtain together.

1”

2”

1”

2”

1/4”

1/4”

49

Section 8: Troubleshooting State Description Green Yellow

(fault code) Red (Trouble)

Notes

Normal 1 System OK ON OFF OFF System fully functional.

Normal 2 Power on/Self-test active.

Blinking Blinking Blinking Approximately 12 seconds to complete.

Normal 3 System in calibration.

1-blink every 5s. 1-blink every 5s. OFF

System in calibration.

Normal 4 LAS active.

ON 1-blink every 5s. OFF Normal operation with full deploy

Normal 5 FSCS close or open active.

ON 2-blinks every 5s.

OFF Normal operation with deploy in accordance with FSCS request.

Normal 6 No AC, battery active.

1-blink every 5s. OFF 1-blink every 5s.

Low voltage power supply or main power off. Running on battery.

Error 1 Battery health low.

OFF 1-blink every 5s. ON Battery or Main Controller problem.

Error 2

Obstruction or out of calibration.

OFF 2-blinks every 5s.

ON If obstructed, may indicate a fault deployment.

Error 3

LAS open circuit.


ON No EOL detected.

Error 4

Moving up or down timeout.


ON Motor, controller, or Up Limit Switch problem.

Error 5 Up Limit Switch Fault.


ON Up Limit Switch not functioning.

Error 6

Motor overcurrent.


ON Motor stopped due to overcurrent.

Error 7 Super Sensor Fault.


ON Super Sensor low battery.

Error 8 Satellite Controller Fault.

OFF

8-blinks every 5s.

ON Satellite Controller is in fault state.

Error 8A Satellite Controller overcurrent.


1-blink every 5s.

Satellite Controller(s) stopped due to overcurrent.

50

Error 8B Satellite Controller Connection.


2-blinks every 5s.

Main Controller has lost connection to Satellite Controller(s).

Error 8C Satellite Controller AC off.


3-blinks every 5s.

Satellite Controller(s) have lost AC power and Main Controller has not.

Error 9 Brake Fault.


ON Brake failure.

If you are unable to solve your problem by reviewing the checklist or troubleshooting table, contact Smoke Guard at 1-800-215-6138 or [email protected]. Additional contact information can be found on page 48.

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Appendix

A1 – Contact Smoke Guard Smoke Guard can be reached for customer service, troubleshooting and general questions on any of your Smoke Guard products by phone, email or standard mail. You can also contact Smoke Guard to learn more about upgrades to your Smoke Guard products as well as other services. Physical address: 287 N. Maple Grove Boise, ID 83704 Business hours are from 7:30am – 5:30pm, Monday – Friday (Mountain Time). Phone: Customer service: 1-800-574-0330 Customer service after hours: 1-208-850-1618 Technical support: 1-800-215-6138 Technical support after hours: 1-208-473-0844 Fax: 1-208-639-7851 Email: [email protected] Website: www.smokeguard.com

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A2 – M4000 Installation Checklist Check off items as completed

Section 2: Control System WARNING: The Main Controller must be within 30 conduit feet of the unit.

Consult with site GC/electrician to identify Main Controller location. Reference your Installation Layout Sheets to determine conduit routing paths. Requirements: Main Controller must be within 30 conduit feet of the Main Junction Box mounting location. 1” conduit is routed between the Main Controller low voltage compartment and Main Junction

Box. ½” conduit is routed to Main Controller high voltage compartment to supply 120VAC. A 120VAC service disconnect is required at the Main Controller.

Consult with site GC/electrician to coordinate additional power drops around perimeter of curtain housing (not required for single motor system). Reference your Installation Layout Sheets to determine conduit routing paths and number of circuits. Requirements: ½” conduit is required at each High Voltage Junction Box location on the curtain housing

to supply 120VAC. A 120VAC service disconnect is required at each High Voltage Junction Box location.

Consult with site GC/electrician to coordinate routing of conduit between Main Controller low voltage compartment and initiating device (smoke detector or fire alarm). Requirements: ½” conduit is required between initiating device and Main Controller low voltage

compartment. Two 18 or 20 AWG stranded wires labeled 14 and 15 between initiating device and Main


Consult with site GC/electrician to identify optional Wall Switch and/or Door Activation Switches. Reference your Installation Layout Sheets to determine conduit routing paths and number of circuits. Requirements: ½” conduit is required between Wall Switch box and Main Controller low voltage

compartment. Two 18 or 20 AWG stranded wires labeled 16 and 17 between Wall Switch box and

Main Controller low voltage compartment. ½” conduit is required between Door Activation Switch box(es) and Main Controller low

voltage compartment. Two 18 or 20 AWG stranded wires for each switch between Wall Switch box and Main

Controller low voltage compartment. First switch labeled 11 and 13, second switch labeled 12 and 13.

2.1 Install the Main Controller.

Section 3: Housing

Layout all Housing sections under the installation site according to the Installation Layout Sheets shipped with the unit. Mark Housing outer alignment lines on mounting surface.

3.1 Attach motors with supplied hardware according to Installation Layout Sheets.

53

Attach drive sprocket. Ensure sprocket is evenly spaced on the motor drive shaft and tighten set screws. 3.2

(If applicable) Install Satellite Controllers and junction boxes. Attach motors, Satellite Controllers and junction boxes.

3.3 Install all initial anchors through pre-drilled ½” holes.

o It may be necessary to pre-install the Outer Covers on some installations. Align all Housing sections. Install all permanent #12 anchors through pre-drilled ¼” holes.

3.4 Route cables and feed through the large grommet holes on the support brackets. Secure with zip ties and

ensure there is 2” of clearance above the bottom edge of the Housing. Ensure all systems are linked by cabling, and that harnesses are plugged in.

Anchor Housing to header and route motor and controller cables through grommet holes.

Section 4: Drive System 4.1

Square the bevel gear. Secure the bevel gear to the Housing.

4.2 Attach U-joints to drive shafts. Install U-joint section with drive shafts into Housing by closing the rotating plate over the shafts.

Attach bevel gears and U-joints to the Housing.

4.3 Install drive shafts. Tighten all rotating plates to secure drive shafts.

4.4 Verify drive shafts are secure and can rotate freely by hand. Verify sprockets on motors and drive shafts are aligned.

Install drive shafts and connect shafts to U-joints and bevel gears.

4.5 Verify the Up Limit Switch assembly is fastened to the same support bracket as the primary motor. Connect the Up Limit Switch to the primary motor. Verify Curtain Deflector is secure to support bracket.

Attach Up Limit Switch, Curtain Deflector and drive chain.

54

Section 6: Curtain 6.1

Motors are rotating in the same direction. 6.2

Inspect chain is installed securely around both sprockets. Tension chain so that the slack on the top of the chain does not exceed 1/8”.

6.3 All drive shafts rotate in the same direction when jogged.

Connect drive chain and conduct a successful drive line test.

6.4 Metal Tape is properly attached and tensioned to the reels. All reels have Metal Tape installed. Ensure all tape is centered on reels and aligned correctly between pulleys. All springs are crimped.

6.5 All Curtain Tray sections are aligned and joined correctly. Up Limit Bracket is installed. Metal Tape is secured in the tape clamps.

Curtain Trays are aligned and connected to Metal Tape. Tape is secured to clamps.

6.6

All metal tape has proper tension to the Curtain Tray. All Curtain Tray sections are level. All adjustment screws and tape clamps are tightened.

Curtain Trays are level and all fasteners are tightened.

6.7 Verify the Curtain Tray has been properly aligned and seated into the Housing. Ensure the Up Limit Switch and Up Limit Switch Bracket are properly configured.

Curtain Tray rises properly into the Housing and the Up Limit Switch interacts with the Up Limit Bracket correctly.

6.8 Place the Curtain sections on the Curtain Tray and overlap the edges with at least 4” of overlap.

6.9 Install all aluminum bars into the Curtain Measure all steel bars to fit the Curtain. Install all steel bars into the Curtain.

Curtain Trays are aligned and connected to Metal Tape. Tape is secured to clamps.

55

6.10 Insert guide pins into all of the Curtain pockets allowing 4” of overlap between the pins and the metal

bars and allowing the guide pins to extrude at least 2”. Attach the bottom guide pins.

6.11 Screw the Curtain to the Hat Channel. Inspect the top bar and address any sagging you may find.

Attach Curtain to the Hat Channel and address sagging. If applicable install optional guides.

6.12 Insert the steel rod into the bottom pocket. Clamp down the entire length of the Curtain under the clamping plate.

6.13 Insert all guide pins into the Side Guide Assembly Anchor the Side Guide assembly into the wall.

Clamp Curtain to Curtain Tray. If applicable, anchor Side Guide assembly to wall.

6.14

Attach all necessary covers to the Housing. 6.15

Install Batteries. Attach covers to Housing and install batteries.

Section 7: System Testing 7.1

Successfully calibrate the M4000. 7.2

Test the optional Keyed Switch. 7.3

Test the optional Door Activation Switches. 7.4

Sew two seams down the entire length of the Curtain over the 4” overlap at the edges. Successfully calibrate M4000, conduct tests of optional systems and sew Curtain.

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A3 – Glossary AC – Alternating Current, this refers to the primary power supply for the M4000. AHJ – Authority Having Jurisdiction. Armed – Armed is the operational condition the M4000 is in during normal operation. Armed is indicated on

the Main Controller by a green LED. Batteries – The M4000 has two batteries which provide emergency backup power in the event primary power

is lost. Bevel Gear – A type of gear used to connect Drive Shafts at 90° joints in the M4000. BOM – Bill of Materials, a detailed list of parts shipped with the unit. Brake – The M4000 uses electromagnetic brakes in the motors to stop the curtain. Calibration – The process which captures the total travel distance of the curtain. This value is used by the Main

Controller to keep track of the curtain position. Chain Tensioner – The Drive Chain is held in place by a Chain Tensioner located between the drive shafts and

motor. COM – Common, one of two device settings which can be set on the Main Controller. Also refers to a

connection tab on the Up Limit Switch. Configuration Switches – Refers to control switches located on the PCA in the Main Controller. These are

used to put the M4000 into different modes.

Curtain Tray – The Curtain Tray is the part of the M4000 which touches the floor during normal deployment. The Curtain Tray is lowered down by Metal Tape from the Drive Shafts. The Curtain is attached to the Curtain Tray.

Door Activation Switches – An optional feature on the M4000 which allows the Curtain to be temporarily

raised to Egress Height after it has been deployed. Drive Chain – The drive chain allows the motors to turn the drive shafts. Drive Line – Refers to the drive shafts and motors of the unit working together once assembled. Drive Shaft – Refers to the one or more shafts used throughout the M4000 to raise and lower the Curtain. Drive

shafts are connected to motors located in the unit Housing which provide power to the drive shafts. Egress Height – The height the M4000 Curtain will rise if a wall switch is activated. Default egress height on

an M4000 is 7’.

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EOL – End-of-Line diode, a component located at the smoke detector which maintains a circuit between the M4000 and the smoke detector.

FSCS – Firefighters’ Smoke Control Station. Some building facilities incorporate this station as an aid for

firefighting. The M4000 has an optional interface for such a station. Guide Pin – Guide Pins are an optional feature on some M4000 units which allow the Curtain to be guided

down a Side Guide system. Hat Channel – The Hat Channel is the channel located at the top of the housing. This is the location where the

Curtain is attached to the Housing. High Voltage Junction Box – Power routing box used in longer section of M4000. Houses the connections

between building power and AC chain cables. Housing – Refers to the metal components which house the M4000. The housing is typically only seen during

installation or deployment of the Curtain. During normal operation the Housing is concealed in the ceiling of the building where it is installed.

Jog Mode – A controller service mode where the Curtain is manually moved up or down. It is used as an

installation aid. The green LED will constantly blink in this mode. Additionally, the yellow LED will illuminate up when the Up Limit Switch is engaged.

Keyed Switch – The Keyed Switch is a switch that will cause the M4000 to deploy for testing purposes. The

key is given to the building manager following installation of the unit. LAS – Local Alarm System, refers to the building’s alarm circuit which commands the M4000 to deploy. Layout Sheet – The Layout Sheets are a series of documents shipped with the M4000 that show how the

system is to be organized prior to installation. LCC – Large Curtain Controller. Generic term for Smoke Guard control systems. LED – Light Emitting Diode, refers to the lights on the Main Controller which indicate the status and any errors

in the unit. For more information on LED status and error codes, see Section 8. Main Controller – The primary controller for the M4000. The Main Controller houses status LEDs, the

ON/OFF switch and backup batteries. Metal Tape – The Curtain Tray is suspended by Metal Tape. NO – Normally Open contacts of an electrical switch. Applies to the connection tabs on the Up Limit Switch. PCA – Printed Circuit Assembly, refers to the circuit board located inside the Main Controller. Satellite Controller – Secondary controller under the control of the Main Controller. Satellite Controllers are

used to control additional motors. The number of Satellite Controllers is dependent on the total length of the M4000.

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Side Guide – Side Guides are an optional feature on some M4000 units which allow the Curtain to be guided down via guide pins and railing.

Smoke Guard – Idaho-based company which produces the M4000 and other fire protection systems. Contact

information is available in the appendix. Super Sensor – Super Sensors are an optional feature on some M4000 units which detect obstructions. TDS – Test Deploy Switch, located on the Main Controller. Used to calibrate the system, deploy the curtain and

clear system faults. Terminate – Point at which a wire begins or ends. U-Joint – A type of connector used to connect Drive Shafts at angles smaller or larger than 90° in the M4000. Up Limit Switch – Electrical switch located in the housing that indicates to the Main Controller that the

Curtain is fully retracted.

M4000 Installation Manual

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