SPIRIT HD HIGH SPEED FABRIC ROLL-UP DOOR OWNER S MANUAL

Transcription

1 SPIRIT HD HIGH SPEED FABRIC ROLL-UP DOOR OWNER S MANUAL MODELS 215 Spirit HD ELECTRIC DOOR MODEL: 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. Manual Part number: 17A

2 GENERAL INFORMATION 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 ASI Technologies, Inc. Manual Part Number: 17A

3 GENERAL INFORMATION Safety Practices Continued Read these safety practices before installing, operating or servicing the HIGH-SPEED door. Failure to follow these safety practices could result in property damage, serious bodily injury or death. READ AND UNDERSTAND THE OPERATING INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE HIGH-SPEED DOOR. If you do not understand the instructions, ask your supervisor to teach you how to use the HIGH-SPEED 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: 17A ASI Technologies, Inc. Page 3

4 GENERAL INFORMATION 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 ASI Technologies, Inc. Manual Part Number: 17A

5 GENERAL INFORMATION Marathon Spirit HD High Speed Fabric Roll-Up Door General Information Maintenance Begins on Page 2 Begins on Page 37 Safety Practices Page 2 Preventative Page 37 Warranty Policy Page 4 Troubleshooting Page 39 Crates and Contents Page 6 Installation Begins on Page 8 Door Measurements Page 8 Side Support Installation Page 9 Header Installation Page 12 Operator Installation Page 14 Attaching Counterweight Page 16 Warning Labels Page 17 Electrical Controls Page 18 PLC Inputs Page 23 PLC Outputs Page 25 Other Electrical Functions Page 27 Start-Up Page 29 Electrical Start-Up Page 30 Final Checks Page 33 Resetting Bottom Bar Page 34 Photoeye Adjustment Page 35 Barrel/Operator Shroud Page 36 Replacement Parts Begins on Page 40 Instructions for Ordering Page 40 Door Identification Page 40 ID Tag Location Page 41 Door Assembly Page 42 Curtain and Barrel Assembly Page 44 Bottom Bar Assembly Page 45 Idler Side Column Assembly Page 46 Drive Side Column Assembly Page 47 Operator Assembly Page 48 Panel Assembly Page 50 Lintel Brush Assembly Page 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: 17A ASI Technologies, Inc. Page 5

6 GENERAL INFORMATION Crates and Contents Figure 1: Crates and Contents DESCRIPTION QTY. DESCRIPTION QTY. Installation Instructions Warning Label #60 Drive Chain #60 Master Link J-Clip #8 x 3/4" Screws for J-Clip...10 Lintel Brush Assembly /8"-16 x 3" Hex Bolt /8" Lockwasher /8" Flat Washer /8" Nut Counterweight Counterweight Guide Counterweight Clamp /16"-18 x 3/4" Screw /4"-20 x 3/4" Screw /2"-13 x 2" Bolt /2"-13 x 1" Bolt /2" Lockwasher /2" Flat Washer /18"-16 x 1" Bolt /2"-13 x 4" Bolt Manual Release Clip /4"-14 x 3/4" Screw Page ASI Technologies, Inc. Manual Part Number: 17A

7 Crates and Contents Continued GENERAL INFORMATION 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: 17A ASI Technologies, Inc. Page 7

8 INSTALLATION 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 ASI Technologies, Inc. Manual Part Number: 17A

9 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. INSTALLATION Figure 4: Side Support and Cover Figure 5: Use Fork Lift to Place Side Support Against Wall Manual Part Number: 17A ASI Technologies, Inc. Page 9

10 INSTALLATION 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 ASI Technologies, Inc. Manual Part Number: 17A

11 INSTALLATION 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: 17A ASI Technologies, Inc. Page 11

12 INSTALLATION 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 ASI Technologies, Inc. Manual Part Number: 17A

13 INSTALLATION 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. Figure 12: Idler Side View 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 13: Centering Barrel Between Side Columns Manual Part Number: 17A ASI Technologies, Inc. Page 13

14 INSTALLATION 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 Figure 15: Sprocket Alignment Prior to Attaching Roller Chain Page ASI Technologies, Inc. Manual Part Number: 17A

15 INSTALLATION 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). Figure 16: Chain Attachment (Side View) 1 /4" MAXIMUM Figure 16a: Chain Tension Maximum Deflection Figure 16b:Attaching Brake Release Manual Part Number: 17A ASI Technologies, Inc. Page 15

16 INSTALLATION 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 Keep area beneath lifting crate clear while removing. Failure to do so could result in property damage, death or serious injury. SIDE VIEW OF STRAP BEVELED EDGE (TOWARDS STRAP) 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. Figure 18: Attaching Counterweight to Strap Page ASI Technologies, Inc. Manual Part Number: 17A

17 Warning Labels INSTALLATION 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. Figure 19: Warning Labels Installation Wall Mount Figure 20: Warning Labels Installation Side Frames Manual Part Number: 17A ASI Technologies, Inc. Page 17

18 INSTALLATION Electrical Controls Control box contains HIGH VOLTAGE! 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. MULTI-CONDUCTOR/ COILED CORD BRACKET MOUNTING HOLES Figure 19: Cable Mounting Bracket Location 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. 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 ASI Technologies, Inc. Manual Part Number: 17A

19 L1 L2 L3 NC A1 T1 T2 T3 NC A2 STOP 95 NC NC 98 T1 OPEN W RESET A T2 T3 NC A2 RESISTOR L1 L2 L3 NC A1 CLOSE T1 T2 T3 NC A2 SIMATIC S7-200 PORT 0 SF RUN STOP QO 1L L L R N L1 AC Q1 CPU AC/DC/RELAY Run Term Stop IO I1 1M M M GND GND L1 L2 L3 T1 T2 T3 B1 B A INSTALLATION Electrical Controls Continued Protect and cover all electrical 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. 456 INTLK BRAKE REV EDGE E-STOP PHOTOEYE LOOP GND GND L1 L2 L3 T1 T2 T3 B1 B2 Figure 21: ASI Control Panel Manual Part Number: 17A ASI Technologies, Inc. Page 19

20 INSTALLATION 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 ASI Technologies, Inc. Manual Part Number: 17A

21 INSTALLATION Electrical Controls Continued Control box contains HIGH VOLTAGE! 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 3φ. 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 1L L L R N L1 AC QO Q1 CPU AC/DC/RELAY Run Term Stop IO I1 1M M M PORT 0 Figure 25: PLC Layout Manual Part Number: 17A ASI Technologies, Inc. Page 21

22 INSTALLATION Electrical Controls Continued Output LED's PLC System Fault SIMATIC S7-200 Run Mode Stop Mode EEPROM Socket Communications Port PORT 0 SF RUN STOP 1L L L R N L1 AC QO Q1 CPU AC/DC/RELAY PLC Modes (Dipswitch Settings, Shown in Run Mode) Cover Cutout Pot 0 Time to Close Run Term Stop IO I1 1M M M 0 1 Socket for adding I/O modules Pot 1 Preannounce to Close or Partial Open Timer Input LED's Figure 26: PLC Description 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 ASI Technologies, Inc. Manual Part Number: 17A

23 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 () 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. INSTALLATION M 1M 50 I0.0 OPEN I0.1 I0.2 I0.3 CLOSE OPEN/CLOSE PARTIAL OPEN CR1 55 LSO 57 LSC 58 I0.4 I0.5 I0.6 E-STOP OPEN LIMIT CLOSE LIMIT I0.7 M 2M 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. 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. I1.1 REVERSING PHOTOEYE I1.2 EXTERNAL CUTOUT I1.3 BREAKAWAY TABS I1.4 RESET BUTTON I1.5 POT 1 MODE PLC 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: 17A ASI Technologies, Inc. Page (12) (14) JUMPER (11) EXT. CUTOUT 63 JUMPER P.E. (21) (22) (22) (21) 65 JUMPER FOR PARTIAL OPEN Figure 27: PLC Input Connections (See electrical drawing provided for specific electrical connections.) M M

24 INSTALLATION 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 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 to I1.5 is open, Preannounce to Close can be used (See Other Electrical Functions for description of this function). When to I1.5 is closed (with jumper wire), Partial Open can be used (See Other Electrical Functions, Page 25, for description of this function). 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 ASI Technologies, Inc. Manual Part Number: 17A

25 INSTALLATION 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. 24 VAC 1L 1 DOOR CLOSED Q 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. DOOR OPEN Q0.1 DOOR CLOSING Q0.2 PREANNOUNCE Q0.3 TO CLOSE 31 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. 2L OPEN Q 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). CLOSE Q0.5 PLC Q VAC 3L FAULT/RESET Q0.7 COUNTER Q1.0 BRAKE Q1.1 GND N L1 (120 VAC) 3 (120 VAC) Figure 29: PLC Output Connections Manual Part Number: 17A ASI Technologies, Inc. Page 25

26 INSTALLATION 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 Q VAC 3L FAULT/RESET Q COUNTER Q BRAKE Q PLC GND N L1 (120 VAC) 2 3 (120 VAC) Figure 30: PLC Output Connections Fault Condition Motor Run Timer Start-Up Fault LED Sequence Fault Cause Action to Clear Fault One quick flash every 4 seconds Two quick flashes every 4 seconds The motor ran continuously for greater than 10 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. Correct problem, then cycle Power off and on or cycle E-Stop off and on. E-Stop Fault Two quick flashes every 4 seconds Open, close, open/close, partial open, reversing edge or reversing photoeye signal coming out of E-Stop. Correct problem, then cycle Power off and on or cycle E-Stop off and on. Double Limits Multiple Reversing Edge Three quick flashes every 4 seconds Four quick flashes every 4 seconds 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. 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. Breakaway Switch Continuous Light A breakaway switch was activated. Reset the bottom bar, then press Fault/Reset button. Page ASI Technologies, Inc. Manual Part Number: 17A

27 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. INSTALLATION 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: 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: 17A ASI Technologies, Inc. Page 27

28 INSTALLATION 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 ASI Technologies, Inc. Manual Part Number: 17A

29 Start-Up INSTALLATION CAM NYLOCK NUT ROTATE SHAFT TO MOVE BLOCK LOCATION 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. COMMON NORM OPEN NORM CLOSED NORM CLOSED LSO OPEN NORM COMMON LSC SPROCKET 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 Be sure to close counterweight shroud covers before operating door. Door may not operate properly with side cover open. 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). 1/4" MAXIMUM 3/8" BOLTS (BEHIND LIMIT BOX) Figure 33: Alignment of Limit Switch Gear Figure 34: Limit Switch Drive Chain Adjustment Manual Part Number: 17A ASI Technologies, Inc. Page 29

30 INSTALLATION Electrical Start-Up M 1M 50 I0.0 OPEN 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. CR I0.1 CLOSE I0.2 OPEN/CLOSE I0.3 PARTIAL OPEN I0.4 E-STOP 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. LSO LSC M I0.5 OPEN LIMIT I0.6 CLOSE LIMIT I0.7 2M CR2 60 I1.0 REVERSING EDGE 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. 61 P.E. (12) (14) JUMPER (11) EXT. CUTOUT 63 JUMPER (21) (22) (22) (21) 65 JUMPER FOR PARTIAL OPEN M I1.1 REVERSING PHOTOEYE I1.2 EXTERNAL CUTOUT I1.3 BREAKAWAY TABS I1.4 RESET BUTTON I1.5 POT 1 MODE M PLC Figure 35: PLC Input Connections (See electrical drawing provided for specific electrical connections.) The photoeye amplifier is preset at the factory and usually requires no field adjustment Figure 36: ASI Control Panel GND GND L1 L2 L3 T1 T2 T3 B1 B2 Page ASI Technologies, Inc. Manual Part Number: 17A

31 INSTALLATION 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. LIMIT SWITCH ACTUATING BLOCK CAM NYLOCK NUT ROTATE SHAFT TO MOVE BLOCK LOCATION COMMON OPEN + + CLOSE Figure 37: Limit Switch Adjustment NORM LSC OPEN NORM CLOSED NORM CLOSED LSO CAM NYLOCK NUT OPEN NORM COMMON 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: 17A ASI Technologies, Inc. Page 31

32 INSTALLATION 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. 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. 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 CHECK PHOTOEYE OPERATION DAILY. 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. CAUTION WARNING WARNING WARNING Figure 40: Testing Reversing Photoeye Page ASI Technologies, Inc. Manual Part Number: 17A

33 Final Checks INSTALLATION 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. 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: 17A ASI Technologies, Inc. Page 33

34 INSTALLATION 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 Figure 41: Step 2 handle to unlock and slide towards the 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 ASI Technologies, Inc. Manual Part Number: 17A