ASI DOORS 615 Owner's Manual

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OWNER’S MANUAL

MODEL 615/615F

High Speed Interior/Exterior/ Freezer Fabric Roll-Up

Manual: 17A260

GENERAL INFORMATION

3-6

Safety Practices 3

Warranty Policy 5

Crates and Contents 6

615 MANUAL INSTALLATION

7-34

Door Measurement 7

Assembly on the Floor 8

Door Assembly 9

Door Mounting 11

Optional Mounting 13

Counterweight Installation 16

Mount Control Panel/Photo Eyes 17

Manual Operation 18

Precaustions W/Frequency Inverter 18

Warranty & Liability 19

Electrical Controls 20

Error Messages 24

Electrical Installation 25

Primary Connections 25

Photo Eye Connections 27

Encoder Connections 29

Wiring Accessories 30

Final Checks and Verification 30

Set Door Limits 31

Install Activation Devices 34

Set Timers 35

Calibrate WDD Reversing Edge 38

Photocell Installation and Set-Up 39

MAINTENANCE

40-41

Preventative Maintenance 40

Maintenance Table 41

REPLACEMENT PARTS

42-53

Instructions for Ordering 42

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Safety Practices

This is a 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 a safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage

NOTE

NOTE explains general information

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Warning read these safety practices before installing, operating or servicing the SLIDING door Failure to follow these safety practices could result in property damage, death or serious injury

READ AND UNDERSTAND ALL WARNING LABELS AND OPERATING INSTRUCTIONS IN THIS

MANUAL BEFORE OPERATING THE SLIDING DOOR If you do not understand the instructions, ask your supervisor to teach you how to use the SLIDING door

Safety Practices (cont’d)

1 Do not operate the door while under the influence of drugs or alchohol

2 Do not use the door if it looks broken or does not seem to work properly 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 inside door opening

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 availale from ASI Doors, Inc or its representatives

10 If you have any questions, contact your supervisor or your local ASI Doors, 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

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Warranty Policy

ASI Doors, 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 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 year, 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

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Crates and Contents

SIDE

FRAMES

CRATE

HEADER AND

MOTOR ASSEMBLY

SHROUD ASSEMBLY

(OPTIONAL)

CONTROL BOX

LOOSE PARTS

BOX

CRATE

Figure 1: Crate Contents

Upon receipt of the shipment, check that you have received the correct number of pieces as shown (Figure 1) Crate will contain the side-covers, the header assembly, the loose parts box, 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

NOTE

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.

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.

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Loose Parts

Sales

Qty.

Installation

Misc. Activation Devices

Manual

As Ordered

2 Warning Name Plate Assembly

Control Enclosure Box

Control Box

Lubricant

6mm Hex Drive

Eyes

Misc. Activation Devices As Ordered asidoors.com

Door Measurements

1 Make contact with the person responsible at the customer’s place of business – check access conditions and prevailing safety practices

2 First check the dimensions of the construction opening The exact measurements can be found on the production sheet supplied with the door

3 Carefully unpack the door and check the various components:

• Left and right side frames

• Roll-up mechanism and installation manual included in the packing list

• Control box, wiring diagram, photo eyes and cable for anti-roll off switch

• Fasteners for the door, the operating controls and other accessories

Header

17-1/2”

Bolt Hole Locations

Figure 2: Door Measurements

Idler Side

3-1/8”

1/2 WIC + 7-1/8”

Drive Side

7-1/8”

1/2 WIC + 3-1/8”

Figure 3: Marking Bolt Holes

Description

Tape

Water

Pencil

General Purpose Pliers

Cutters

Wire Strippers

Digital Volt/Ohmmeter

Silcone Caulk Gun

Tools Required

Hammer 1

Screw Drivers 1

Extension Corder 1

Electric Screwdriver

Electric

Hammer Drill 1

Set of Contrete Drill Bits 1/4” to 5/8”

Set of Metal Drill Bits 1/4” to 5/8”

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Assembly On The Floor

NOTE

Note only ASI Doors qualified personnel are authorized to carry out this work

Assembly on the floor:

Complete any additional structure support for the doorframe before you begin assembling the door To ease the installation of the door, you may find it desirable to use a fore frame, particularly where the mounting wall is substantially out of true and plumb

Remember to verify the door measurements For the most accurate measurements, measure the width of the door just above the reintroduction points located on each side See Figure 4

1 Measure the height and width of the door opening

2 Compare these measurements to the width of the head assembly

Figure 4: Measuring the Door

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Door Assembly

1 Clear the door mounting area of all obstructions

2 Attach the side guides to the head assembly

3 Secure the side guides to the header unit with the bolts, nuts and washers

Figure 5: Attaching the Slide Guides

4 Align the inner guide with the re-introduction points to assure a straight path for the curtain to travel

NOTE

Note tighten the hold-down scres firts

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Figure 6: Securing the Slide Guides asidoors.com

Door Assembly

Continued

5 Tighten the top stud with the lock nut when the path is achieved

Figure 7: Aligning the Inner Guide

6 Place the head assembly of door of the forklift, ensuring that the forks are beneath the u-profile

Caution strap the head unit to the forks to ensure that it does not slip from the forks while you are rasing it

Figure 8: Placing the Head Assembly on the Forks

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Door Mounting

1 Lift the door with the forklift The door will tilt to a vertical position as you lift the forks(Figure 9)

Caution clear area of obstructions if the frame drags along the ground and may be snagged or damaged during installation

Figure 9: Tilting the Door

2 Place the unit against the door opening while checking the levels (drum, struts and side posts)

(Figure 10)

Figure 10: Placing the Door Against the Opening

Figure 11: Temporarily Attach the Door

3 Temporarily attached the door with clamps or some other secure method (Figure 11)

4 Using a level, check each side of the door opening for level and plumb

5 If necessary, shim the low side of the opening where the side guide of the door will be positioned (Figure 12)

6 Continue to adjust the door’s postition until it is absolutely plumb and level (Figure 13)

Figure 12: Level and Plumb the Door

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Figure 13: Check Inside Dimension Measurement asidoors.com

Door Mounting

Continued

Figure 14: Anchoring the Door

7 Measure the inside dimension (W) between the two side guides, ensruing that it is the same at the top, middle and bottom

8 Permanently anchor the door in the following order: a Head unit mounting points b Side rail mounting points

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Optional Mounting

Mounting The Door Using A Fore Frame:

Door can be mounted using a “Fore Frame” or “Build Out” between door frame and face of opening All steps for dimensions, plumb & level apply as in standard mounting

Caution vertical alignment of the side-guides is very important! Failure to ensure aplum and level mounting may result in a door with a curtain that is not smooth and flat This prevents the curtain from properly sealing

Figure 15: Mounting Door Using Fore Frame

See figure 16 for various wall mounting techniques

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Optional Mounting

Continued

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Figure 16: Wall Mounting Options asidoors.com

Optional Mounting

Continued

1 Remove protective shipping material from the curtain

2 With one person at each end of the door, loosen the curtain from the roll-up drum and position the first tooth at each side within the drive

NOTE

Note for best results, use two people to complete this prcedure

3 Apply provided lube to side guides

4 Insert the ratchet and key into the drive motor fan opening

5 While holding moderate pressure to each zipper, rotate the drive motor backwards slowly to push the zipper back and slip the first tooth of each zipper into the next tooth of the drive gears

6 Reverse direction of the ratchet and rotate the drive motor until the last tooth on booth sides of the curtain are even with the reintroduction point

Caution Do not leave the door unattended without the counterweight installed Until you install the counterweight,there is risk of the curtain slowly unraveling onto the floor

NOTE

Note use of a powered drill or impact driver is NOT recommended, and may damage motor or hex drive

Figure 17: Feeding the Curtain

Figure 18: Move Curtain Through Drive

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Counterweigh Installation

1 Ensure the curtain is in the up position

2 Locate the pre-assembled belt on the rollup drum shaft

3 Unroll the belt until 2" remain on th shaft

4 Pass the belt behind the counterweight pulley without twisting it

5 Securely support the counterweight at

20 inches above the floor (The counterweight may be lower depending on door size)

6 Attach the belt to the counterweight with the hardware provided

7 Manually lower the door to verify that travel of the counterweight is unobstructed

8 Remove any excess belt

9 Verify that the weight is mounted straight vertically and at an angle Figure 19: Wind Belt on Shaft

Figure 20: Counterweight Pulley

Figure 21: Attach Counterweight

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Mount Control Box and Photoeyes

1 Mount the Control Box on the motor side of the door, approximately 5’ 3” above the floor level

2 Run the conduit as appropriate

3 Mount the photo eyes in the predrilled holes in the side guides (located approximately 12” from the floor)

Caution run conduit and cables into the bottom of the control box only! Do not drill into the side or top of the control box Doing so will void the warranty! (If you are running conduit, place the motor cable in its own conduit )

Figure 22: Photoeyes

NOTE

Note if more than one pair of photo eyes is used, do not install two transmitterson the same side

Note the photo eyes emit a low frequency pulsed signal

They must beclean and directly aligned for proper operation

Note the photo eyes will not line up if the side guides are not plumb and level

Caution ensure that the photo eye is flush with the inside attachment nut and does not project into the side rail duit, place the motor cable in its own conduit )

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Manual Operation

In the event that the door must be moved up or down manually, the ratchet and key from the accessory kit may be used to operate the door manually

1 Check that the door is disconnected from the power source

2 Insert the ratchet and key into the drive motor fan opening

3 Turn the ratchet to move the door up and down

Caution Use of a powered drill or impact driver is NOT recommended, and may damage motor or hex drive

Warning remove the ratchet and key before applying power

Figure 23: Manual Operation

Precautions With The Frequencey Inverter:

Danger when a frequency inverter has power supplied to it, the electrical elements and a number of operating controls are also ‘live’ Never touch these elements This is extremely dangerous The cover of the frequency inverter must always be closed

When the emergency stop is activated, the frequency inverter remains ‘live’’ If this is a threat to the safety of the staff, the power circuit must be interrupted by locking the main switch on the control box

After turning off and locking the main power switch, it is always necessary to wait 5 minutes before starting work This is the time required to discharge the capacitors of the frequency inverter

The frequency inverter has integrated safety systems for stopping the door A mechanical block, fluctuations in voltage and interruptions of the power supply, can also bring a door to a stop This is shown with a fault message on the frequency inverter screen After locking the main switch, and having removed the blockage, the main switch has to be unlocked and the door opened manually to re-charge the frequency controller

In the event of work (on the electrical and/or mechanical part of the installation), the power supply to the frequency inverter must be switched off; to do this, the main switch on the control box must be locked

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Warranty and Liability

Warning check all warnings weekly Door may unexpectedly close Failure to mount and maintain all warnging labels and instructional literature could result in death or serious injury

Figure 24: Warning Label installation - Wall Mount

Warranty claims will only be considered if the door was being operated and treated correctly In the event of unauthorized repairs and modification to the construction and the operation of the door, the warranty will be invalidated This rule also applies to damage resulting from defects that are the consequence of failure to follow the operating instructions or of inadequate maintenance of the door

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Electrical Controls

WARNING control box contain HIGH VOLTAGE! The following procedures should be performed by qualified 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

WARNING disconnect power at the fused disconnect during all electrical or mechanical service

Disconnect must be properly locked out during maintenance or service or equipment Failure to do so could result in death or serious injury

NOTE

NOTE wiring must be completed by a licensed electrician All wiring connections must be in accordance with alllocal state, federal, NEC or other governing agency codes Reference electrical drawings shipped with door

NOTE refer to electrical schematic for connections

1 Make sure prewired 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

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

CAUTION protect and cover all electrical components inside the control box prior to drilling enclosure

Failure to do so may result in component malfunctions

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Electrical Controls

Continued

NOTE

NOTE fused disconnect complying with applicable electrical codes must be supplied by others

1 Prewired cable from motor must not be spliced Run this cable to control box (Figure 25)

2 From a fused disconnect, route power supply wires to the control panel and connect to terminal blocks“L1”,

“L2”, “L3” Also attach a ground to control panel terminal

3 All connections for motor, encoder, photoeyes, anti-roll switch, and any activation devices should bemade per the schematic All wiring connections from harness must be terminated in the control box(see Figures 25 & 26)

NOTE

NOTE any wiring by others MUST come into control box from bottom as shown, or warranty is void

Prewired motor cable supplied by ASI - installed by others

DO NOT SPLICE

Control box

Incoming power and activators by others

Encoder, photoeye cables, and anti-roll switch wires by ASI Connections by others (See Figure 14)

Figure 25: Wiring Installation

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Electrical Controls

Continued

Install the control box at a location agreed with the user Check that the power supply agrees with the connections of the transformer, motor, and frequency inverter If necessary, modify

Connect the following in accordance with the electrical diagram and the specific notes supplied with the door:

• The motorDO NOT SPLICE THE SUPPLIED HIGH VOLTAGE MOTOR CORD – IT HAS SHIELDING THAT IS

REQUIRED FOR PROPER DRIVE OPERATION.

• The wires for the absolute encoder that controls the OPEN/CLOSED positions of the door

• The photoelectric cell wires from each side frame ( see illustration below for routing non-drive side cable )

• Opening and Interlocking control devices .

Activate the emergency stop button and check whether the the magneto-thermal main switch is off Check that the power cable is not ‘live’ and connect the switch to the power supply

An opening has been provided in the side plate to pull the photoelectric cell cables through the header tube

Mark/tape for upper and lower photoeye cables before pulling through

Option:

Second set of

Photoeyes

Gray

Black

Gray

Figure 26: Electrical Connections

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Electrical Controls

Continued

The ASI Doors Door controller monitors all operations of the door

You use this device to:

• Define the automatic close timers

• Monitor and troubleshoot the input connections

• Interpret and correct any malfunctions or alarms

Note: The door will not run until the controller display reads ‘Ready’

Figure 27: Controller

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Error Messages

Message Display

Ready ####

Drive Error

Rev - Edge Tripped

Opening Expired

Closed Expired

SET LIMITS

ENCODERCOM_LOSS

Trouble Shooting

All required connections are correct and the door is ready for operation The number indicates the cycle counter The Controller will not allow the door to operate unless this message displays

A drive error occured Check drive display for error code

The reversing edge or anti-roll switch is tripped The reversing edge is a normally open circuit and will not fail open, the door will continue to operate with out the edge Also check any other reversing device that may be wired into terminal and input # 4

The open run time timer expired Press and release the E-stop button to clear the fault Jog the door open and closed and verify there are no mechanical problems The open run timer may be set too low Press the

“open run timer” and increase the second with the “program up arrow”

(usually 10 seconds is sufficient)

The close run time timer expired Press and release the E-stop button to clear thecfault Jog the door open and closed and verify there are no mechanical problems Thecclose run timer may be set too low Press the “close run timer” and increase the second with the “program down arrow” (usually

10 seconds is sufficient unless the closing speed has been slowed down)

The limits have not been set Set limits (see Section “Setting Door Limits” for instructions )

The encoder is not communicating with the controller Check the wires connections on the harness that plugs into the controller for loose connections

The encoder may be damaged and may need to be replaced

Table 28: Controller Error Messages

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Electrical Installation

CAUTION ensure that the incoming supply for the door is compatible with the transformer, motor, and inverter

Frequency Inverter Voltage Range:

120 V = Single Phase

480 V = 3 Phase

230 V = Single Phase or 3 Phase

208 V = Single Phase or 3 Phase

Failure to ensure compatible power supply may result in fire and will damage the door

CAUTION refer to the electrical schematic shipped with the door for appropriate circuit protection

CAUTION ensure that the electrical installation for this door complies with the national electrical code

(NEC) and/or your local electrical code

Primary Connections

1 Connect the incoming power CAUTION: run the wires (conduit) through the BOTTOM of the control box, up the left side, and connect them into the terminal strip or optional disconnect (See Figure 16) Bringing in power from the top of the control box will void the warranty

• For a 3-phase unit, use terminals L1, L2, and L3

• For a Single Phase unit use terminals L1 and L2

Power

Connections

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Figure 29: Power Connections in he Control Box asidoors.com

Primary Connections

Continued

CAUTION use only the motor cable provided Do not splice the cable Doing so will void the warranty

Make the Primary Connections:

1 Connect the grounding wire (ground wires and shield wire) to the ground terminals (See Figure 30)

2 Connect the motor wires (black) to terminals T1, T2, and T3

Figure 30: Ground Connections on Terminal Block

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Photoeye Connections

1 Connect the photo-eye wiring to the terminal block See figure 33

• Connect the white wire in the grey transmitter cable to terminal 5

• Connect the shielded wire in the grey transmitter cable to terminal

• Connect the white wire in the black receiver cable to terminal 6

• Connect the shielded wire in the black receiver cable to terminal 8

Photo Eye Connections - CONFIRM WITH ELECTRICAL DRAWINGS

SUPPLIED WITH DOOR

2 Plug the photo eye amplifier into the 11-pin socket See figure 31

3 Confirm set up of the amplifier See figure 40 on page 34 and figure

41 on page 34

Terminal Strip

Figure 31: 11 Pin Socket For Photoeye

Amplifier

Wireless Detector

Base

Figure 32: Terminal Strip, Wireless Detector,

And Photo-Eye Amplifier

Figure 33: Photoeye Base, Transmitter And Receiver Wiring

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Photoeye Connections

Continued

NOTE

NOTE two sets of photoeyes are shown—one photoeye set is standard, the 2nd photoeye set is optional

The grey (Transmitter) and black (Receiver) locations on the side frames are reversed forthe upper (2nd) photoeye set installation as shown below

Black Receiver

Grey Transmitter

2nd Optional

Photoeye Set

Standard Photoeye Set

Figure 34: Photoeye Arrangement With Two Sets Of

Transmitters And Receivers Installed

Grey Transmitter

Black Receiver

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Encoder Connections

Continued

Shield

White

Figure 35A: Attach Encoder Cable

1 Attach Encoder Cable (found inside Control Panel) to bottom of the Encoder located on the Operator (see

Figure 35A)

2 Insert the wires into the green connector as listed below Terminals are ordered left to right (see Figure

35B)

• Shield = Terminal 1

• White = Terminal 2

• Black = Terminal 3

• Red = Terminal 4

• Green = Terminal 5

3 Insert the green connector into the Controller See

Figure 36

Figure 35B: Wiring the Green Connector

Insertion point for green connector

Figure 36: Insertion Point For The Green Connector

Green

Red

Black

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Wiring Accessories

Run Wire for Accessories:

Run the wiring for the activation accessories but do not connect them See the appropriate appendices in this manual for wiring Connect the activation accessories after the installer has finalized the door

WARNING 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

Figure 37: Main Disconnect

Turn on the Main Power:

The controller display should read SET LIMITS on initial power up See the section titled “Set Door Limits” for more information on setting the door’s limits

Final Checks and Verification

Finalizing the door includes setting the door’s open and close limits, ensuring that the door works properly, and connecting the activation accessories

Note: An electrician should connect the accessories to the terminal block if possible

Before you begin:

• Verify that the wiring is properly connected and the control box has power

• Confirm that the connections are properly grounded

• Confirm that the cable connections are positioned in their terminal slots correctly

(Photoeyes and Reversing Edge)

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Setting Door Limits

CAUTION automatic activations should be disconnected prior to setting limits If connected the door may activate and injury or damage may occure

The controller controls and monitors the curtain’s open and closed position Once you set the all the limits, test the door to ensure that it is working properly

MESSAGE DISPLAY COUNTER

Password

CAUTION confirm that all electrical connections are properly wired and terminated before powering up Refer to the wiring diagram that was stored in the control box

1 Enter the programming mode

2 Press and hold both PROGRAM buttons until display changes to password After display changes, release buttons See Figure 38

• Press and release one of the PROGRAM buttons to scroll up or down until the password, 777, displays in the LCD

• Press and release the ENTER button LimitSet displays in the LCD See Figure 39

NOTE

NOTE on initial start up the password screen will be bypassed, and the controller will directly enter the LimitSet screen See Figure 26 If this is the initial startup, skip step #1 & #2 and go to step #3

If not, start at step #1

NOTE The door is out of phase if it moves up instead of down Turn power off and switch T2

& T3 on the terminal block Turn power on and return to step one

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 38: Controller Program Mode

MESSAGE DISPLAY COUNTER

LimitSet

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 39: ENTER Button

PROGRAM

Buttons

ENTER

Button

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Setting Door Limits

Continued

3 Set the close limit position

• Press and release the Enter button ClsLimit displays in the LCD

• Press and release the Enter button

JogToCls displays in the LCD

• Press the JOG DOWN button to bring the door down to desired close position See Figure 40

• Press and release the ENTER buton to save limit setting ClsLimit_Set - OK displays in the

LCD

4 Set the photoeye shut-off position

• Press and release one of the PROGRAM buttons to scroll up or down until the PhtLimit message displays in the LCD (photo eye shut off position) See Figure 41

• Press and release ENTER button

JogToPht_Enter displays in the LCD

• Press the JOG UP/RESET button to bring door up one inch above the photo eyes

• Press and release the ENTER button to save limit setting PhtLimit_Set—OK displays in the LCD

JOG DOWN

Button

MESSAGE DISPLAY COUNTER

JogToCls

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 40: JOG DOWN Button

MESSAGE DISPLAY COUNTER

PhtLimit

JOG UP Button

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

PROGRAM

MC/PB AC/LOOP

TIMERS

MENU ENTER

Figure 41: JOG DOWN Button

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Setting Door Limits

Continued

5 Set the open limit position

• Press and release one of the PROGRAM buttons until the Opn-Limit message displays in the LCD

• Press and release the ENTER button

JogToOpn_Enter displays in the LCD

• Press and release the JOG UP/RESET button until the door is in the desired open position (see Figure 42 & 43)

• Press and release the ENTER button to save limit setting Opn-Limit_Set—OK displays in the LCD

6 Press and release the MENU button twice

Ready displays in the LCD See Figure 44

7 Press the JOG buttons to test the open and close limits Install and test activation accessories

JOG UP

Button

MESSAGE DISPLAY COUNTER

JogToOpn

Enter

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 43: JOG DOWN Button

MESSAGE DISPLAY COUNTER

Ready

####

1-1/2”

Figure 42: Door Open Position

Reintroduction

Point

Button

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

PROGRAM

MC/PB AC/LOOP

TIMERS

MENU ENTER

Figure 44: MENU Button

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Install Activation Devices

Install and Test Activation Accessories:

The controller has nine inputs Inputs are signals coming to the controller that get interpreted to create a certain response For example, if a pull cord is wired to terminal 2, pulling the cord sends a signal to the controller The controller knows what the signal is based on the assigned input (terminal 2), thus moving the door up or down All the inputs have indicator lights and identification See figure 45

Figure 45: Accessory Inputs

CAUTION install, connect, and then test each of the activation accessories individually before proceeding to the next accessory This allows troubleshooting of each component individually

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Set Timers

The open run timer and close run timer act as a failsafe to prevent the door from running continuously when the open or close limit switch fails to stop the door These timers should be set for a period that exceeds the duration of a full open or close cycle

• Press and release the open run timer button Opening_time=## displays in the lcd See figure 46

• Press and release the program buttons to change the countdown time to the desired duration See figure 47

• The controller automatically saves the changes

• Press and release the close run timer button Closing_time=## displays in the lcd

• Press and release the program buttons to change the countdown time to the desired duration The controller automatically saves the changes

MESSAGE DISPLAY COUNTER

Opening

Time = ##

Open/Close

Run Timers

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 46: RUN TIMERS Buttons

Increase

Setting

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Figure 47: Adjust Countdown Time

Decrease

Setting asidoors.com

Set Timers

Continued

Set The MC/PB Timers:

The MC/PB timer activates a countdown timer for use with an activation installed on terminal number 2 (most commonly used for pull cords or push buttons) The

MC/PB timer may be turned on or off, enabling manual operation or automatic operation by assigning a countdown value to the timer

• Press and release MC/PB close timer button MC

Delay_Time=## displays on the LCD See Figure 48

• Press and release the PROGRAM buttons to change the countdown time to the desired duration

(Maximum time 99 seconds) See Figure 49

• The Controller automatically saves the changes

MESSAGE DISPLAY COUNTER

MC Delay

Time = ##

MC/PB

Timer

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 48: MC/PB Timer Button

NOTE

NOTE if the value is set to zero, the timer is deactivated and the activations put on terminal number 2 are now in manual operation Press and release the PROGRAM buttons to change the countdown time to the desired duration

Increase

Setting

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Figure 49: Adjust Countdown Time

Decrease

Setting asidoors.com

Set Timers

Continued

Set The AC/LOOP Timer:

The AC/LOOP timer activates a countdown timer for use with a motion detector or floor loop The AC/

LOOP timer is also used when the reversing edge is triggered

• Press and release AC/LOOP close timer button

AC Delay_Timer=## displays on the LCD

• Press and release MC/PB close timer button MC

Delay_Time=## displays on the LCD See Figure

• Press and release the PROGRAM buttons to change the countdown time to the desired duration (Maximum time 99 seconds) See

Figure 51

• The controller automatically saves the changes

MESSAGE DISPLAY COUNTER

AC Delay

Time = ##

JOG

UP/RESET

JOG

DOWN

OPEN

RUN

TIMERS

MC/PB AC/LOOP

TIMERS

MENU ENTER

PROGRAM

Figure 50: AC/LOOP Close Timer

NOTE

NOTE if the value is set to zero, the Door will come down when it reaches the open limit, after receiving an

AC/Loop input, a reversing edge input, or a Photo-eye input

Increase

Setting

AC/LOOP

Timer

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Figure 51: Adjust Settings

Decrease

Setting asidoors.com

Calibrate WDD Reversing Edge

Wireless Detection Device:

The WDD receiver provides a wireless connection to the bottom edge of the curtain. The WDD receiver programming persists even if the control box power is disconnected.

1. Turn on the main disconnect.

• A red LED illuminates across from connector 9 indicating that the WDD is operational and ready for programming.

2. Lower the door to working level and press the e- stop button.

3. Push and hold the micro switch next to the LED using a small screw driver (See Figure 52).

4. A green LED illuminates. Activate the edge on the curtain.

The LED will go out. Release all buttons.

5. Test the setting by activating the bottom edge. An audible click should be heard and the controller LED should illuminate.

Figure 52: WDD Receiver

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Photocell Installation and Set-Up

1 Confirm Photocell Amplifier is seated properly in gray eleven-pin socket

2 Confirm adjustment knob is in the auto position

3 Confirm power on

4 Lights 1 & 2 will illuminate green Lights 3 & 4 will illuminate amber Refer to Figure 53

5 After door limits are set, verify operation of photocells by blocking beam and assuring the door reverses

6 Under normal operations lights 3 & 4 will go out when beam is blocked

S142ARNT924

Auto Dist

L1 - Illuminated if in Auto Mode

L2 - Illuminated to DIP Switch one’s setting:

A = Green

B = Amber

L3 - Indication of operation:

Red = Alarm Condition

Amber = Good Signal

Non = Beam broken or alignment switch turned on

L4 - Illuminated when beam not blocked

DIP Switch Description:

DIP Switches come preset and need not be adjusted unless otherwise advised Refer to Figure 54

Code A

Code B

Alarm

Signal

Code A/B

Alignment

Level Low/High

Power 50/100

NC/NO

Out/Alarm

DIP Switch 1 - Controls the switch code A or B

• Code A - Single photocell

• Code B - Two sets of photocell, avoids crosstalk between them

DIP Switch 2 - Alignment of photocell

• ON - Able to tune photocell via manual adjust dial/physical alignment of photocell L3 will illuminate steady for a strong signal or blink slowly for a weak signal

• OFF - Normal operation/L3 illuminated

L4 Output

Figure 53: Photoeye Amplifier Controls

DIP Switch 3 - This switch selects the power gain Low or High

DIP Switch 4 - Power level 50% or 100%

DIP Switch 5 - Selection on output contact N/O or N/C

DIP Switch 6 - DIP Switch needs to be left in alarm position, used to alarm when photo eyes shorted or malfunctioning

Install Covers:

As a final step, ensure that all covers are installed on the door

• Motor / Fabric Roll

• Side Guides

Figure 54: Photoeye DIP Switch Presets

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Preventative Maintenance

WARNING only certified personnel should perform maintenance on the doors Maintenance performed by untrained technicians may result in injury and/or damage to equipment

CAUTION Lock out / tag out procedures must be performed while performing maintenance tasks on the doors

NOTE

NOTE service performed by unauthorized persons may void the Door warranty

NOTE the door must be lubricated monthly to ensure proper operation Apply white lithium spray grease along the inner face of the side guides and the curtain teeth

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Preventative Maintenance

Maintenance List

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 pharm 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 doors 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

Call

1-800-558-7068

or visit

asidoors.com/parts

to order parts

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Mechanical Service Parts List

Item #

Description

Curtain

Vision Panel

Rubber Spacer Strips

Bottom Bag

Bellows

Bellows Retaining Straps

Intermediate Airpipe Connector

Airpipe

Zipper

Zipper Tooth

Lintel Sealing Flap

Horizontal U-Profile

Curtain Roll-Up Drum

Shaft with Airpipe Conct (Motor Side)

Airpipe Input Connector

Bearing

Airpipe Input Connector (On Shaft)

Driving Drum C’weight Side (Idler Side)

Shock Absorber

Driving Drum

Driving Drum (Opposite of Motor Side)

Support Plate, Drum Bearings

Shaft, Reducer Side

Support, Motor and Reducer

Driving Unit Elbow Guide

Bottom Guide ( A Guide)

Driving Gearwheel

Upper Guide (B Guide)

Re-introduction Unit

Reducer

Motor

Motor Juction Box

Drivig Gearwheel of Limit Switch

Limit Switch Chain

Fast Link

Chain Cover

NOTE

NOTE this table lists description of parts for identification purpose shown on page 45 through

58 Consult ASI parts department to order replacements

Item #

118

Description

Limit Switch

Movement Gearwheel (Limit Switch)

Declutching Washer

Limit Switch Support

Return Pulley of the Counterweight Belt

Mounting Bracket of the Return Pulley

Counterweight Cover

Mounting Bracket of the Counterwieght Cover

Upper Post

Guide Jenction

Side Guide

Inner Side Guide (Slide)

Sealing Flap

Hammer Screw

Spindle

Side Guide Spring

Frame Cover

Rubber Reinforcement Strip

Galv U-Profile Side Guide Reinf (All Weather Only)

Infrared Sender - Receiver

Control Box

Motor Cover (Option)

Counterweight

Belt Cover

Gearwheel Cover

Drum Cover (Option)

Brackets for Drum Cover

Bracket Holder for C’Weight Bracket

Counterweight Belt

Support Plate Belt Cover

Support Plate Motor Cover

Access Plate for Adjustment of Limit Switches

Motor Handle Access Cover

Shaft, Return Pulley

Corner Bracket for Fixing Horz U-Profile

When ordering parts, specify

Job Number, Door Number and Manufacture Date

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Replacement Parts

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

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Replacement Parts

Continued

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

118

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Replacement Parts

Continued

118

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

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Replacement Parts

Continued

12 13

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

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Replacement Parts

Continued

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

ASI DOORS, INC.

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Replacement Parts

Continued

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

ASI DOORS, INC.

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Replacement Parts

Continued

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

ASI DOORS, INC.

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Replacement Parts

Continued

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

ASI DOORS, INC.

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Replacement Parts

Continued

76 NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

ASI DOORS, INC.

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Replacement Parts

Continued

ASI Part Number

23A0409

23A0410

23A0411

23A0412

23A0436

23A0413

23A0415

23A0414

23A0427

615/615F Service Parts

Description

Photoeye set COMPLETE includes transmitter, receiver, amplifier

Photoeye transmitter AND receiver

Photoeye AMPLIFIER

Photoeye amplifier BASE/SOCKET

Diablo Mag Loop

Transformer, Step-down, 208/230/460 50VA

Transformer, Step-down, 24/110V 100VA

Transformer, Step-down, 208/230/460 100VA (Doors w/opt relays)

Relay 24VAC - DPDT for optional interlocking, flashers, etc

23A0429

23A0430

23A0431

23A0432

23A0433

23A0434

23A0437

23A0438

23A0439

23A0422

23A0423

23A0406NV

23A0401NV

23A0421

23A0400

50A0170NN

49A0020

50A0173NN

24A0106NN

05A0031NV

23A0424

23A0425

23A0426

23A0403NV

50A0174NN

10A0041NN

Nameplate, Pushbutton, Standard (one dozen nameplates)

Emergency Stop Pushbutton

Nameplate, Emergency Stop, (one dozen nameplates)

Selector Switch, Airlock

Nameplate, Airlock, ON/OFF

Terminal block, Ground 1 Dz

Terminal block, 35A, Blk, 1 Dz

Terminal block, 35A, Red 1 Dz

Fuse 0 5 Amp 600V Class CC - (one dozen fuses)

Fuse 2 0 Amp 250V Class M - (one dozen fuses)

Cable, motor (per FT)

Cable, Encoder (per FT)

ASILogix II Controller Board

Encoder

Teeth, Replacement

Spare Patch Material 05A0030NN

16B0051NV

16B0053NN

Window, Banner, PVC, 15” H Per Ft Width

Window, Banner, PVC, 24” x 24”

24A0118NV (OPTION) Curtain assembly, < 45 sq Ft, 615/615F

24A0118NV (OPTION) Curtain assembly, < 96 sq ft, 615/615F

24A0118NV (OPTION) Curtain assembly, < 175 sq ft, 615/615F

24A0118NV (OPTION) Curtain assembly, < 215 sq f,t 615/615F

24A0118NV (OPTION) Curtain assembly, < 270 sq ft, 615/615F

24A0118NV (OPTION) Curtain assembly, < 325 sq ft, 615/615F

24A0118NV (OPTION) Curtain assembly, < 390 sq ft, 615/615F

16B0054NV

50A0171NN

Insulated Panel Up Charge, Per Sq Ft

6” Mutylene Inner Guide Piece

Spring Kit 1 2” 14PCS (Power)

Upper Drive Mutylene

Lower Drive Mutylene

Re-introduction Block, Model 615/615F

Counterweight Replacement Belt

WDD Transmitter, ≤ 12’ WIDTH (Inside bottom of Curtain)

WDD Transmitter, > 12’ WIDTH (Inside bottom of Curtain)

WDD Receiver (DIN rail mount-no socket)

Cable, Anti-roll switch (per FT)

6MM Allen Wrench - (For manual operation of door)

Loctite adhesive for spare patch material

NOTE

NOTE this table lists description of parts for identification purpose shown on page 44 through

58 Consult ASI parts department to order replacements

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asidoors.com

ASI DOORS, INC.

5848 North 95th Court, Milwaukee, WI 53225 (800) 558-7068

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