ASI Technologies Spirit HD 215 High Speed Fabric Roll-Up Door OWNER’S MANUAL
The Spirit HD 215 is a high-speed fabric roll-up door that is designed for industrial applications. It features a durable fabric curtain that can withstand high winds and heavy usage. The door is also equipped with a powerful motor that can quickly open and close the door.
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S
PIRIT
HD™ H
IGH
S
PEED
F
ABRIC
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OLL
-U
P
D
OOR
O
WNER
’
S
M
ANUAL
M O D E L S
215
Spirit HD
E
LECTRIC
D
OOR
M
ODEL
: 91D535
Do not install, operate or service this product unless you have read and understand the Safety
Practices, Warnings, Installation and Operating Instructions contained in this manual. Failure to do so could result in property damage, death or serious injury.
© 2005, ASI Technologies, Inc.
1-800-558-7068 www.asidoors.com
Manual Part number: 17A136-112912
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215 Spirit HD
Safety Practices
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTE explains general information.
Page 2 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Safety Practices
Continued
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Read these safety practices before installing, operating or servicing the H IG H-S PE E D door.
Failure to follow these safety practices could result in property damage, serious bodily injury or death.
R EAD AN D U N D E R STAN D TH E OPE RATI N G I N STR U CTI ON S I N TH I S MAN UAL B E F OR E
OPE RATI NG TH E H IG H-S PE E D DOOR. If you do not understand the instructions, ask your supervisor to teach you how to use the H IG H-S PE E D door.
1. Do not operate the HIGH-SPEED door while under the influence of drugs or alcohol.
2. Do not use the door if it looks broken or does not seem to work right. Advise your supervisor at once.
3. Stay clear of the door when it is moving.
4. Keep hands, feet and head clear of the door at all times.
5. Do not operate the door with equipment, material or people directly underneath the door.
6. Disconnect power before performing any electrical or mechanical service, cleaning or other maintenance on the door. OSHA requires disconnect to be properly tagged and locked out during all maintenance or service of equipment. With the power supply disconnected, always verify using a volt meter.
7. All electrical troubleshooting or service must be completed by a qualified electrician or service person and must meet all applicable local, state, federal, international and other governing agency codes.
8. When it is necessary to service the control box with power on, USE EXTREME CAUTION. Do not place fingers or uninsulated tools inside the control box. Touching wires or other parts inside the enclosure may cause electrical shock, serious injury or death.
9. It is your responsibility to keep all warning labels and instructional literature legible, intact and kept with the door. Replacement labels and literature are available from ASI Technologies, Inc.
or its representatives.
10. If you have any questions, contact your supervisor or your local ASI Technologies, Inc.
representative for assistance.
11. Train all service and personnel using or near door on intended use(s) and operation of the door.
12. Failure to operate the door as intended, as described, or heed any warning may result in equipment damage, property damage, serious bodily injury or death.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 3
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ASI Technologies, Inc. Warranty Policy
ASI Technologies, Inc. (herein called "ASI") warrants solely for the benefit of its customer that each door system manufactured by ASI (each a "Door System") will be free from defects in material and manufacture for a period of one (1) year from the date of original shipment by ASI. The foregoing limited warranty shall not apply to defects which result from improper installation, abuse, misuse, alteration, modification or failure to maintain the Door System in accordance with the ASI Owner's Manual. Periodic lubrication and adjustment of the Door System as described in the ASI Owner's Manual are the sole responsibility of the customer. All claims for defects must be made to ASI within thirty (30) days after the defect is discovered or should, with reasonable care, have been discovered. THE FOREGOING LIMITED WARRANTY CONSTITUTES THE
EXCLUSIVE WARRANTY OF ASI WITH RESPECT TO THE DOOR SYSTEM. ASI EXPRESSLY
DISCLAIMS ALL OTHER GUARANTEES OR WARRANTIES—WHETHER EXPRESS, IMPLIED, OR
STATUTORY—INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE.
If a Door System does not comply with the foregoing limited warranty, and a claim is made by customer within the one (1) year warranty period, ASI will, at the option of ASI, either repair or replace any defective equipment or parts free of charge, and pay the reasonable labor costs to repair or replace the defective equipment or parts.
The remedy of repair or replacement shall be the exclusive and sole remedy for any breach of the foregoing limited warranty.
ASI SHALL NOT IN ANY EVENT BE LIABLE FOR ANY INCIDENTAL, INDIRECT, SPECIAL, EXEMPLARY
OR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING WITHOUT LIMITATION ANY LOST
PROFITS, ARISING FROM THE SALE OR USE OF THE DOOR SYSTEM, OR FROM ANY OTHER CAUSE
WHATSOEVER, WHETHER THE CLAIM GIVING RISE TO SUCH DAMAGES IS BASED UPON BREACH
OF WARRANTY (EXPRESSED OR IMPLIED) BREACH OF CONTRACT, TORT, STRICT LIABILITY OR ANY
OTHER THEORY OF LIABILITY, EVEN IF A PARTY HAS BEEN ADVISED OF THE POSSIBILITY THEREOF,
AND REGARDLESS OF ANY ADVISE OR REPRESENTATION THAT MAY HAVE BEEN RENDERED BY ASI
CONCERNING THE SALE OR USE OF THE DOOR SYSTEM.
At ASI's request, customer shall return to ASI for inspection any Door System for which a warranty claim has been made, F.O.B. ASI's facility with freight prepaid. The customer is responsible for any removal costs.
The customer shall comply with the following procedures in filing a warranty claim with ASI:
1. Notify ASI of any and all defects in writing. ASI will review the warranty request and issue a Returns
Goods Authorization (RGA) form if the defective parts need to be returned to ASI for inspection and verification. The RGA form must accompany any materials returned for warranty consideration.
2. All replacement parts or equipment will be invoiced to the customer. Upon verification by ASI that the Door
System is defective, ASI will issue a full credit to customer for the replacement parts or equipment.
3. If outside labor is needed to install the replacement parts or equipment, ASI requires a written estimate of the labor charges in advance so ASI may approve the labor charges and issue a purchase order. ASI will not accept any labor charges unless previously approved by ASI and accompanied by the ASI purchase order number.
4. The ASI extended warranty coverage for hydraulic components does not cover reimbursement of labor charges for the diagnosis or replacement of hydraulic components. Warranty reimbursement is limited to credit for replacement parts purchased from ASI.
The customer must file a claim with the shipper for any damage and/or losses that may occur during transit.
Installation hardware and start up of the Door System equipment is the responsibility of the installation contractor. Periodic adjustments and normal maintenance are the responsibility of the customer.
Page 4 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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215 Spirit HD
Marathon ® Spirit HD™ High Speed Fabric Roll-Up Door
General Information
Safety Practices
Warranty Policy
Crates and Contents
Begins on Page
Page
Page
Page
2
2
4
6
Maintenance
Preventative
Troubleshooting
Begins on Page
Page
Page
Installation
Begins on Page
Door Measurements
Side Support Installation
Page
Page
Header Installation Page
Operator Installation
Attaching Counterweight
Warning Labels
Electrical Controls
PLC Inputs
PLC Outputs
Page
Page
Page
Page
Page
Page
Other Electrical Functions
Start-Up
Electrical Start-Up
Final Checks
Resetting Bottom Bar
Photoeye Adjustment
Barrel/Operator Shroud
Page
Page
Page
Page
Page
Page
Page
14
16
17
18
23
25
9
12
8
8
27
29
30
33
34
35
36
Replacement Parts
Begins on Page
Instructions for Ordering Page
Door Identification
ID Tag Location
Door Assembly
Page
Page
Page
Curtain and Barrel Assembly Page
Bottom Bar Assembly Page
Idler Side Column Assembly Page
Drive Side Column Assembly Page
Operator Assembly
Panel Assembly
Page
Page
Lintel Brush Assembly Page
37
37
39
44
45
46
47
48
50
40
40
40
41
42
52
Do not install, operate or service this product unless you have read and understand the Safety
Practices, Warnings and Installation and Operating Instructions contained in this manual.
Failure to do so could result in property damage, death or serious injury.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 5
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Crates and Contents
Figure 1: Crates and Contents
DESCRIPTION QTY.
Installation Instructions . . . . . . . .1
DESCRIPTION QTY.
Counterweight Guide . . . . . . . . .2
Warning Label . . . . . . . . . . . . . . .4
Counterweight Clamp . . . . . . . . .4
#60 Drive Chain . . . . . . . . . . . . . .1
#60 Master Link . . . . . . . . . . . . . .1
5/16"-18 x 3/4" Screw . . . . . . . .8
1/4"-20 x 3/4" Screw . . . . . . . . .4
J-Clip . . . . . . . . . . . . . . . . . . . . . .10
#8 x 3/4" Screws for J-Clip . . .10
Lintel Brush Assembly . . . . . . . . .1
3/8"-16 x 3" Hex Bolt . . . . . . . . .2
3/8" Lockwasher . . . . . . . . . . . . .6
3/8" Flat Washer . . . . . . . . . . . . .6
3/8" Nut . . . . . . . . . . . . . . . . . . . .2
Counterweight . . . . . . . . . . . . . . .2
1/2"-13 x 2" Bolt . . . . . . . . . . . . .4
1/2"-13 x 1" Bolt . . . . . . . . . . . . .4
1/2" Lockwasher . . . . . . . . . . . . .4
1/2" Flat Washer . . . . . . . . . . . . .4
3/18"-16 x 1" Bolt . . . . . . . . . . . .2
1/2"-13 x 4" Bolt . . . . . . . . . . . . .2
Manual Release Clip . . . . . . . . . .1
1/4"-14 x 3/4" Screw . . . . . . . . .2
Page 6 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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Crates and Contents
Continued
Upon receipt of the shipment, check that you have received the correct number of pieces as shown (Figure 1). Crate one will contain the side frame assembly and top support tube, the curtain and barrel assembly and the loose parts box. Crate two will contain the operator and control box.
For your protection, note any damages or shortages on the carrier’s bill of lading before signing the bill for receipt.
The installation of this door will require at least a two man crew and a fork lift. Select a fork lift with lifting height based upon the height of the door plus a minimum additional two feet.
Because of variances in the construction of walls on which the door will be mounted, fasteners are not supplied. For proper anchoring of the door, we recommend the use of thru-bolts. DO NOT remove door sections from crate until you encounter the step in which they are to be installed.
Note:
Unless specifically called out as “Provided by ASI”, installer is to provide all necessary mounting hardware, anchors, inserts, hangers, supports and equipment needed to install door in accordance with final shop drawings and manufacturer’s instructions.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 7
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Door Measurements
1. Find the door centerline by measuring the width of the door opening in inches and divide by two. Mark the door centerline on the floor (Figure 2).
2. The area around the opening must be a finished, flat surface. As shown in Figure 2, the finished surface must extend 14" on both sides and 27 1 /
4
" at the header.
3. For proper installation, mark a line on the wall from the centerline, a distance 1 /
2 the Width In Clear (WIC), plus
14" on both sides. The area around the opening must be a finished flat surface.
4. Determine if the floor is level. If not, shimming of one of the side supports will be necessary. Shim lower to meet higher side (Figure 3). DO NOT cut any material from side frames.
If area around opening is not finished up to the edges, or if the side frames are mounted more than 1 /
2
" off of floor, door will not provide proper seal.
Figure 2: Door Measurements
Figure 3: Leveling the Side Supports
Page 8 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Side Support Installation
1. Uncrate side supports and open the side support covers.
Remove the side support cover and lift off of hinges (Figure
4). INSTALLATION SUGGESTION: You can keep side support cover on, but you must unbolt and open. On doors over 10’0" high, side support covers should be kept on to facilitate installation.
2. Place the operator side support against the wall (Figure 5) with the outside edge on the mark from step 3 in door measurement instructions. The inside edge of the side support should be flush with the opening.
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215 Spirit HD
Figure 4: Side Support and Cover
Figure 5: Use Fork Lift to Place Side
Support Against Wall
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 9
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Side Support Installation
Continued
We strongly recommend that thru-holes be drilled for proper anchoring of the door to the wall.
Improper installation of anchoring devices, installation into aged or unsound concrete or mounting to a non-plumb wall without proper shimming; could result in premature product wear or product failure. Failure to properly install equipment could result in property damage, death or serious injury.
3. Align the operator side support so it is plumb, square and true (Figure 6). Mark hole locations on wall. Move side support away from wall for drilling clearance. Drill, then move side support back into place. Secure it to the wall, using thru-bolts in the preset locations (Figure 7).
Side support should be flush with the opening to side frame or slightly away from the door opening to allow breakaway bottom bar to release in either door direction.
Figure 6: Use Clamp to Hold Side Support
In Place While Thru-bolting
Figure 7: Preset Drilling Locations
Page 10 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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215 Spirit HD
Side Support Installation
Continued
4. Using the lintel brush seal and mounting tube (which is packaged in the header crate) as a spacing guide at top and bottom of side support, align the idler side support against the wall. Secure it the same as in Step 3,
Page 10. The width opening should be the same at top, midpoint and bottom (Figure 8).
Side columns should be exactly WIC apart.
Tolerance is +1/2",–0.0".
5. Align the lintel brush mounting tube and optional barrel shroud mounting tube to top of brackets on operator and idler side support (Figure 8). Mark hole locations on wall. Move mounting tubes away from wall for drilling clearance. Drill, then move mounting tubes back into place. Secure it to the wall, using thru-bolts in the preset locations.
6. It is essential for proper operation to check squareness between the supports (Figure 9).
Remember: If necessary, always shim under the lower side support to meet higher side support (Figure 8).
Figure 8: Attaching Header Brush Sealer
If fork lift is used, the brush may interfere with crate removal.
Figure 9: Checking for Squareness
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 11
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Header Installation
Do not lift people with the fork lift, or climb ladders while the operator assembly is being lifted. Operator could fall during lifting hitting ladders and/or people causing death or serious injury.
1. Lift the header assembly from bottom by placing forks into the lifting crate. (Tips of forks MUST NOT protrude through crate)
(Figure 10).
2. Cut tie wraps from counterweight straps
(Figure 11).
Figure 10: Lifting Header Assembly
Figure 11: Header Assembly Before Mounting to Side
Support
Page 12 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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215 Spirit HD
Header Installation
Continued
3. Align the header assembly with bolts from the pillow blocks as required.
Counterweight straps should hang into side supports, make sure white breakaway tabs are in side column slot.
Secure the header using the 1 /
2
" whiz bolts supplied, to barrel plates at top of side supports (Figure 12).
4. Center barrel between side columns.
Check for bottom bar clearance of approximately 1" from side frame (on both sides).
5. Lock two pillow block collar set screws to secure the barrel position.
Once proper location is achieved – insure set screws are tight.
Be sure to check both pillow blocks.
Drive side gear and pillow block are preset at the factory and should not require adjustment. The idler side pillow block may require repositioning to insure that the barrel is centered. Loosen set screw on bearing prior to repositioning the pillow block (Figure 13).
6. DO NOT remove lifting crate at this time.
Figure 12: Idler Side View
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Figure 13: Centering Barrel Between
Side Columns
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215 Spirit HD
Operator Installation
1. Mount operator assembly to side support operator mounting bracket (Figure 14). Use
(4) 1 /
2
" × 1" bolts with flat and lock washers.
Do not tighten at this time. Insert two 1 /
2
" × 4" drive chain adjusting bolts located at front of operator.
2. Verify that both the operator and barrel drive sprockets are in line (Figure 15). If not, move sprocket attached to barrel by loosening the taper lock bushing and adjusting the sprocket accordingly. Attach the #60 pitch roller chain around drive sprockets on the end of the barrel shaft and the operator. Join the chain ends with the master connecting link supplied. The chain tension can then be tightened by turning the drive chain adjusting screws in or out
(Figure 16). The chain should be tensioned to have a maximum of 1 /
4
" deflection midway between the two sprockets (Figure 16a). DO
NOT
overtighten chain. When chain is tensioned correctly, tighten the four 1 /
2
" operator mounting bolts on bottom of operator bracket, locking the operator in place. Ensure chain is not touching any adjacent parts.
Figure 14: Mounting Operator Assembly
Page 14
Figure 15: Sprocket Alignment Prior to
Attaching Roller Chain
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Operator Installation
Continued
3. Insert brake release shaft through looped end of cable release wire and screw into brake release at bottom of operator. Attach cable pulley and bracket to drive side barrel/motor support at existing pre-drilled holes
(Figure 16b).
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215 Spirit HD
Figure 16: Chain Attachment (Side View)
1
/
4
" MAXIMUM
Figure 16a:Chain Tension Maximum Deflection
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Figure 16b:Attaching Brake Release
Page 15
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215 Spirit HD
Attaching Counterweight
1. Open drive side hinged cover and unwind the strap found on the drive side of the barrel— do not rotate the barrel.
IMPORTANT: Two dead wraps of counterweight strap must remain on the barrel. Door curtain must be in the
"UP" position at this time.
Run the strap passed the header roller guide. Lead the strap between the inside of the guide and the roller
(Figure 17).
2. Attach counterweight guide to top of counterweight with bolts provided in loose parts box (Figure 18).
3. To attach the counterweight to the strap, remove bolts on strap clamp. (Figure 18). Insert strap through pin on top of counterweight. Adjust strap so counterweight is about 8" off the floor (Figure 18) when door is in fully opened position. Replace and retighten bolts on strap clamp.
4. Remove lifting crate at this time.
Figure 17: Leading the Strap Passed the
Header Roller Guide
SIDE VIEW
OF STRAP
BEVELED EDGE
(TOWARDS STRAP)
Keep area beneath lifting crate clear while removing.
Failure to do so could result in property damage, death or serious injury.
5. Pull brake release and operate door manually through fully closed and fully opened positions. Place the bottom bar into guide while pulling down on the door. Check for proper tracking of counterweight strap and curtain fabric to ensure desired counterweight travel: when door is fully opened --- the counterweight should be 8" above floor; and when door is fully closed --- the counterweight and clamp should not interfere with header roller guide (Figure 17).
6. Close hinged side guide covers and secure with fasteners.
Page 16
Figure 18: Attaching Counterweight to
Strap
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Warning Labels
Check all warnings weekly. Door may unexpectedly close.
Failure to mount and maintain all warning labels and instructional literature could result in death or serious injury.
1. Inspect Warning Labels on side frame covers (Figure 19).
Mount Warning Labels provided on other side of the wall opposite the side covers (Figure 20). The bottom of the
Warning Label should be approximately 60" from the floor.
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215 Spirit HD
Figure 19: Warning Labels Installation – Wall Mount
Manual Part Number: 17A136-112912
Figure 20: Warning Labels Installation – Side Frames
©2005 ASI Technologies, Inc.
1-800-558-7068
Page 17
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Electrical Controls
Control box contains H I G H VOLTAG E! The following procedures should be performed by qualified electrical personnel only. Wiring must meet all local, state, federal and international, or other governing agency codes. Keep hands and body parts clear of high voltage areas. Failure to do so could result in death or serious injury.
DRIVE SIDE
BARREL/MOTOR
SUPPORT
Disconnect power at the fused disconnect during all electrical or mechanical service. Disconnect must be properly locked out during maintenance or service of equipment. Failure to disconnect power could result in death or serious injury.
1. Make sure pre-wired cable supplied is of sufficient length to enable location of control box where desired.
Mount control box to a convenient location, leaving sufficient room for control box door to be opened.
MULTI-CONDUCTOR/
COILED CORD BRACKET
MOUNTING HOLES
Figure 19: Cable Mounting Bracket Location
• Follow electrical wiring schematics supplied with the door.
• Make sure when drilling holes in control enclosure that debris does not fall into control components.
Debris can damage control components.
2. All wiring should be installed and connected by a qualified electrician who is knowledgeable with
NEC Article 430 and with local regulations.
Electrician should make sure that the voltage and frequency of the electrical supply corresponds with the motor data listed on the control box cover.
3. Mount photoeye/coil cord bracket to drive side barrel/motor support (Figure 19). Route pre-wired control power cord from control box to connector on motor support. Align pins on plug and receptacle, then twist collar on plug down until it clicks in place (Figure 20).
MOTOR SUPPORT
CONTROL POWER CORD
BOTTOM BAR COIL CORD
Figure 20: Pre-wired Connections
Page 18 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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215 Spirit HD
Electrical Controls
Continued
P r o t e c t a n d c o v e r a l l e l e c t r i c a l components inside control panel prior to drilling enclosure. Failure to do so may result in component malfunctions.
4. Motor wires should be marked T1, T2, T3 and ground. (B1 & B2 lead to motor brake).
Run wires from the control box to the junction box on the motor as shown in electrical schematic.
Fused disconnect complying with applicable electrical codes must be supplied by others.
5. From a fused disconnect, route power supply wires to the control panel and connect to terminal blocks “L1”, “L2”, “L3”
(Figure 21). Also attach a ground to control panel terminal.
6. All connections should be made per the schematic. All wiring connections from harness MUST be terminated in control box.
L1 L2 L3 NC A1 L1 L2 L3 NC A1
1 2 3 4 5 6
OPEN CLOSE
T1 T2 T3 NC A2 T1 T2 T3 NC A2
W A
STOP RESET
95 NC 96 97 NC 98 A2
T1 T2 T3 NC
RESISTOR
SIMATIC
S7-200
SF
RUN
STOP QO
1L
.0
0.0 0.1 0.2 0.3
.1
.2 .3 .4 .5 .6 .7
Q1
2L 0.4 0.5 0.6
.0 .1
3L 0.7 1.0 1.1
R N L1
CPU 224
AC/DC/RELAY
AC
Run
Term
Stop
0 1
IO
.0
.1
.2 .3 .4 .5 .6 .7
I1
.0
.1
.2 .3 .4 .5
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4
1.5
M L+
PORT
0
E-STOP PHOTOEYE LOOP
2
4
4A
12
1
1
2
2
52
57
58
61
63
1
L+
L+
50
51
B1
B2
L+
L+
L3
T1
T2
T3
GND
GND
L1
L2
24
25
38
39
13
14
20
21
22
23
26
27
80
81
• •
Figure 21: ASI Control Panel
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
2 3 4 5 6
L3
T1
T2
T3
B1
B2
GND
GND
L1
L2
L+
L+
Page 19
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215 Spirit HD
Electrical Controls
Continued
7. REVERSING EDGE: The reversing edge is already pre-wired into the bottom bar assembly. The other end of the coil cord should be connected to the harness connector located on the drive side column
(Page 13, Figure 20).
A cable clamp has been added to limit movement of the coil cord during door operation. This requires the installation of the coil cord cable clamp and self-tapping screw as described below.
8. Occasionally, after the initial break-in period, the coil cord will stretch and contact the floor. It is recommended to attach coil cord with a "J" clip to midpoint of side column.
9. Route prewired plug from a harness in side column to bottom of rotary limit switch. Align pins on plug and receptacle, then twist collar on plug until it clicks in place (Figure 22).
Figure 22: Connecting Limit Switch
Page 20 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
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215 Spirit HD
Electrical Controls
Continued
Control box contains H I G H VOLTAG E! The following procedures should be performed by qualified electrical personnel only. Wiring must meet all local, state, federal and international, or other governing agency codes. Failure to do so will result in death or serious injury.
The PLC (Programmable Logic Controller) control system is designed specifically for ASI Technologies
Doors. The PLC’s programmed self-diagnostic features convey both door status and troubleshooting indicators through individual LED’s. Additional inputs are available for a Reversing Edge and Reversing
Photoeyes. Troubleshooting time is significantly reduced since the LED indicator lights direct you to specific problems. Initial electrical hookup is made easy with conveniently located plug-in type connectors. Individual timers for automatic Time to Close, Preannounce to Close signaling or Partial
Open offer flexible adjustment for existing or future applications. Special features include a nonresettable counter that can be used to establish periodic maintenance programs.
INPUT POWER
The nominal supply voltage for the control panel is typically 208, 240, or 480 VAC 3
φ. This control has been setup for the supply voltage indicated on the order. Be sure to verify this voltage prior to supplying power to the control panel. The control circuit includes both 120 VAC (for the PLC) and
24 VAC (for other sensing and electrical) devices.
SIMATIC
S7-200
SF
RUN
STOP
QO
1L
.0
.1
0.0 0.1 0.2 0.3
• 2L 0.4 0.5 0.6
• 3L 0.7 1.0 1.1
R N
.2 .3 .4 .5 .6 .7
Q1
.0 .1
L1
CPU 224
AC/DC/RELAY
AC
Run
Term
Stop
0 1
IO
.0
.1
.2 .3 .4 .5 .6 .7
.0
.1
.2 .3 .4 .5
I1
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4
1.5
M L+
PORT
0
Figure 25: PLC Layout
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 21
I
NSTALLATION
215 Spirit HD
Electrical Controls
Continued
Output
LED's
PLC
System Fault
Run
Mode
Stop
Mode
EEPROM
Socket
SIMATIC
S7-200
SF
RUN
STOP
Communications
Port
PORT
0
Input
LED's
QO
1L
.0
0.0 0.1 0.2 0.3
• 2L 0.4 0.5 0.6
• 3L 0.7 1.0 1.1
R N
.1
.2 .3 .4 .5 .6 .7
Q1
.0 .1
L1
CPU 224
AC/DC/RELAY
AC
PLC Modes
(Dipswitch Settings,
Shown in Run Mode)
Cover
Cutout
Run
Term
Stop
Pot 0
Time to Close
0 1
IO
.0
.1
.2 .3 .4 .5 .6 .7
.0
.1
.2 .3 .4 .5
I1
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4
1.5
M L+
Figure 26: PLC Description
Socket for adding
I/O modules
Pot 1
Preannounce to Close or Partial Open Timer
LED is lit LED is not lit
If I1.5 is not lit, the door will be in Preannounce to Close mode
If I1.5 is lit, the door will be in Partial Open mode
Typical LED status with door stopped in middle of door travel is shown on PLC above.
PLC Fault: Indicates a system fault has occurred. Try to recycle power to clear (by leaving power off several minutes before applying power to control). If this fault does not clear, call ASI service.
Run Mode: Indicates the PLC is in Run Mode, which is required to operate. If this LED is not lit, position the dip switch to Run Mode (top position). If PLC does not go into Run Mode, call ASI service.
Stop Mode: Indicates the PLC is in Stop Mode, which disables PLC operation.
Term Mode: Indicates the PLC is in Terminal Mode. This is used when the PLC is connected to a personal computer or other interface device.
EEPROM Socket: This is used to load the PLC program. The PLC is shipped with a blank module since the PLC stores the program into memory.
Communications Port: This is used to connect the PLC to a personal computer or other programming device.
Output LED’s: Indicates the status of each PLC output.
Input LED’s: Indicates the status of each PLC input.
Pots 0 and 1: These adjustable potentiometers are used for adjusting the time to close and preannounce to close or partial open functions. The pots are located under an access cover on the right of the PLC.
Page 22 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
I
NSTALLATION
215 Spirit HD
PLC Inputs
(14) 24V DC inputs are located on the lower section of the PLC. The first bank of (8) inputs are designated as I0.0 – I0.7 and the second bank of (6) inputs are designated as I1.0 – I0.5. To signal a particular input, the input common (L+) circuit is connected to the input.
ACTIVATOR SIGNALS
Input I0.0 – OPEN: This input is connected to a normally open pushbutton or other momentary contact that, when activated, causes the door to open.
Input I0.1 – CLOSE: This input is connected to a normally open pushbutton or other momentary contact that, when activated, causes the door to close.
NOTE: This signal is ignored while the door is opening.
L+
L+
L+
L+
L+
L+ CR1 55
LSO
LSC
50
51
52
53
57
58
M
1M
I0.0
OPEN
I0.1
CLOSE
I0.2
OPEN/CLOSE
I0.3
PARTIAL OPEN
I0.4
E-STOP
I0.5
OPEN LIMIT
I0.6
CLOSE LIMIT
I0.7
M
2M
L+
CR2
60
I1.0
REVERSING EDGE
Do not close door until doorway is clear. Closing the door with a Close or Open/Close command will close the door immediately. Unexpected door closing could result in property damage, death or serious injury.
L+ 61
JUMPER
L+
P.E.
62
(12)
(11)
(14)
EXT. CUTOUT 63
L+
JUMPER
(21) (22) (22) (21)
64
I1.1
REVERSING PHOTOEYE
I1.2
EXTERNAL CUTOUT
I1.3
BREAKAWAY TABS
I1.4
RESET BUTTON
L+ 65
Input I0.2 – OPEN/CLOSE: This input is connected to a normally open pushbutton or other momentary contact that signals the door to open or close dependent on door position.
Input I0.3 – PARTIAL OPEN: This input is connected to a normally open pushbutton or other momentary contact that, when activated, causes the door to open short of full open. See the “Other Electrical Functions” section for adjustment instructions.
JUMPER FOR PARTIAL OPEN
M
L+
I1.5
POT 1 MODE
M
L+
PLC
Figure 27: PLC Input Connections
(See electrical drawing provided for specific electrical connections.)
NOTE: PLC must be set for Partial Open mode (See Input I1.5 to set).
Input I0.4 – E-STOP: This input is connected to a closed contact or pushbutton that removes the signal causing the door to stop. The door will not operate until this signal is made.
LIMIT SIGNALS
Input I0.5 – OPEN LIMIT: This input is connected to a normally closed limit switch that, when activated, initiates the door to stop opening. The indicator light will be off when the door is fully open.
Input I0.6 – CLOSE LIMIT: This input is connected to a normally closed limit switch that, when activated, initiates the door to stop closing. The indicator light will be off when the door is fully closed.
Input I0.7 – NOT USED:
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 23
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215 Spirit HD
PLC Inputs
Continued
ADDITIONAL SIGNALS
Input I1.0 – REVERSING EDGE: This input is connected to a normally closed switch. If the signal is interrupted at any time while the door is closing, the door will instantly reverse and open.
This input has no effect if the door is fully closed or opening.
Input I1.1 – REVERSING PHOTOEYE: This input is connected to a normally closed switch. If this signal is broken while the door is closing, the door will reverse and fully open. NOTE: ASI supplied photoeyes must be set to light operate mode and wired to normally open contacts that are held closed when the light beam is made. When the light beam is blocked, the contact switches to an open state. Additional reversing devices can be added by wiring the normally closed contacts between terminals
L+ and 61 (Input I1.1 of the PLC).
Input I1.2 – EXTERNAL CUTOUT (Interlock): This input is connected to a normally closed switch. When this signal is broken the door will not open. This input can be used to interlock this door with other doors, conveyors, security system, etc.
Input I1.3 – BREAKAWAY TABS: This input is connected to a normally closed switch that opens when the bottom bar of the door is impacted. The signal causes the door to stop. The bottom bar of the door must reset by following the instructions in the owners manual.
Input I1.4 – RESET: This input is connected to a normally open pushbutton (located on the control box cover). This pushbutton is used to reset the controls to allow for normal door operation if the breakaway tabs stop the door (when impacted).
Input I1.5 – POT 1 MODE: This input toggles the door operation between “Preannounce to Close” mode and “Partial Open” mode
(Figure 28). When L+ to I1.5 is open, Preannounce to Close can be used (See Other Electrical Functions for description of this function). When L+ to I1.5 is closed (with jumper wire), Partial
Open can be used (See Other Electrical Functions, Page 25, for description of this function).
L+ – COMMON TERMINALS: Several input common terminals are provided for convenient wiring on the terminal strip of the control panel.
NOTE: PLC must be in run mode for door to operate.
Run
Term
Stop
0 1
Figure 28: Time to Close Settings
Page 24 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
I
NSTALLATION
215 Spirit HD
PLC Outputs
Relay outputs are located at the upper section of the PLC. These terminals are used to provide signals to operate the motor, provide door position signals, and provide door fault indicators.
INDICATOR OUTPUTS
Output Q0.0 – DOOR CLOSED: This output relay closes when the door is in the fully closed position.
The LED of the output will be lit when the door is fully closed.
Output Q0.1 – DOOR OPEN: This output relay closes when the door is in the fully open position.
The LED of the output will be lit when the door is fully open.
Output Q0.2 – DOOR CLOSING: This output relay closes when the door is closing. Contacts from the relay can be used to connect to lights, security alarms, etc. The LED of the output will be lit when the door is closing.
Output Q0.3 – PREANNOUNCE TO CLOSE: This output relay closes prior to the door closing.
Contacts from a control relay (required to protect
PLC output) can be used to connect to lights, security alarms, etc. The LED of the output will remain lit while the door is closing.
NOTE: PLC must be set for Preannounce to Close mode (See Input I1.5).
24 VAC 1L
DOOR CLOSED Q0.0
DOOR OPEN Q0.1
DOOR CLOSING Q0.2
PREANNOUNCE Q0.3
TO CLOSE
2L
OPEN Q0.4
CLOSE Q0.5
Q0.6
6
7
8
1
28
31
24 VAC 3L
FAULT/RESET Q0.7
COUNTER Q1.0
BRAKE Q1.1
GND
PLC
N
L1
(120 VAC)
1
11
10
18
2
3 (120 VAC)
Figure 29: PLC Output Connections
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 25
I
NSTALLATION
215 Spirit HD
PLC Outputs
Continued
MOTOR CONTROL OUTPUTS
Output Q0.4 – OPEN: This output relay closes to signal the door to open.
Output Q0.5 – CLOSE: This output relay closes to signal the door to close.
Output Q0.6 – NOT USED:
FAULT OUTPUT
Output Q0.7 – FAULT: This output flashes in different sequences to indicate a door fault. These faults are shown below.
OTHER OUTPUTS
Output Q1.0 – COUNTER: This output relay is connected to a mechanical non-resettable counter to be used for maintenance.
Output Q1.1 – BRAKE: This output relay closes to engergize the motor brake.
24 VAC 1L
DOOR CLOSED Q0.0
DOOR OPEN Q0.1
DOOR CLOSING Q0.2
PREANNOUNCE Q0.3
TO CLOSE
2L
OPEN Q0.4
CLOSE Q0.5
Q0.6
24 VAC 3L
FAULT/RESET Q0.7
COUNTER Q1.0
BRAKE Q1.1
GND
PLC
N
L1
(120 VAC)
1
11
10
18
6
7
8
1
28
31
2
3 (120 VAC)
Figure 30: PLC Output Connections
Fault Condition
Motor Run Timer
Start-Up Fault
E-Stop Fault
Double Limits
Multiple Reversing
Edge
Breakaway Switch
LED Sequence Fault Cause
One quick flash every 4 seconds
Action to Clear Fault
The motor ran continuously for greater than 10 seconds.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Two quick flashes every 4 seconds
PLC receives open, close, open/close, partial open, reversing edge or reversing photoeye signal at power up.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Two quick flashes every 4 seconds
Three quick flashes every 4 seconds
Four quick flashes every 4 seconds
Continuous Light
Open, close, open/close, partial open, reversing edge or reversing photoeye signal coming out of E-Stop.
Both limit input signals are off. Door is on open and close limits at the same time.
Reversing Edge was activated four times without door reaching close position.
A breakaway switch was activated.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Reset the bottom bar, then press
Fault/Reset button.
Page 26 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Other Electrical Functions
TIME TO CLOSE: This is a rotary pot (pot 0) used to set a 2–20 second timer (Figure 31). The Time to Close function signals the door to close automatically after a preset amount of time when the door is open. This function can be enabled or disabled. Adjusting this pot with a small screwdriver on the PLC completely counterclockwise will disable this timer. Adjusting the pot more than
10% clockwise will enable the timer. This timer can be typically adjusted from 2 to 20 seconds. Rotating 10% clockwise will set the timer to 2 seconds, 50% clockwise will set the timer to 10 seconds, and fully clockwise will set the timer to 20 seconds.
The Time to Close timer begins when the door reaches the open limit and the activating pushbutton or contact has been released and the reversing photoeyes (when used) are not detecting any obstacles.
The timer will reset whenever the PLC receives a signal from an open or partial open input or when a signal is removed from a reversing photoeye, reversing edge, or stop input.
I
NSTALLATION
215 Spirit HD
NOTE: PLC must be in run mode for door to operate.
Run
Term
Stop
0 1
Figure 31: Time to Close
Settings
Adjust pot lightly and do not rotate passed end stop. Rotary pots are designed for 270º of rotation. Additional turning will damage pot and may affect pot function.
Do not close door until doorway is clear. Closing the door with a Close or Open/Close command will close the door immediately. Unexpected door closing could result in property damage, death or serious injury.
PREANNOUNCE TO CLOSE: A rotary pot (pot 1) is used to set a second timer. NOTE: L+ to I1.5 must be open for Preannounce to
Close to function. This timer can be used to provide a PLC output signal (Q0.3) to indicate the door will close after a preset time.
NOTE: This timer and output signal will only function when Time
to Close is used. This preset time can be set from 0 – 100% of the
Time to Close time. The Preannounce to Close time is set by adjusting the 2nd pot switch with a small screwdriver on the PLC. As the pot is adjusted clockwise, the Preannounce to close signal will turn on for a longer duration prior to the door automatically closing.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 27
I
NSTALLATION
215 Spirit HD
Other Electrical Functions
Continued
Example with Time to Close timer set to 5 seconds: Adjusting the Preannounce to Close pot fully counterclockwise will turn on the Output Q0.3 at the same time the door starts to close.
Rotating 50% clockwise will set the Preannounce to Close timer to 2.5 seconds prior to door closing and 100% clockwise will set the timer to 5 seconds prior to door closing.
PARTIAL OPEN: This feature can be used when the user desires to have the door open to a partial open position in addition to fully opening the door. By using the PLC’s input I0.3
with the rotary pot (pot 1), this feature allows the user to partially open the door. NOTE: PLC must be set for Partial
Open mode (See Input I1.5 to set). All partial open devices must be wired to input I0.3 while full open devices must be wired to inputs I0.0 or I0.2. The distance the door travels before stopping can be adjusted by rotating pot 1 with a small screwdriver on the PLC. Adjusting the pot clockwise will allow the door to travel greater in the open direction while adjusting pot 1 counterclockwise will reduce the distance the door travels in the open direction. NOTE: All other door functions
remain the same while using this feature.
MOTOR RUN TIME: To prevent damage to the door, a timer has been programmed into the PLC to stop the motor after a preset run time has been exceeded. This timer protects the motor by monitoring the run time and turns the motor off and signals a fault when it exceeds the preset time. After determining and correcting the cause of the Motor Run Time fault, the control must be reset by removing and reapplying supply power to the control panel.
Page 28 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
I
NSTALLATION
215 Spirit HD
Start-Up
CAM NYLOCK NUT
ROTATE SHAFT TO
MOVE BLOCK LOCATION
LSO
Read and understand the start-up procedure in this manual before attempting to power-up the door. Failure to do so could result in damage to the door and/or death or serious injury to the installer and will void the warranty.
LSC
All limit switches, photoeyes and reversing edge have been tested at the factory. These must be checked at the end of startup before putting door into service.
1. MANUALLY move door fully open and closed to ensure smooth operation. Throughout duration of travel, look for any sign of binding or possible interference in all moving components. Correct any binding prior to operating door under power. Verify that counterweight and belt are tracking correctly in side column.
LIMIT SWITCH
ACTUATING BLOCK
CAM NYLOCK NUT
Figure 32: ASI Limit Switch
ALIGN
CHAIN
SPROCKET
Be sure to close counterweight shroud covers before operating door. Door may not operate properly with side cover open.
3
/
8
" BOLTS
(BEHIND LIMIT BOX)
2. Locate bottom bar at approximately mid-point of opening.
3. Open the limit switch box and disconnect the limit switch chain. Move the limit switch actuation block to the center of the rotating shaft by manually rotating gear sprocket
(Figure 32).
4. Reattach the limit switch chain to the drive shaft assembly.
If necessary, loosen the four (4) 3 /
8
" bolts, and tension chain as required. The limit switch gear may be moved in or out slightly to achieve proper chain alignment (Figure 33).
5. Check tension of limit switch drive chain and allow 1 /
4
" maximum deflection (Figure 34).
Figure 33: Alignment of Limit Switch Gear
1
/
4
" MAXIMUM
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Figure 34: Limit Switch Drive Chain Adjustment
Page 29
I
NSTALLATION
215 Spirit HD
Electrical Start-Up
Disconnect power at the fused disconnect during all electrical or mechanical service. Disconnect must be properly locked out during maintenance or service of equipment. Failure to disconnect power could result in serious injury or death.
1. Position the door in the middle of the opening.
2. With the power “OFF”, manually operate the door to the fully open and fully closed positions and verify the limit switches activate. Confirm that the switches are being tripped.
When powering up door, check phasing. Unit may operate in an unexpected direction if phased incorrectly. Failure to do so could result in death or serious injury.
3. Again, with the door in the middle of the opening, turn on power to control panel and wait 10 seconds. Supply any open activation signal. The door should open. If the door starts to close, shut the power off immediately.
Reverse any two “L” or “T” lead wires at the terminal strip.
L+
L+
L+
L+
L+ CR1 55
50
51
52
53
M
1M
I0.0
OPEN
I0.1
CLOSE
I0.2
OPEN/CLOSE
I0.3
PARTIAL OPEN
L+ LSO 57
LSC
58
I0.4
E-STOP
I0.5
OPEN LIMIT
I0.6
CLOSE LIMIT
L+
CR2
60
L+ 61
JUMPER
L+
P.E.
62
(12)
(11)
(14)
EXT. CUTOUT 63
JUMPER
L+
(21) (22) (22) (21)
64
L+
65
JUMPER FOR PARTIAL OPEN
I0.7
M
2M
I1.0
REVERSING EDGE
I1.1
REVERSING PHOTOEYE
I1.2
EXTERNAL CUTOUT
I1.3
BREAKAWAY TABS
I1.4
RESET BUTTON
I1.5
POT 1 MODE
M
M
PLC
L+
L+
Figure 35: PLC Input Connections
(See electrical drawing provided for specific electrical connections.)
T h e p h o t o e y e a m p l i f i e r i s p r e s e t a t t h e factory and usually requires no field adjustment
Page 30
2 3 4 5 6
T2
T3
B1
B2
L+
L+
GND
GND
L1
L2
L3
T1
Figure 36: ASI Control Panel
• •
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
I
NSTALLATION
215 Spirit HD
Electrical Start-Up
Continued
5. To verify that photoeyes are aligned properly, make sure door opening is clear of obstructions and photoeye beam is not blocked. Next check amplifier located in control panel and make sure power light and output status light(s) are illuminated. If these lights are off, photoeyes are not in alignment and door will not operate properly.
6. The travel limits are adjusted at the factory short of fully open and closed. Final adjustments are made at the limit switch box. The large slotted screw heads are for adjusting door travel. A decal located adjacent to them indicates which direction to turn (Figure 37).
7. Adjust the limit switch until the door is operating within the desired open/close range. Door should stop just short of full opening on the "UP" cycle and not drive into the floor on the "DOWN" cycle. If the door hits the floor and reverses, shorten the travel, as the reversing edge is activating the operation. After adjusting limits, secure nylon lock nuts on opposite side housing to retain proper limit setting and reattach cover of limit switch (Figure 38).
To open or close the door more, turn the OPEN or CLOSE screw in the “+” direction.
To open or close the door less, turn the OPEN or CLOSE screw in the “–” direction.
8. Run door at least 20 cycles to insure desired limit settings are achieved. Minor adjustment may be required during initial start-up.
–
OPEN
+
+
CLOSE
–
Figure 37: Limit Switch Adjustment
CAM NYLOCK NUT
ROTATE SHAFT TO
MOVE BLOCK LOCATION
LSC
LSO
LIMIT SWITCH
ACTUATING BLOCK
CAM NYLOCK NUT
SPROCKET
Figure 38: ASI Limit Switch
Rotating the adjustment screws in the direction of the arrow indicated will increase the door travel with respect to the open or close cycle.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 31
I
NSTALLATION
215 Spirit HD
Electrical Start-Up
Continued
9. Test the reversing edge while closing the door and keeping your body clear of the door, lightly tap the bottom edge of the door with your hand (Figure 39). The door should immediately stop and reverse to fully open. If the reversing edge does not function as described above, remove the door from service until repairs are made.
CH ECK R EVE R S I NG E DG E OPE RATION DAI LY.
Correct any problems immediately or remove door from service until reversing edge is operational.
Failure to do so could result in death or serious injury.
10. This door is equipped with photoeyes. Test the photoeyes while closing the door and keeping your body clear of the door, block the photoeye beam with your hand (Figure 40).
The door should immediately stop and reverse to fully open. If the photoeye does not function as described above, remove the door from service until repairs are made.
Figure 39: Testing Reversing Edge
CH ECK PHOTOEYE OPE RATION DAI LY.
Correct any problems immediately or remove door from service until reversing photoeyes are operational.
Failure to do so could result in death or serious injury.
CA
UTI
ON
RN
WA
ING
RN
WA
ING
WA
RN
ING
Page 32
Figure 40: Testing Reversing Photoeye
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Final Checks
DO NOT put door into operation until the reversing edge, photoeyes and door operation are fully functional and adjusted. Failure to do so could result in property damage, death or serious injury.
1. Check door limits and make any final adjustments.
2. Test all other activation and sensing devices. Verify door operates as intended. Correct any problems.
3. Train all personnel using or near door on intended use(s) and operation of door.
I
NSTALLATION
215 Spirit HD
Train all service and personnel using or near door on intended use(s) and operation of the door. Failure to do so could result in death or serious injury.
4. Put door into service.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 33
I
NSTALLATION
215 Spirit HD
Resetting Bottom Bar
Remove power at the fused disconnect during all electrical or mechanical service. Disconnect must be properly locked out during maintenance or service of equipment. Failure to disconnect power could result in death or serious injury.
1. The Spirit HD door features a breakaway bottom bar that snaps out of the side column when the door is hit (Figure 41,
Step 1). Resetting the door is quick and easy. Begin by pushing in the red "STOP" button on the control panel.
2. Although this door can be reset at any height, it's more convenient when the bottom bar is four to five feet from the floor. To move the door manually – pull the manual brake release cord – and position bottom bar approximately four to five feet from the floor.
3. Using one hand to push curtain fabric out of the way, grasp Bolt-Action™ handle to unlock and slide towards the
Figure 41: Step 2 center of the door until breaking tab clears the side guide.
Move bottom bar back into the guide and slide Bolt-Action handle so tab is inserted back into the side guide. Return
Bolt-Action handle to down position to lock in place (Steps
2 – 4). Repeat procedure for other side of bottom bar.
4. Pull brake release cable and manually operate door to make sure the door is moving smoothly, with no binding or moving part interference. Check to make sure all of the curtain fabric has returned inside the side column track. If needed, fold or guide curtain fabric back into side column track on both sides.
5. Pull out "STOP" button and push "RESET" button. Door should be run several cycles to insure proper travel is maintained.
Figure 41: Step1
Figure 41: Step 3
Be careful not to scratch or tear fabric on edge of front guide when inserting curtain into guide.
Figure 41: Step 4
Page 34 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Photoeye Adjustment
1. Route and connect wiring as shown in
Figures 42 and 43.
2. Remove mounting plate from side frame
(Figure 44).
3. Mount photoeye to face and reattach to side frame.
N O T E
If side column is hit or damaged – it may be necessary to realign photoeye.
4. During the closing cycle, try interrupting the beam – the door should stop and reverse its direction. Repeat procedure described above if desired operation is not achieved.
Check photoeye operation on a daily basis.
I
NSTALLATION
215 Spirit HD
Figure 42: Cable Routing (Drive Side)
Figure 43: Cable Routing (Idler Side) Figure 44: Adjusting Beam
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 35
I
NSTALLATION
215 Spirit HD
Barrel/Operator Shroud Installation
1. Align operator shroud support to drive side barrel/motor support (Figure 46). Bolt front and back of operator shroud support at predrilled holes (Figure 45).
2. Align barrel shroud support assembly to operator shroud support and idle side barrel support (Figure 45). Bolt at right and left locations using pre-drilled holes.
3. Position barrel shroud over barrel shroud support assembly and on top of barrel shroud tube. Attach on top of barrel shroud support tube and bottom of barrel shroud support using self drilling/tapping screws.
4. Position operator shroud over operator shroud support and drive side barrel/motor support. Attach operator shroud at bottom left and right flanges using selfdrilling/tapping screws.
OPERATOR
SHROUD
SUPPORT
MOUNTING
HOLES
DRIVE SIDE
BARREL/MOTOR
SUPPORT
OPERATOR
SHROUD
SUPPORT
Figure 45: Operator Shroud Support
OPERATOR
SHROUD
SUPPORT
MOUNTING
HOLES
Figure 46: Barrel/Operator Shroud Supports
Page 36 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
M
AINTENANCE
215 Spirit HD
Preventative
Note: For monthly and quarterly inspections record the date of inspection and the cycle count. The cycle counter is located in the control box. Recording daily inspections is usually not necessary.
This door requires only a minimum of maintenance. In this section, we cover the items that should be inspected, adjusted or serviced on an ongoing basis. Refer to shaded area for recommended schedule.
See Page 38 for inspection details.
Daily Monthly Quarterly
Check Door Operation
Visual Damage Inspection
Reversing Edge Inspection
Photoeye or Other Safety Device Inspection
Mounting Hardware
Operator Hardware
Seal Inspection
Door Limits
Chain Inspection
Cord Inspection
Manual Operation
Breakaway System
Control Box Inspection
Electrical Connections
Bearing Inspection
Counterweight & Strap
Fluid Levels
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 37
M
AINTENANCE
215 Spirit HD
Preventative
Continued
DAILY
1. Check for proper operation and inspect door for damage.
2. Visually inspect the door to see that components have not been damaged.
3. Test the reversing edge while closing the door and keeping your body clear of the door, lightly tap the bottom edge of the door with your hand. The door should immediately stop and reverse to fully open.
If the reversing edge does not function as described above, remove the door from service until repairs are made.
CHECK REVERSING EDGE OPERATION DAILY.
Correct any problems immediately or remove door from service until reversing edge is operational.
Failure to do so could result in death or serious injury.
4. Test the photoeyes while closing the door and keeping your body clear of the door, block the photoeye beam with your hand.
The door should immediately stop and reverse to fully open. If the photoeye does not function as described above, remove the door from service until repairs are made.
CH ECK PHOTOEYE OPE RATION DAI LY.
Correct any problems immediately or remove door from service until reversing photoeyes are operational.
Failure to do so could result in death or serious injury.
MONTHLY
1. Check mounting hardware, including frame, counterweight and door panel, tighten where necessary.
2. Check operator mounting bolts, and all bolts and nuts of the operator assembly. During runin period, these attachments may loosen.
3. Check for a tight door seal and adjust as per door adjustment section. Replace if worn or torn. See Replacement Parts Section.
4. Check door open and close limits. Adjust to correct position.
5. Check chain tension on operator. There should be
3
/
8
" maximum deflection. To adjust, loosen the bolts and move the operator as required.
DO NOT OVERTIGHTEN CHAIN.
6. Check fittings on coil cord and coil harness for any breaks or cracks. If cord or harness connections are damaged repair or replace immediately.
7. Check manual release system for smooth operation. The manual brake release will allow the curtain to be lifted aided by the counterweight.
Adjust and replace parts as necessary.
8. Break the bottom bar out of the track to insure the cutout switches and reset switch are working correctly. Replace components as necessary.
9. Check control box wiring. All wires should be tightly secured to terminals.
10. Check incoming electrical connections.
QUARTERLY
1. Check flange bearings to ensure they are tight and holding the barrel without any rubbing.
Adjust if necessary. Make sure bolts and taperlocks are tight. Lubricate both flange bearings if necessary. NOTE: BE CAREFUL
NOT TO OVER-LUBRICATE THE BEARINGS.
2. Check to insure the counterweight, strap, strap clamp and idler wheel are in proper working condition. Replace worn or broken parts as necessary.
3. Check oil level and oil quality in gearbox. The correct oil level is when the surface of the oil is level with the lowest point of the tapped holes.
Page 38 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
M
AINTENANCE
215 Spirit HD
Troubleshooting
Fault Condition
Motor Run Timer
Start-Up Fault
E-Stop Fault
Double Limits
Multiple Reversing
Edge
Breakaway Switch
LED Sequence Fault Cause
One quick flash every 4 seconds
Action to Clear Fault
The motor ran continuously for greater than 10 seconds.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Two quick flashes every 4 seconds
PLC receives open, close, open/close, partial open, reversing edge or reversing photoeye signal at power up.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Two quick flashes every 4 seconds
Three quick flashes every 4 seconds
Four quick flashes every 4 seconds
Continuous Light
Open, close, open/close, partial open, reversing edge or reversing photoeye signal coming out of E-Stop.
Both limit input signals are off. Door is on open and close limits at the same time.
Reversing Edge was activated four times without door reaching close position.
A breakaway switch was activated.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Correct problem, then cycle Power off and on or cycle E-Stop off and on.
Reset the bottom bar, then press
Fault/Reset button.
Problem
A. Motor will not start.
Probable Cause
1. No power.
2. Overload relay tripped.
3. Control circuit breaker tripped while stopping.
4. Wired for wrong voltage.
5. Both limit switches open.
6. Loose or disconnected wire.
7. Defective actuator.
Corrective Measures
1. Check power switches, fuses and connections. Verify 3 phase voltage at operator.
2. Push to reset.
3. Reset – determine cause.
4. Check transformer, motor and overload relay for proper wiring.
5. Reset limit switches.
6. Check wiring and connections.
7. Check actuator and wiring with ohm meter.
1. Check power supply – verify 3 phase voltage. Check contactor/motor wiring.
B. Motor runs but
“lacks power”.
1. Single phasing.
C. Overload trips out.
1. Door not adjusted properly.
2. Limit switches not adjusted.
(Motor runs after door is full open or shut.)
3. Improper overload size.
4. Short in wiring.
5. Defective motor or contactor.
D. Control circuit breaker is tripped.
1. Short in control circuit.
1. Operate motor manually – adjust for proper free travel.
2. Adjust limit switches.
3. Compare overload to motor nameplate. The overload is set for average conditions at S.F. = 1.0. If necessary, adjust slightly higher.
4. Check out wiring – a short may also have blown branch fuse.
5. Test as necessary – replace if required.
1. Trace wiring - particularly to pull stations with ohm meter.
E. Inconsistent starting, stopping and reverse.
1. Loose or poor connection.
2. Check location of lintel brush.
1. Check connections in control circuit.
2. Move lintel brush to prevent interference with bottom bar when door is fully open. Reset open limit to stop door short of HIC.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 39
R
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P
ARTS
General Information
Instructions for Ordering
This parts manual is intended to assist in the correct identification of the more commonly replaced parts; covering, generally, all models and styles offered within the Marathon
Spirit HD line. The manual will also help identify obsolete parts, part design changes and current production parts. For more specific parts information, please contact an authorized representative or consult the Factory's Customer Service or
Engineering Departments. ASI Technologies reserves the right to discontinue any part and make design changes without notice.
General Instructions for Ordering Door Parts
Accurate information is always necessary to serve you correctly and promptly. Several steps should be followed to determine exactly the parts that are needed.
Refer to the information tag on your door and record the:
1. Door model number
2. Job number
3. Door number
4. Manufacturing date.
Use part numbers referenced in this manual.
If the item is not found in the manual, the product code on the back of the item is helpful.
If your door has no information label, the approximate purchase date is helpful.
Once you have gathered the information above, call:
1-800-558-7068
or
Order Parts Online at: www.asidoors.com
and follow the “Parts” link
Page 40 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
R
EPLACEMENT
P
ARTS
Door Identification
Determining the Door Model, Job Number, Door Number and
Manufacture Date of your door is necessary to provide quick and accurate parts identification. The following is a description of labels and their locations.
General Information
ASI TECHNOLOGIES, INC.
DOOR MODEL JOB NUMBER DOOR NUMBER
MFG. DATE INSPECTED BY ENCLOSURE TYPE
OPERATOR TYPE
MOTOR INFO
HP FL
MODEL NAME WIRING DIA. #
CONTROL PANEL
VOLTAGE/PHASE HZ AMPERAGE
MILWAUKEE, WI USA
ID Tag Location
WORK ORDER TAG
(IDLER SIDE TOP FLAG)
ELECTRICAL
INFORMATION TAG
When ordering parts, have your ASI job number and door number available.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 41
R
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P
ARTS
215 Spirit HD
Door Assembly
91D535F1 RH, HIC
≤
91D535F2 LH, HIC
≤
91D535F3 RH, HIC
>
91D535F4 LH, HIC
>
2
4
3
1
12
13
Page 42
14
7
6
9
11
10
8
15
17
18
19
When ordering parts, specify
Job Number, Door Number and Manufacture Date
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
R
EPLACEMENT
P
ARTS
215 Spirit HD
Door Assembly
Continued
91D535F1 RH, HIC
≤
91D535F2 LH, HIC
≤
91D535F3 RH, HIC
>
91D535F4 LH, HIC
>
When ordering parts, specify
Job Number, Door Number and Manufacture Date
Item Part No.
Description
1 76D352F1 Idler Side Column, RH Operator, HIC
≤ 164.75"
76D352F2 Idler Side Column, LH Operator, HIC
≤ 164.75"
76D352F3 Idler Side Column, RH Operator, HIC
> 164.75"
76D352F4 Idler Side Column, LH Operator, HIC
> 164.75"
2 28D133F1 Barrel Shroud Support Weldment, RH
28D133F2 Barrel Shroud Support Weldment, LH
3 24C578 Lintel Brush Assembly
4 76D350F1 Drive Side Column, RH Operator, HIC
≤ 164.75"
76D350F2 Drive Side Column, LH Operator, HIC
≤ 164.75"
76D350F3 Drive Side Column, RH Operator, HIC
> 164.75"
76D350F4 Drive Side Column, LH Operator, HIC
> 164.75"
5
6 28D136 Barrel Weldment
7 24D065F1 Operator Assembly (SK32), RH, HIC or WIC
≥ 144"
24D065F2 Operator Assembly (SK32), LH, HIC or WIC
≥ 144"
24D069F1 Operator Assembly (SK22), RH, HIC or WIC
< 144"
24D069F2 Operator Assembly (SK22), LH, HIC or WIC
< 144"
8 18D209 Control Box Assembly
Item Part No.
Description
9 55C773F1 Barrel Shroud Assembly, RH
55C773F2 Barrel Shroud Assembly, LH
10 55C774F1 Operator Shroud Assembly, RH
55C774F2 Operator Shroud Assembly, LH
11 23B036F1 Kit, Coil Cord, HIC
> 144"
– 23B036F3 Kit, Coil Cord, HIC
≤ 144"
12 13B406 Panel Retainer
13 13C324
14
Wind Bar
Curtain Assembly (Consult Factory)
15 24D064F1 Bottom Bar Assembly, Galvanized, RH
24D064F2 Bottom Bar Assembly, Galvanized, LH
240064F3 Bottom Bar Assembly, Stainless Steel, RH
240064F4 Bottom Bar Assembly, Stainless Steel, LH
16
17 05A017 Counterweight Strap, 1" Wide, (L = HIC + 68")
18 13A355
19 28C184
Counterweight Clamp
Counterweight Weldment
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 43
R
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P
ARTS
215 Spirit HD
Curtain & Barrel Assembly
81D510F1 RH
81D510F1 LH
When ordering parts, specify
Job Number, Door Number and Manufacture Date
9
10
12
11
12
9
17
26
27
28
16
25
14
18
13
15 22
13
14
18
17
20
8
23
24
2
3
Item Part No.
Description
1 24D064F1 Bottom Bar Assembly, Galvanized, RH
24D064F2 Bottom Bar Assembly, Galvanized, LH
240064F3 Bottom Bar Assembly, Stainless Steel, RH
240064F4 Bottom Bar Assembly, Stainless Steel, LH
2
Consult Factory
Assembly, Curtain, Specify Color
3 13B019F1 Bar, Mounting, Outer Panel, Galvanized
13B019F2 Bar, Mounting, Outer Panel, Stainless Steel
4 13B542F1 Bar, Mounting, Inner Panel, Galvanized
13B542F2 Bar, Mounting, Inner Panel, Stainless Steel
5 41A439 Screw, 1 /
4
"–20 × 1", FL, WZLK, ZN
6 41A430
7 41A532
Washer, Lock,
Nut, 1 /
4
1 /
4
", Reg. Split, ZN
"–20, Hex, Acorn, Nickel
8 13C324
9
10 28D136
11 13B406
12 41A466
Windbar, (L = WIC + 6")
Screw, 1 /
2
"–13 × 2", HX WZLK, ZN
Weldment, Barrel
Retainer, Panel (L = WIC + 10")
Screw, 1 /
4
"–20 × 5 /
8
", FHMS, ZN
4
Page 44
5 6 7
1
4
3
Item Part No.
Description
13
14
47A065
41A634
15 50B030
16 50A103
17 05A017
Bearing, Pillow Block, 2"
Collar Shaft, 2"
Sprocket, 25T, #60, Q1 Bore
Bushing, Split Taper, Browning, Q1 × 2"
18 41A456
19
20 50A113
Strap, 1" (L = HIC + 68")
Screw, 5 /
16
"–18 × 3 /
4
", SL, PHMS, ZN
Clamp, Rubber Cushioned Loop, 3 /
8
" Dia. (coil cord clip)
21
22 50A117 Key, 1 /
2
" × 1 /
2
" × 2.5"
23
Consult Factory
Wear Pad, Windbar (Specify Color)
24 12A052-1
25 24A015-1
26 13A355-K
27 11B035
Window 18" × 18" Standard w/Velcro
Pulley
Counterweight Clamp Kit
Counterweight Guide and Bolts
28 28C184, F1 Counterweight Weldment (Job# & DR # Required)
– 28C184, F2 Counterweight Weldment (Job# & DR # Required)
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Bottom Bar Assembly
24D064F1 RH
24D064F2 LH
When ordering parts, specify
Job Number, Door Number and Manufacture Date
R
EPLACEMENT
P
ARTS
215 Spirit HD
24 25
8 9 11
2
4
10
29
1
23
22
26
27
28
1
4
30
3
8 9 11
7
22
23
10
6
5 12
6
13
14
32
33
19
20
7
17
18
31
15
21
15
31
Item Part No.
Description
1 28D143F1 Weldment, Bottom Bar, Galvanized, RH
– 28D143F2 Weldment, Bottom Bar, Galvanized, LH
– 28D143F3 Weldment, Bottom Bar, Stainless Steel, RH
– 28D143F3 Weldment, Bottom Bar, Stainless Steel, LH
2 28C183F1 Weldment, Breakaway Tube, Galvanized, RH
– 28C183F3 Weldment, Breakaway Tube, Stainless Steel, RH
3 28C183F2 Weldment, Breakaway Tube, Galvanized, LH
– 28C183F4 Weldment, Breakaway Tube, Stainless Steel, LH
4 41A297 Screw, 3 /
8
"–16 × 5 /
8
", FL, WZLK, ZN
5 13B540 Space, Tab, Breakaway
6 11B034
7 41A199
8 41A054
Tab, Breakaway
Screw, #10–24 × 1", PH, FHMS, SS
Screw, 1 /
4
"–20 × 4", SL, RHMS, ZN
9 41A182
10 41A639
11 11A111
12 11A109
13 23B008
14 41A115
15 21A128
Washer, Flat, 1 /
4
", Standard, ZN
Nut, 1 /
4
"–20, Hex, Lock, Nylon, SS
Cover, Bottom Bar Breakaway
Tube, Spacer, Handle Mounting
BreakawaySwitch
Screw, #10–24 × 1 1 /
2
", SL, RHMS, SS
Gasket, Retainer, Aluminum (L = WIC – 2")
Item Part No.
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Description
16
17
18
11A038
41A053
19 24A011-s
20 11A039
21
22
15A013
13B538
23 13B539
24 41A489
25 41A337
Mounting Channel (L = WIC – 2")
Screw, 1 /
4
"–14 × 3 /
4
", HD, SLFDR, ZN
Switch, Sensing Edge (L = WIC – 3")
Housing, Sensing Edge Gasket
Gasket, 12" (L = WIC + 6")
Handle, Breakaway
(Job# & DR # Required)
Bracket, Breakaway Handle Mounting
Screw,
Screw,
1
1
/
/
4
4
"–20 × 3 /
4
", SL, PHMS, ZN
"–20, Hex, Lock, Nylon, SS
26 13A177
27 41A339
Access Plate
Screw, #10–24 × 3 /
8
", SL, RHMS
28 23B036F1 Coil Cord Kit, 6' (HIC > 12')
– 23B036F3 Coil Cord Kit, 3' (HIC
≤ 12')
29 22A205 Connector, Electrical, Closed End
30 10A021
31 41A542
32 22A038
33 22A208
Tape, 3" Yellow/Black (L = WIC – 33")
Screw, #8 × 3 /
4
", SLDR, HEX, ZN
Strain Relief, Nylon
Cable, 18–3, SVT (L = WIC)
Page 45
R
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P
ARTS
215 Spirit HD
Idler Side Column Assembly
76D352F1 Idler Side, RH, HIC
≤
76D352F2 Idler Side, LH, HIC
≤
76D352F3 Idler Side, RH, HIC
>
76D352F4 Idler Side, LH, HIC
>
When ordering parts, specify
Job Number, Door Number and Manufacture Date
6
7
10
1
16 17 18
19
6
8
10
15
6
9
10
Page 46
2 3
4 5
10 11 12
Item Part No.
Description
1 28D132F1 Weldment, idle side column, RH, HIC
≤ 164.75"
– 28D132F2 Weldment, idle side column, LH, HIC
≤ 164.75"
– 28D140F1 Weldment, idle side column, RH, HIC > 164.75"
– 28D140F2 Weldment, idle side column, LH, HIC > 164.75"
2 13D144F1 Cover, non-splice side column, RH, HIC
≤ 137"
2 13D144F2 Cover, non-splice side column, LH, HIC
≤ 137"
3 13D147F1 Cover, bottom side column, RH, HIC > 137"
– 13D147F2 Cover, bottom side column, LH, HIC > 137"
– 13D148F1 Cover, top side column, RH, HIC > 137"
– 13D148F2 Cover, top side column, LH, HIC > 137"
4 13C171
– 13C172
5 41A017
6 13A384
Splice, inner, side column cover, HIC > 137"
Splice, outer, side column cover, HIC > 137"
Rivet, 3 /
16
" × 3 /
8
", AD MNBOLT, AL
Hinge, mounting shroud cover
7 28A018F1 Weldment, short pin hinge, RH
– 28A018F2 Weldment, short pin hinge, LH
8 28A017F1 Weldment, medium pin hinge, RH
– 28A017F1 Weldment, medium pin hinge, LH
9 28A012F1 Weldment, long pin hinge, RH
– 28A012F1 Weldment, long pin hinge, LH
10 41A456
11 23B047-1
Screw, HHCS, 1 /
4
"–20 × 3 /
8
", WZLK
Photoeye Transmitter
12 13A393F1 Plate, photoeye, Galvanized
— 13A393F2 Plate, photoeye, Stainless Steel
13
14
15 11A126
16
17
18
19
24A015-1
41A653
41A391
17C013
Grommet, 3 /
16
" ID
Assembly, pulley, counterweight
Screw, 5 /
8
" × 2 1 /
2
", SHSS
Washer, flat, 5 /
8
" (SAE “N”), ZN
Warning label, roll-ups
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
R
EPLACEMENT
P
ARTS
215 Spirit HD
Drive Side Column Assembly
76D350F1 Drive Side, RH, HIC
≤
76D350F2 Drive Side, LH, HIC
≤
76D350F3 Drive Side, RH, HIC
>
76D350F4 Drive Side, LH, HIC
>
When ordering parts, specify
Job Number, Door Number and Manufacture Date
23 1
11
10
12 13
6
7
10
6
8
10
15
6
9
10
Manual Part Number: 17A136-112912
19 20
24 25 26
16 17 18
2 3
4 5
22
Item Part No.
Description
1 28D131F1 Weldment, Drive Side Column, RH Operator, HIC
≤ 164.75"
– 28D131F2 Weldment, Drive Side Column, LH Operator, HIC
≤ 164.75"
– 28D139F1 Weldment, Drive Side Column, RH Operator, HIC
> 164.75"
– 28D139F2 Weldment, Drive Side Column, LH Operator, HIC
> 164.75"
2 28D132F1 Weldment, Idler Side Column, RH Operator, HIC
≤ 164.75"
– 28D132F2 Weldment, Idler Side Column, LH Operator, HIC
≤ 164.75"
– 28D140F1 Weldment, Idler Side Column, RH Operator, HIC
> 164.75"
– 28D140F2 Weldment, Idler Side Column, LH Operator, HIC
> 164.75"
3 13D144F1 Cover, Non-Splice Side Column, RH, HIC
≤ 137"
– 13D144F2 Cover, Non-Splice Side Column, LH, HIC
≤ 137"
– 13D147F1 Cover, Bottom Side Column, RH, HIC > 137"
– 13D147F2 Cover, Bottom Side Column, LH, HIC > 137"
– 13D148F1 Cover, Top Side Column, RH, HIC > 137"
– 13D148F2 Cover, Top Side Column, LH, HIC > 137"
4 13C171
– 13C172
5 41A017
6 13A384
Splice, Inner, Side Column Cover, HIC > 137"
Splice, Outer, Side Column Cover, HIC > 137"
Rivet, 3 /
16
" × 3 /
8
", AD MNBOLT, AL (Qty. 20)
Hinge, Mounting, Shroud Cover
7 28A018F1 Weldment, Short Pin Hinge, RH
– 28A018F2 Weldment, Short Pin Hinge, LH
8 28A017F1 Weldment, Medium Pin Hinge, RH
– 28A017F2 Weldment, Medium Pin Hinge, LH
9 28A012F1 Weldment, Long Pin Hinge, RH
– 28A012F2 Weldment, Long Pin Hinge, LH
10 41A546
11 23D032
Screw, HHCS, 1 /
4
"–20 × 3 /
8
", WZLK
Harness, Sideframe/Photoeye
12 13A393F1 Plate, Photoeye, Galvanized
– 13A393F2 Plate, Photoeye, Stainless Steel
13 41A546
14 41A104
15 11A126
Screw, HHCS, 1 /
4
"–20 × 3 /
8
", WZLK
Screw, Set, #10–24 × 1 /
4
", FLG, WZLK
Grommet, 3 /
16
" ID
16 24A015–1 Assembly, Counterweight
17 41A122 Screw, 5 /
8
" × 1 3 /
4
", SHSS
18 47A048 Bushing, Machined, 1 × 5 /
8
" × 14GA, ZN
Bracket, Mounting, Wiring Harness
Screw, HHCS, 3 /
8
"–16 × 5 /
8
", FLG, WZLK
19 13B535
20 41A297
21
22 17C013
23 17B015
24 41A717
Warning Label, Roll-Ups
Warning Label, Gears
Screw, #8–32 × 1 /
2
", PH, PHSTS, SS
25 41A476
26 41A247
Screw, #6–32 × 3 /
8
", PH, PHMS, ZN
Nut, #6–32, Hex, KEPS, ZN
©2005 ASI Technologies, Inc.
1-800-558-7068
Page 47
R
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P
ARTS
215 Spirit HD
SK22 Operator Assembly – for HIC or WIC
<
24D069F1 RH
24D069F2 LH
When ordering parts, specify
Job Number, Door Number and Manufacture Date
1
3
10
20
2
8
9
21
5
13
15
17 16
6
7
11
12
14
18
19
Item Part No.
Description
1 23B010 Motor, Electric Brake Gear, Nord SK22
2 28B168F1 Weldment, Limit Switch/Motor Mounting, RH
28B168F2 Weldment, Limit Switch/Motor Mounting, LH
3 24D102F1 Limit Switch, RH
24D102F2 Limit Switch, LH
4 41A021 Screw, 3 /
8
"–16 × 1 1 /
2
", GR5, HHCS, ZN
5 41A038
6 41A107
7 41A130
Washer, Lock,
Screw, 1 /
4
Washer, Lock,
3
"–20 ×
1
/
/
8
4
", Reg, Split, ZN
3 /
4
", HHCS, ZN
", Reg, Split, ZN
8 50B029
9 50A046
Sprocket, 16T/25T Dual
Bushing, Split Taper, P1 × 1
10
Consult Factory
Limit Switch Sprocket
1 /
4
" Bore
Page 48
Item Part No.
11 50A246
12 50A255
13 50A017
14 50A015
15 28B063
16 50A016
17 50A018
18 49A024
19 50A254
20 13B551
21 50A112
©2005 ASI Technologies, Inc.
1-800-558-7068
Description
Chain, Roller, #40
Link, Master, #40
Cable Clamp, 1 /
8
"
Cable, 1 /
8
" Uncoated (L = HIC – 60")
Pulley
Sleeve, 1 /
8
" Dual Swage
Thimble, 1 /
8
" Cable
Spring, Extension Chain
Chain, 3'
Plate, Shim, Limit Switch
Key, 1 /
8
" SQ. × 3 /
4
" Long
Manual Part Number: 17A136-112912
R
EPLACEMENT
P
ARTS
215 Spirit HD
SK32 Operator Assembly – for HIC or WIC
≥
24D065F1 RH
24D065F2 LH
When ordering parts, specify
Job Number, Door Number and Manufacture Date
1
3
10
20
2
8
9
21
5
13
15
17 16
6
7
11
12
14
18
19
Item Part No.
Description
1 23B009 Motor, Electric Brake Gear, Nord SK32
2 28B179F1 Weldment, Limit Switch/Motor Mounting, RH
28B179F2 Weldment, Limit Switch/Motor Mounting, LH
3 24D102F1 Limit Switch, RH
24D102F2 Limit Switch, LH
4 41A377
5 41A119
6 41A107
Screw, 1 /
2
"–13 × 1 3 /
4
", GR5, HHCS, ZN
Washer, Lock, 1 /
2
", Reg, Split, ZN
Screw, 1 /
4
"–20 × 3 /
4
", HHCS, ZN
7 41A130
8 50B029
Washer, Lock, 1 /
4
", Reg, Split, ZN
Sprocket, 16T/25T Dual
9 50A258 Bushing, Split Taper, P1 × 1 5 /
8
" Bore
10
Consult Factory
Limit Switch Sprocket
Item Part No.
11 50A246
12 50A255
13 50A017
14 50A015
15 28B063
16 50A016
17 50A018
18 49A024
19 50A254
20 13B551
21 50A112
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Description
Chain, Roller, #40
Link, Master, #40
Cable Clamp, 1 /
8
"
Cable, 1 /
8
" Uncoated (L = HIC – 60")
Pulley
Sleeve, 1 /
8
" Dual Swage
Thimble, 1 /
8
" Cable
Spring, Extension Chain
Chain, 3'
Plate, Shim, Limit Switch
Key, 1 /
8
" SQ. × 3 /
4
" Long
Page 49
R
EPLACEMENT
P
ARTS
215 Spirit HD
Panel Assembly
18D209 Spirit HD
6 10 11
12 13 51
4 49
6 14
15 44
51
When ordering parts, specify
Job Number, Door Number and Manufacture Date
51 1
L1 L2 L3 NC/21 A1 L1 L2 L3 NC/21 A1
NO
54
NC
62
NO
74
NO
84
NO
54
NC
62
NO
74
NO
84
T1 T2 T3 NC/22 A2 T1 T2 T3 NC/22 A2
W A
STOP RESET
95 NC 96 A2
T1 T2 T3 NC22
RESISTOR
2 23 9 51
SIMATIC
S7-200
SF
RUN
STOP
1L
QO
.0
0.0 0.1 0.2 0.3
.1
.2 .3 .4 .5 .6 .7
•
Q1
2L 0.4 0.5 0.6
.0 .1
• 3L 0.7 1.0 1.1
R N L1
CPU 224
AC/DC/RELAY
AC
Run
Term
Stop
0 1
IO
.0
.1
.2 .3 .4 .5 .6 .7
I1
.0
.1
.2 .3 .4 .5
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4
1.5
M L+
PORT
0
1 2 3 4 5 6
3 50
5
51
22 24 25
27 52
8
26
27
80
81
21
22
23
24
2
4
12
13
14
57
58
61
63
1
1
1
2
2
L+
L+
50
51
52
B1
B2
L+
L+
L3
T1
T2
T3
GND
GND
L1
L2
OPEN
CLOSE
OPEN/CLOSE
REVERSING PHOTOEYE
EXTERIOR CUTOUT
E-STOP
26
29
43
27
30
32 33
LOOP (OPTIONAL)
LOOP (OPTIONAL)
DOOR CLOSED (OPTIONAL)
DOOR CLOSED (OPTIONAL)
52
28
31
89 PREANNOUNCE TO CLOSE (OPTIONAL)
INTLK BRAKE REV
EDGE
E-STOP PHOTOEYE LOOP
51 7 43 17 20 21 17 19 21 16 18
Page 50
ENCLOSURE COVER
INSIDE OUTSIDE
ASI TECHNOLOGIES, INC.
ASI
SPIRIT
FAULT
OPEN
CLOSE
PUSH TO
STOP
PULL
TO RELEASE
WARNING
45
41 42
37
48
35
36
46
47
24
NONE
NONE
NONE
14
21
22
23
NONE
NONE
NONE
64
1
12
13
L+
L+
57
58
BLACK
ORANGE
WHITE
RED
BLUE
WHT/BLK
ORG/BLK
GRN/BLK
RED/BLK
BLK/WHT
BLUE/BLK
BLK/RED
BLUE/WHT
GREEN
RED/WHT
GRN/WHT
WHT/RED
ORG/RED
BLUE/RED
39 40
34
©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
R
EPLACEMENT
P
ARTS
215 Spirit HD
Panel Assembly
Continued
18D209 Spirit HD
When ordering parts, specify
Job Number, Door Number and Manufacture Date
Item Part No.
Description
1 14D012
2 13C366
Enclosure, 16" × 14"
Subpanel
3 23A003 Counter, 24 VAC
4 23A190–200 Resistor, 200 Ohms (for electric reversing edge only)
5 13B679
6 22B025
7 22B026
8 22B027
9 23B025
Bracket, DIN rail
Rail, DIN, 100 mm
Rail, DIN, 175 mm
Rail, DIN, 375 mm
Transformer, 208/230/460V to 24/120V
10 24A500
11 23A231-5
– 23A231-7
12 23A246
13 22A226
14 23A236
15 18B010-6
Contactor, reversing, Siemens
Overload, motor, Siemens, 2.8–4.0 amps
Overload, motor, Siemens, 4.5–6.3 amps
Suppressor, RC
Seal, security
Programmable logic controller
Program, Siemens PLC
16 23A233
17 23A232
18 23A226
19 23A234
20 23A235
21 23A241
22 23A239
23 22A209-1
24 22A210-1
25 22A210-2
26 22A007
Base, 11 pin
Base, relay, Finder
Detector, photoeye, dual channel
Relay, 24 VAC, Finder
Relay, 12 VAC, Finder (for electric reversing edge only)
Suppressor, RC, Finder
Block, fuse, 2 pole
Fuse, class CC, 1 amp
Fuse, midget, 6 /
10 amp
Fuse, midget, 3 amp
Block, terminal
Item Part No.
Description
27 22A008
28 22A012
29 22A009
30 11B039
Retainer, end
Label, terminal block
Barrier, terminal block
Insulator, terminal block
31 22A019
32 22A010
Separator, link rail
Link rail, 2 position
33 22A011 Link rail, 3 position
34 23C022F1 Harness, 19 conductor (HIC
≤ 14')
– 23C022F3 Harness, 19 conductor (HIC
> 14')
35 22A059
36 22A060
Pushbutton, green
Pushbutton, illuminated, yellow
37 22A061
38 23C027
39 22A217
40 22A196
41 22A109-1
42 22A218
43 17B020
44 17B021
45 17A107
46 17C012
47 17B007
48 17C002
49 41A052
50 41A720
51 41A721
52 22A091-1
Pushbutton, E-Stop
Harness, control panel (not shown)
Strain relief, nylon
Locknut, nylon
Cable tie, 3.5" long
Base, mounting, cable tie
Label, subpanel
Label, PLC
Label, UL 508
Label, warning
Label, rating plate
Label, Spirit
Screw, #4–40 ×
Screw, #6–32 ×
Varistor, Z230
1
3
Screw, #10–32 ×
/
/
3
4
8
/
", PAN, PHL
", PAN, PHL, type “F”
8
", PAN, PHL, type “F”
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 51
R
EPLACEMENT
P
ARTS
215 Spirit HD
Lintel Brush Assembly
24C578
When ordering parts, specify
Job Number, Door Number and Manufacture Date
4
3
1
2
Item Part No.
Description
1 44A007
2 13B506
3 15A103
4 41A053
Retainer, Straight Aluminum Track, 2" (L = WIC)
Support Tube, Shroud/Lintel Brush
Brush, 3" Polypropylene (L = WIC)
Screw, 1 /
4
"–14 × 3 /
4
", HD, SLFDR, ZN
Page 52 ©2005 ASI Technologies, Inc.
1-800-558-7068
Manual Part Number: 17A136-112912
Labels
R
EPLACEMENT
P
ARTS
215 Spirit HD
When ordering parts, specify
Job Number, Door Number and Manufacture Date
CAUTION
Connect Reversing edge switch.
Test edge daily.
See Instructions.
2
1
EMERGENCY
MANUAL RELEASE
In the event of a power outage pull handle down while lifting bottom of door.
Release handle when door approaches full open.
WARNING
3
1. Read, study and understand all warning labels, operating instructions and installation manual furnished with this equipment prior to use. If any portion of this material is unclear, contact your factory representative for clarification.
2. This is a high speed door designed for vehicular traffic.
Operation may be automatic. Keep doorway clear at all times. Door impact may cause personal injury or property damage.
3. Do not start door downward unless doorway is clear.
Once door has begun closing…Do Not Enter Doorway!
4. Check reversing edge, photoeye and any other activation device for proper operation daily. See operating instructions for procedure.
5. Do not operate door with side columns open or without factory provided shrouds properly installed.
6. Mount door operator more than 8 feet (2.44 M) above the floor.
7.
It is your responsibility to keep all warning labels and instructional literature legible and intact. Replacement labels and literature are available from the factory.
8. Failure to heed these warnings may result in equipment and/or personal or fatal injury.
ASI TECHNOLOGIES, INC.
WARNING
1. Read, study and understand all warning labels, operating instructions and installation manual furnished with this equipment prior to use. If any portion of this material is unclear, contact your factory representative for clarification.
2. This is a high speed door designed for vehicular traffic.
Operation may be automatic. Keep doorway clear at all times. Door impact may cause personal injury or property damage.
3. Do not start door downward unless doorway is clear.
Once door has begun closing…Do Not Enter Doorway!
4. Check reversing edge, photoeye and any other activation device for proper operation daily. See operating instructions for procedure.
5. Do not operate door with side columns open or without factory provided shrouds properly installed.
6. Mount door operator more than 8 feet (2.44 M) above the floor.
7.
It is your responsibility to keep all warning labels and instructional literature legible and intact. Replacement labels and literature are available from the factory.
8. Failure to heed these warnings may result in equipment and/or personal or fatal injury.
ASI TECHNOLOGIES, INC.
4
Item Part No.
Description
1 17A034
2 17B004
3 17C013
4 17A119
Manual operation decal
Reversing edge decal
Warning label
Warning label nameplate assembly
Manual Part Number: 17A136-112912 ©2005 ASI Technologies, Inc.
1-800-558-7068
Page 53
S
PIRIT
HD™ H
IGH
S
PEED
F
ABRIC
R
OLL
-U
P
D
OOR
5848 N. 95th Court • Milwaukee, WI 53225 • (414) 464-6200 • (800) 558-7068 • FAX: (414) 464-9863 • www.asidoors.com

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Key features
- Durable Fabric Curtain
- Powerful Motor
- Safety Features
- Easy Installation
- High Speed Operation
- Low Maintenance
- Quiet Operation