OWNER S MANUAL WARNING

Transcription

1 HYDRAROL HIGH SPEED RIGID PANEL ROLL-UP DOORS OWNER S MANUAL MODELS 09 HYDRAULIC WARNING 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, bodily injury or death. 00, ASI Technologies, Inc. Manual Part number: 7A

2 SAFETY PRACTICES / WARRANTY Safety Practices WARNING Read these safety practices before installing, operating or servicing the 09 door. Failure to follow These safety practices could result in property damage, serious bodily injury or death. READ AND UNDERSTAND ALL WARNING LABELS AND OPERATING INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE 09 DOOR. If you do not understand the instructions, ask your supervisor to teach you how to use the 09 door.. Do not operate the 09 door while under the influence of drugs or alcohol.. 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. 0. If you have any questions contact your supervisor or your local ASI Technologies, Inc. representative for assistance.. 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. Product Warranty All products are inspected prior to shipment and are guaranteed against defective materials and workmanship for one year after shipment. ASI, at its discretion, will repair or replace free of charge, any parts proven to be defective in material or workmanship, freight prepaid. There are no other guarantees or warranties, either expressed or implied. All replaced material will be invoiced to the purchaser. If material is proven defective, the purchaser will receive full credit upon return of material (freight prepaid to the factory). Page 000 ASI Technologies, Inc. Manual Part Number: 7A

3 TABLE OF CONTENTS Marathon Hydrarol Rigid Panel Roll-Up Doors Packaging Replacement Parts Begins on Page 4 Begins on Page 38 Crates and Contents Page 4 Instructions for Ordering Page 38 Door Identification Page 39 Installation ID Tag Location Page 39 Begins on Page 5 Door Assembly Page 40 Side Frame Assembly Page 5 Barrel Assembly Page 4 Operator Assembly Page 6 Drive Assembly Page 43 Curtain and Drum Assembly Page 7 Ratchet Assembly Page 43 Operator to Drum Connection Page 0 Top Tube Hardware Page 44 Manual Disconnect Page Side Guides Page 45 Electrical Controls Page Curtain Assembly Page 46 PLC Inputs Page 6 End Caps Page 47 PLC Outputs Page 8 Bottom Slat Assembly Page 48 Other Electrical Functions Page 0 Operator Assembly Page 50 Start-Up Page Panel Assembly Page 5 Motor Phasing Page 6 Limit Switch Assembly Page 53 Operating Adjustments Page 7 Reversing Photoeyes Page 30 Over Travel Limit Switch Page 3 Barrel/Operator Shroud Page 3 Maintenance Begins on Page 34 Preventative Overview Page 34 Preventative Daily & Monthly Page 35 Preventative Quarterly Page 36 Troubleshooting Page 37 WARNING 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, bodily injury or death. Manual Part Number: 7A ASI Technologies, Inc. Page 3

4 PACKAGING Crates and Contents CRATE CRATE HYDRAULIC OPERATOR CURTAIN AND BARREL ASSEMBLY LOOSE PARTS BOX SIDE FRAME ASSEMBLY AND TOP SUPPORT TUBE CONTROL BOX Figure : Hydraulic Operator Crates and Contents Upon receipt of the shipment, check that you have received the correct number of pieces as shown (Figure ). 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. 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. DESCRIPTION QTY. Installation Instructions Sales Drawings Warning Nameplate Assembly..4 Door Curtain Drive Sprocket.... Taperlock, 3 /8" Drive Chain, # Connecting Link, # Offset Links, # Chain Hoist Wall Clip Allen Wrench, 3mm Whizlock Bolts, / 3 3 /4"... Flat Washer, /" Lock Washer, /" Nylon Lock Nut, /" Hex Bolts, / 3 /" Page ASI Technologies, Inc. Manual Part Number: 7A

5 Side Frame Assembly INSTALLATION WARNING 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, bodily injury or death. (W.I.C.) /4" TYPICAL (W.I.C. + /") OVERALL WALL SIDE FRAME. Familiarize yourself with the sales drawing included in the parts box and this installation book. Where possible, we have shipped parts or sections assembled. Some disassembly may be necessary prior to installation. Figure : Side Frame Detail NOTE Check the sales drawing to see if the door operator is right or left hand mounted. If the door operator is right hand mounted, then the door operator will be mounted opposite than that in Figure 5.. Open crate with side frames and top support tube. Lay these parts in front of opening and assemble support tube to side frames (Figures 3 & 4). 3. Position the assembly against the wall using support tube for lifting. Level support tube and tack or bolt one side of frame to wall (Figures & 5). Check plumb of this piece, and when plumb, tack or bolt at base. Now check width at support tube of the side frames (should be W.I.C. + /", Figure 5) and match the dimension at bottom of frames. Check square and adjust if necessary. This assembly must be plumb, square and true. Figure MOUNTING HOLES 3: Mounting Hole Detail NOTE: SIDE FRAME MUST NOT EXTEND INTO OPENING SUPPORT TUBE (W.I.C. + 3") OPERATOR MOUNT Figure 4: Side Frame Assembly OPENING (W.I.C.) CHECK SQUARE W.I.C. + /" SIDE FRAMES USE OUTSIDE TWO BOLT HOLES FOR ALL DOORS SUPPORT TUBE BOLT TOGETHER HERE WITH /-3" /" HEXHEAD CAP SCREW, WASHER, LOCKWASHER AND NYLOCK NUT. WALL Figure WIDTH AT TOP AND BOTTOM IS TRUE W.I.C. + /" SIDE FRAMES 5: Checking plumb and square, mounting of side frames to wall (L/H mount) Manual Part Number: 7A ASI Technologies, Inc. Page 5

6 INSTALLATION Operator Assembly WARNING Do not lift people with the fork lift, or climb ladders while the operator assembly is being lifted. If operator falls during lifting, it could hit ladders and/or people causing serious injury or death.. Lift operator into place using chain or strap on lifting bracket. Bolt to side frame and note placement of operator mounting plate on Page 5, Figure 5. Place the operator so the four adjusting slots on operator bracket (Figure 6) can be used to adjust the assembly up and down to achieve proper drive chain tension.. Disconnect limit switch chain and set aside for reinstallation when the door is ready for start-up. Connect line voltage through a fused disconnect box. Turn power off until start-up instructions advise you to turn it on. Figure 6: Hydraulic Operator Page ASI Technologies, Inc. Manual Part Number: 7A

7 Curtain and Drum Assembly. Familiarize yourself with the curtain and drum assembly (Figure 7). Disassembly of the door from the way it was shipped should not be necessary. NOTE Figure 7 is drawn as left hand assembly right hand is opposite. Prior to lifting the curtain drum assembly, loosen but do not remove bearing set screws on end plate bearings (Figure 8). This is to permit alignment of curtain to side rails when assembly is in position. 3. The curtain/drum is placed into the side frame by hoisting with slings or lifting with a fork lift. Protect the curtain from damage using shielding or packing between curtain and forks while lifting or carrying (Figure 7). 4. Loosen the / 3 " hex head cap screws on the clamping plates and bearings. DO NOT REMOVE THESE. Between the clamping plate and bearing is a special bearing washer (Figure 8). The drum assembly will be carried by this bearing washer when placed in the side frame on the wall. CAUTION Do not remove shipping straps around curtain assembly. DRIVE SIDE CLAMP PLATE CLAMP PLATE Figure SLING INSTALLATION REVERSING EDGE POSITION DURING THE LIFTING OF CURTAIN AND DRUM ASSEMBLY SPACER 7: Curtain and Drum Assembly SIDE FRAME BEARING SET SCREW /" 3 " HEX HEAD CAP SCREW LOOSEN SCREWS ON BEARING SHIPPING STRAPS DO NOT REMOVE UNTIL "START-UP" RATCHET ADJUSTING CLAMP PLATE SPACER SPECIAL BEARING WASHER DRUM /" 3 NUT AND LOCKWASHER PAWL SPRING RATCHET PAWL SPRING RATCHET RATCHET ADJUSTING CLAMP PLATE Figure 8: Clamping Plate Drive Side Manual Part Number: 7A ASI Technologies, Inc. Page 7

8 INSTALLATION Curtain and Drum Assembly Continued 5. Refer to Figure 9 for correct barrel centerline. Slide curtain/barrel into position on side frame until it is about a 0 angle to the curtain as it enters the side frame (Figure 0). Check both ends of barrel to ensure equal values of barrel centerline are achieved. 6. Clamp side frame with clamping plate and bearing making sure the special washer in the slot carries the weight of the assembly (Figure ). Make sure the ratchet clamp plate is in proper position. Ratchet can be removed to facilitate attaching clamp plate (Figure ). Tighten the bolts and nuts. NOTE The drum shaft must not rest on the framework of the side frame. (See Figure 9 for detail) OPENING HEIGHT (FEET) Figure BARREL CENTERLINE (INCHES) 9 / 0 0 / 0 3 /4 /4 3 /4 3 /8 5 /8 3 9: Barrel Centerline Location SIDE FRAME SEE CHART WALL 0º- 5º BACK ANGLE ENTERING SIDE FRAME RAILS RATCHET PLATE INSTALLED PROPERLY NOTE: RATCHET PAWL TOWARDS THE TOP OF THE PLATE Figure0: Drum Position SIDE FRAME BEARING SET SCREW SPECIAL BEARING WASHER DRUM /" 3 " HEX HEAD CAP SCREW /" 3 NUT AND LOCKWASHER Figure : Ratchet Position Figure : Clamping Plate Drive Side Page ASI Technologies, Inc. Manual Part Number: 7A

9 INSTALLATION Curtain and Drum Assembly Continued 7. Center the curtain to fit evenly into the side frame rails. The curtain should not contact the side frame plates. If the curtain is centered and still touches the side frame plate, move (pry) the plate away from the curtain. Tighten the set screw on the bearing when the curtain is down (Figure 3). NOTE Do not release curtain yet. Figure 3: Curtain Clearance PRY BAR CURTAIN MUST NOT TOUCH DURING OPERATION. MAINTAIN /" CLEARANCE ON BOTH SIDES END CLEARANCE SPACE BEARING SET SCREW CURTAIN HANGER SIDE FRAME END PLATE IF THE CURTAIN IS CENTERED AND STILL TOUCHES THE SIDE FRAME END PLATE, MOVE (PRY) THE PLATE AWAY FROM THE CURTAIN. TIGHTEN THE SET SCREW ON THE BEARING. WHEN THE CURTAIN IS DOWN TO ADJUST END CLEARANCE SPACING OF CURTAIN SLATS, PRY GENTLY ON METAL ENDS TO CORRECT. USE A SMALL PRY BAR AGAINST THE SIDE FRAMES. Manual Part Number: 7A ASI Technologies, Inc. Page 9

10 INSTALLATION Operator to Drum Connection. Mount the large driver sprocket on the shaft protruding from the drum (Figure 4). Align with driving gear on operator drive shaft and attach drive chain using master links and half links supplied. Adjust the chain using the mounting bolts (Page 6, Figure 6) on the operator so the drive chain has /" deflection on one side as maximum slack (Figure 5). SPROCKET TAPERLOCK BUSHING NOTE: THE SPROCKET CAN BE REVERSED IF NECESSARY FOR ALIGNMENT Figure 4: Mounting Drive Sprocket (L/H mount shown) ALIGN MAXIMUM /" DEFLECTION DRIVE GEAR LIMIT SWITCH GEAR NOTE: THIS DIMENSION IS WITH THE DOOR IN THE CLOSED POSITION. CHECK AGAIN AFTER THE DOOR HAS BEEN OPERATIONAL FOR A SHORT TIME. Figure 5: Drive Chain Attachment Page ASI Technologies, Inc. Manual Part Number: 7A

11 Manual Disconnect INSTALLATION WARNING Releasing (or disconnecting) the drive to manually operate the door could cause the door to move since it is not completely balanced. You must hold on to the chain or latch it with the wall bracket. Failure to do so could result in property damage, bodily injury or death.. Mount the manual disconnect bracket to wall beneath the operator, approximately 4' to 4 /' above the floor (Figure 6).. Pull the manual disconnect to engage the wheel and chain assembly. Rotate the wheel, using the manual chain, until the disconnect assembly locks into the pocket wheel. With tension on the manual disconnect, place the chain into the wall bracket to maintain this tension. This keeps the door in the manual mode of operation (Figure 7). NOTE Manual disconnect wall bracket mounts horizontally as in Figures 6 & 7. CABLE SPRING CHAIN MANUAL OPERATION: PULL ON CHAIN TO EXERT TENSION AND PLACE IN WALL BRACKET HOLDING CHAIN DISCONNECT CHAIN 4' TO 4 /' ABOVE THE FLOOR POCKET WHEEL MANUAL DISCONNECT PULL ASSEMBLY MANUAL DISCONNECT WALL BRACKET IS SET AT A HEIGHT TO ACCEPT CHAIN TO HOLD MANUAL DISCONNECT IN THE ENGAGED POSITION. POWER OPERATION: NO TENSION ON CHAIN AND PLACE IN WALL BRACKET MANUAL DISCONNECT WALL BRACKET Figure 7: Operation of Disconnect Chain and Bracket Figure 6: Disconnect Bracket Mounting Manual Part Number: 7A ASI Technologies, Inc. Page

12 L L L3 NC A T T T3 NC A STOP 95 NC NC 98 T OPEN W RESET A T T3 NC A RESISTOR L L L3 NC A CLOSE L L L3 NC A T T T3 NC A T T T3 NC A SIMATIC S7-00 PORT 0 SF RUN STOP QO L L L R N L AC Q CPU AC/DC/RELAY Run Term Stop IO I M M M 3456 GND GND L L L3 T T T3 B B A INSTALLATION Electrical Controls WARNING 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 could result in serious injury or death. WARNING 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. NOTE Remove power at fused disconnect and lock out prior to the following steps.. Motor wires should be marked T, T, T3, and ground (Figure 9).. Run the multi-conductor cable between the control box and the wire harness bracket (Figure 8). 3. From a fused disconnect, route power supply wires to control box and connect to terminal blocks "L", "L", "L3". (Figures 8 & 9). Also attach a ground to control box terminal. (See enclosed schematic for terminations located in the control box). 4. Wires should be pulled from the control box to the motor box BRAKE RELEASE CHAIN MOTOR MANUAL CHAIN FALL REVERSING EDGE COIL CORD CONTROL 60" SUGGESTED Figure 8: Wiring to the Door FUSED DISCONNECT INTLK BRAKE REV EDGE E-STOP PHOTOEYE LOOP GND GND L L L3 T T T3 B Figure 9: ASI Control Panel Page 000 ASI Technologies, Inc. Manual Part Number: 7A

13 INSTALLATION Electrical Controls Continued 5. All connections should be made per the schematic. All wiring connections from harness MUST be terminated in control box. NOTE If using Induction Loop System, all loops should be in series. 6. ELECTRIC REVERSING EDGE: The reversing edge is already pre-wired into the bottom bar assembly. The other end of the cord should be connected to the junction box per the schematic (Figure 0). REVERSING EDGE COIL CORD Figure 0: Reversing Edge Connections Manual Part Number: 7A ASI Technologies, Inc. Page 3

14 INSTALLATION Electrical Controls Continued WARNING 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 could result in serious injury or death. 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 non-resettable counter that can be used to establish periodic maintenance programs. INPUT POWER The nominal supply voltage for the control panel is typically 08, 40, 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 0 VAC (for the PLC) and 4 VAC (for other sensing and electrical) devices. SIMATIC S7-00 SF RUN STOP L QO L L R N L AC Q CPU AC/DC/RELAY Run Term Stop IO I M M M PORT 0 Page ASI Technologies, Inc. Manual Part Number: 7A

15 INSTALLATION Electrical Controls Continued Output LED's PLC System Fault SIMATIC S7-00 Run Mode Stop Mode EEPROM Socket Communications Port PORT 0 SF RUN STOP L L L R N L AC QO Q CPU AC/DC/RELAY PLC Modes (Dipswitch Settings, Shown in Run Mode) Cover Cutout Pot 0 Time to Close Run Term Stop IO I M M M 0 Socket for adding I/O modules Pot Preannounce to Close or Partial Open Timer Figure : PLC Description Input LED's LED is lit LED is not lit If I.5 is not lit, the door will be in Preannounce to Close mode If I.5 is lit, the door will be in Partial Open mode I.3 should not be lit when breakaway is normally open (See Note ) I.3 should be lit when breakaway is normally closed (See Note ) Note : Switch type is shown on electrical drawing provided 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 : 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. Manual Part Number: 7A ASI Technologies, Inc. Page 5

16 INSTALLATION PLC Inputs (4) 4V 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 I.0 I0.5. To signal a particular input, the input common () circuit is connected to the input M M I0.0 OPEN I0. CLOSE I0. OPEN/CLOSE 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. 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. CR LSO LSC CR0 59 M I0.3 PARTIAL OPEN I0.4 E-STOP I0.5 OPEN LIMIT I0.6 CLOSE LIMIT I0.7 OVER TRAVEL LIMIT M WARNING CR 60 I.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, bodily injury or death. 6 JUMPER P.E. () (4) EXT. CUTOUT 63 JUMPER 6 I. REVERSING PHOTOEYE I. EXTERNAL CUTOUT I.3 Input I0. OPEN/CLOSE: This input is connected to a normally open pushbutton or other momentary contact that signals the door to open or close dependent on door position. Input I0.3 PARTIAL OPEN: This input is connected to a normally open pushbutton or other momentary contact that, when activated, causes the door to open short of full open. See the Other Electrical Functions section for adjustment instructions. JUMPER FOR PARTIAL OPEN NOTE: PLC must be set for Partial Open mode (See Input I.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 OVER TRAVEL 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. M I.4 I.5 POT MODE M PLC Figure : PLC Input Connections (See electrical drawing provided for specific electrical connections.) Page ASI Technologies, Inc. Manual Part Number: 7A

17 INSTALLATION PLC Inputs Continued ADDITIONAL SIGNALS Input I.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 I. 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 state to open. Additional reversing devices can be added by wiring the normally closed contacts between terminals and 6 (Input I. of the PLC). Input I. EXTERNAL CUTOUT: This input is connected to a normally closed switch. When this signal is broken the door will not open. This input is used to indicate when the door is in the manual operation mode. Input I.3 NOT USED: Input I.4 NOT USED: Input I.5 POT MODE: This input toggles the door operation between Preannounce to Close mode and Partial Open mode. When to I.5 is open, Preannounce to Close can be used (See Other Electrical Functions for electrical Functions for description of this function). COMMON TERMINALS: Several input common terminals are provided for convenient wiring on the terminal strip of the control panel CR LSO LSC CR0 59 CR P.E. 60 () (4) JUMPER EXT. CUTOUT 63 JUMPER JUMPER FOR PARTIAL OPEN 6 M M M M I0.0 OPEN I0. CLOSE I0. OPEN/CLOSE I0.3 PARTIAL OPEN I0.4 E-STOP I0.5 OPEN LIMIT I0.6 CLOSE LIMIT I0.7 OVER TRAVEL LIMIT M I.0 REVERSING EDGE I. REVERSING PHOTOEYE I. EXTERNAL CUTOUT I.3 I.4 I.5 POT MODE M PLC Figure 3: PLC Input Connections (See electrical drawing provided for specific electrical connections.) NOTE: PLC must be in run mode for door to operate. Run Term Stop Manual Part Number: 7A ASI Technologies, Inc. Page 7 0 Figure 4: Preannounce to Close or Partial Open Setting

18 INSTALLATION PLC Outputs (0) Relay outputs are located at the upper section of the control. These terminals are used to provide signals to operate the motor, provide door position signals, and provide door fault indicators. INDICATOR OUTPUTS Output Q0.0 DOOR CLOSED: This output relay closes when the door is in the fully closed position. The LED of the output will be lit when the door is fully closed. Output Q0. DOOR OPEN: This output relay closes when the door is in the fully open position. The LED of the output will be lit when the door is fully open. Output Q0. 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 I.5). 4 VAC L DOOR CLOSED Q0.0 DOOR OPEN Q0. DOOR CLOSING Q0. PREANNOUNCE Q0.3 TO CLOSE PLC L OPEN Q0.4 CLOSE Q0.5 Q0.6 4 VAC 3L FAULT/RESET Q0.7 COUNTER Q.0 BRAKE Q. GND N L (0 VAC) (N for 0 VAC) 3 (0 VAC) Figure 5: PLC Output Connections Page ASI Technologies, Inc. Manual Part Number: 7A

19 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 Q.0 COUNTER: This output relay is connected to a mechanical non-resettable counter to be used for maintenance. Output Q. NOT USED: 4 VAC L DOOR CLOSED Q0.0 DOOR OPEN Q0. DOOR CLOSING Q0. PREANNOUNCE Q0.3 TO CLOSE L OPEN Q0.4 CLOSE Q0.5 Q0.6 4 VAC 3L FAULT/RESET Q0.7 COUNTER Q.0 0 BRAKE Q. Figure 6: PLC Output Connections PLC GND N (N for 0 VAC) L (0 VAC) 3 (0 VAC) 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 0 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 Over Travel Continuous Light Door over traveled past open limit switch. Correct problem, then press Fault/Reset button Power-Up Continuous Light Power has been lost and restored to panel. Door must be clear of open limit then press Fault/Reset button Manual Part Number: 7A ASI Technologies, Inc. Page 9

20 INSTALLATION Other Electrical Functions TIME TO CLOSE: This is a rotary pot (pot 0) used to set a 0 second timer. 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 0% clockwise will enable the timer. This timer can be typically adjusted from to 0 seconds. Rotating 0% clockwise will set the timer to seconds, 50% clockwise will set the timer to 0 seconds, and fully clockwise will set the timer to 0 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. NOTE: PLC must be in run mode for door to operate. Run Term Stop 0 Figure 7: Time to Close & Preannounce to Close or Partial Open Settings CAUTION Rotary pots are designed for 70º of rotation. Additional turning will damage pot and effect pots function. WARNING 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, bodily injury or death. PREANNOUNCE TO CLOSE: A rotary pot (pot ) is used to set a second timer. NOTE: to I.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 00% of the Time to Close time. The Preannounce to Close time is set by adjusting the nd 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. Page ASI Technologies, Inc. Manual Part Number: 7A

21 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.5 seconds prior to door closing and 00% 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 ), this feature allows the user to partially open the door. NOTE: PLC must be set for Partial Open mode (See Input I.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.. The distance the door travels before stopping can be adjusted by rotating pot 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 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. Manual Part Number: 7A ASI Technologies, Inc. Page

22 INSTALLATION Start-Up. Release the shipping straps from the curtain and carefully, using the manual chain, lower the door to fit into the tracks on the side frames (Page, Figure 3).. Lower the door past the support tube and install the upper travel control bumpers on the support tube (Figure 8). 3. If the black acoustical/wear straps contact the bumpers, then the straps must be moved (Figure 9). 4. Check that the taperlock has been properly installed and screws are tight pawl should be centered on ratchet wheel and ratchet wheel must not be rubbing against the mounting bolts coming through the ratchet plate (Figure 30). Move the ratchet wheel out if ratchet wheel is touching (not clearing) the bolts. 5. Insert a 5 /8" diameter 4" rod into holes on the ratchet wheel and put / turns (8 clicks) of tension on the ratchet wheel. This will tension the springs within the drum and act as an assist to the door during opening and closing (counterbalance) (Figures 30 & 3). /8" GAP WITH DOOR IN CLOSED POSITION Figure 8: Bumper Stop Position STRAP TOP PLATE MOVE STRAPS LEFT OR RIGHT TO CLEAR BUMPERS, TAP LIGHTLY WITH A SCREW DRIVER AT BASE OF PLATE ACOUSTICAL WEAR STRAP STRAP TENSION ROLLER Figure 9: Strap Position RATCHET PAWL RATCHET WHEEL SPRING RATCHET PAWL MOUNTING BOLT RATCHET WHEEL CLEARANCE TAPER LOCK ROD HOLE 5 /8" DIAMETER ROD APPROXIMATELY 4" LONG Figure 30: Ratchet Wheel Figure 3: Ratchet Wheel Page 000 ASI Technologies, Inc. Manual Part Number: 7A

23 INSTALLATION Start-Up Continued 6. Next check the curtain for balance. Using the manual operating chain, manually pull the door up to within " of the fully open position (Figure 3). The door should balance (not coast up or down further than the pressure of your pull). If the door coasts up, you should release tension from the ratchet wheel (rotate counterclockwise). If it coasts down, add more tension to the wheel (rotate clockwise). Repeat the procedure in the zone that is " from the fully closed position of the door and adjust as necessary. NOTE Placing excessive (clicks) turns on the ratchet wheel will adversely effect the cycle life of the springs. TEST WITHIN THIS " AREA FLOORLINE TEST WITHIN THIS " AREA NOTE If further adjustment of the ratchet wheel is necessary, move the ratchet two () clicks in the proper direction and test again. Figure 3 Balancing the Curtain 7. After proper balance is obtained, move (manually) the curtain halfway down the opening (half closed) and place into power mode of operation (release manual disconnect from wall clip). Check that disconnect snaps into the power side of drive shaft assembly (Figure 33). The brake should now hold the door in position. WARNING Releasing (or disconnecting) the drive to manually operate the door could cause the door to move since it is not completely balanced. You must hold on to the chain or latch it with the wall bracket. Failure to do so could result in property damage, bodily injury or death. Figure 33: Manual Disconnect Control box contains HIGH VOLTAGE! The following procedures should be performed by qualified electrical personnel only. Wiring must meet all local, state, federal, international or other governing agency codes. Failure to do so could result in serious injury or death. Manual Part Number: 7A ASI Technologies, Inc. Page 3

24 INSTALLATION Start-Up Continued 8. 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 34). 9. Reattach the limit switch chain to the drive shaft assembly. If necessary, loosen the three (3) 3 /8" nuts and bolts, and tension chain as required. The limit switch gear may be moved in or out slightly to achieve proper chain alignment (Figure 35). CAM NYLOCK NUT ROTATE SHAFT TO MOVE BLOCK LOCATION COMMON NORM LSC OPEN NORM CLOSED NORM CLOSED LSO OPEN NORM COMMON SPROCKET LIMIT SWITCH ACTUATING BLOCK CAM NYLOCK NUT Figure 34: ASI Limit Switch ALIGN CHAIN 3 /8" BOLTS Figure 35: Alignment of Limit Switch Gear Page ASI Technologies, Inc. Manual Part Number: 7A

25 INSTALLATION Start-Up Continued WARNING 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. When powering up door to check phasing, be prepared to disconnect power immediately if phasing is wrong. Failure to do so could result in damage to the door or serious injury. Electrical Start-Up (Initial or Restored Operation). Position door into the middle of the opening.. Turn on power to the unit. At this point the fault light should be lit. 3. Press FAULT/RESET button. 4. Door is ready for further set-up or restored to use if set-up has already been successfully completed. NOTE If reset light does not turn off, verify that the door is not positioned on either the open or overtravel limit. (I0.5 and I0.7 on the PLC should be lit in order to reset. Manual Part Number: 7A ASI Technologies, Inc. Page 5

26 L L L3 NC A T T T3 NC A STOP T OPEN W RESET A 95 NC NC 98 T T3 NC A RESISTOR CLOSE L L L3 NC A T T T3 NC A L L L3 NC A T T T3 NC A SIMATIC S7-00 PORT 0 SF RUN STOP QO L L L R N L AC Q CPU AC/DC/RELAY Run Term Stop IO I M M M 3456 GND GND L L L3 T T T3 B B A PORT 0 SF RUN STOP L L L R N L AC QO Q IO Run Term Stop I M M M INSTALLATION Motor Phasing. Check for proper motor rotation. With the door positioned between limits, momentarily depress the manual operation button on the right hand contactor marked CLOSE (Figure 36). Be sure to let go once the door begins moving so the door does not travel beyond the limit switch. If the door begins closing, the motor is wired correctly, skip steps and 3. If the door begins opening, the motor wiring must be reversed because it is out of phase. Follow steps and 3 to reverse the motor wiring.. Remove power at the fused disconnect. 3. Reverse any two of the three incoming power lead terminals on L, L or L3 (Figure 36 & 37). REVERSING CONTACTORS OPEN L L L3 NC A T T T3 NC A STOP 95 NC NC 98 T OPEN W RESET A T T3 NC A L L L3 NC A CLOSE T T T3 NC A RESISTOR OVERLOAD RELAY L L L3 NC A T T T3 NC A TRANSFORMER CLOSE SIMATIC S7-00 INTLK BRAKE REV EDGE CYCLE COUNTER CPU 4 AC/DC/RELAY E-STOP PHOTOEYE LOOP 3456 CYCLE COUNTER GND GND L L L3 T T T3 B B A TIMER BASE Figure 36: ASI Control Panel 3456 INTLK BRAKE REV E-STOP PHOTOEYE LOOP EDGE GND GND L L L3 T T T3 B Figure 37: ASI Control Panel Page ASI Technologies, Inc. Manual Part Number: 7A

27 INSTALLATION Operating Adjustments. Remove cover of limit switch (Figure 38) and make certain that the limit switch actuating block is located in the center of the rotating shaft. If not, remove timing chain, move the block to the center by rotating sprocket by hand (Figure 38). Then replace timing chain.. Check tension of limit switch drive chain and allow /4" maximum deflection. 3. 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 39). 4. 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. NOTE Decals vary from door to door depending on the type and mounting. LIMIT SWITCH ACTUATING BLOCK CAM NYLOCK NUT ROTATE SHAFT TO MOVE BLOCK LOCATION COMMON NORM LSC OPEN NORM CLOSED NORM CLOSED LSO CAM NYLOCK NUT Figure 38: ASI Limit Switch OPEN + + CLOSE OPEN NORM COMMON SPROCKET NOTE Rotating the adjustment screws in the direction of the arrow indicated will increase the door travel with respect to the open or close cycle. 5. Remove the red shipping plug from the pump tank and replace it with the plastic vent cap supplied. Maintain oil level / " from the top of the tank. If oil is needed: use Benz Oil Flomite 530 for cooler and freezer applications and Benz Oil Flomite 68 for ambient temperature applications. For equivalent hydraulic oil products (Figure 40). Figure 39: Limit Switch Adjustment SHELL MOBIL FLOMITE 530 (Mil-H-5606) AeroShell Fluid 4 Aero HFA FLOMITE 68 (ISO VG 68 HV VI = 30 min.) Tellus T68 DTE 6M Figure 40: Hydraulic Oil Equivalents Manual Part Number: 7A ASI Technologies, Inc. Page 7

28 INSTALLATION Operating Adjustments Continued 6. Valve Adjustments The hydraulic unit is adjusted at the factory. If the door operates smoothly, do not adjust any of the hydraulic valves. Valve locations are shown in Figure 4. However, if adjustment is necessary for smooth operation of the door, proceed as follows. a. Coast Valve Adjustment of this valve controls how quickly or slowly the door stops. Turning the adjustment screw clockwise makes the door coast more and turning counterclockwise makes it coast less. For nominal adjustment, turn the screw fully clockwise and back it out / 3 turns. Notes: To prolong door life, the door should not stop too abruptly. Limit switches may need to be reset after making adjustment. b. Acceleration Valve Adjustment of this valve controls how quickly or slowly the door starts. CAUTION Never adjust the acceleration valve all the way in. Doing so will cause the operating characteristics of the valve to vary. Turning the adjustment screw clockwise makes the door start up more quickly and turning counterclockwise makes the door star up more slowly. When making adjustments, never turn the adjustment screw more than a /4 turn before testing its effect. c. Two Speed Valve (optional) Adjustment of the two speed valve controls how quickly or slowly the door closes. Turning the adjustment screw clockwise makes the door close slowly and turning counterclockwise makes the door close quickly (Figure 4). 7. At times, doors will reverse at the bottom of their (travel) automatically and without any apparent reason. Adjust limit switch. OPEN COAST OPEN ACCELERATION HYDRAULIC RESERVOIR END CLOSE COAST CLOSE ACCELERATION Figure 4: Hydraulic Adjustments RESERVOIR FILLER CAP MOTOR PORTS COAST VALVE Figure 4: Hydraulic Operator TWO-SPEED VALVE (IF APPLICABLE) ACCELERATION VALVE WARNING Check the reversing edge for proper operation daily. If any portion of the reversing edge is not functioning properly, remove the door from service until corrected. Failure to do so could result in property damage, bodily injury or death. 8. Test the reversing edge while door is descending to assure proper functioning (Figure 43). It should reverse on contact. Figure 43: Testing the Reversing Edge Page ASI Technologies, Inc. Manual Part Number: 7A

29 INSTALLATION Operating Adjustments Continued 0. CURTAIN With the door down, check alignment of curtain between the side frames it should be equal on both sides within the track. The entire curtain can be moved sideways on the drum by slightly loosening the socket head screws on the barrel curtain clamp plates. Using a pry bar, gently slide the top slat to the position desired and retighten the socket head screws (Figure 45). NOTE To adjust curtain position it may be necessary to remove tension from the ratchet wheel. The curtain should not contact the side frames as it rolls up. If there is no contact: tighten the set screws on the bearings that were loosened when we were in the curtain and drum assembly (Page 7, Figure 8 and Page 9, Figure 3). If there is contact: pry the end plates away from the curtain/drum and tighten the set screws. Check the side frame plates for markings that show wear (Figure 45 & 46). SCRATCHING AND MARKING FROM CURTAIN CONTACTING THE SIDE FRAME FLAG VIEW WITH DOOR IN THE DOWN POSITION Figure 44: Drum Contacting the Side Frames END CLEARANCE SPACE PRY BAR. The rollers at the top of the door should be adjusted so that they approach curtain only within the /4" after it has closed 75% of the door s full travel (Figure 46).. Close the door fully. 3. Install the brush seal to the top of the lintel, as shown in (Figure 46), so that the seal contacts the curtain all the way across the opening. This blocks outside air from entering. 4. Additional wiring, loop detectors, photoeyes and all other accessories should be placed into the system at this time. Test all operations for continuity. Be sure all elements of the system operate together. Check MAINTENANCE section for periodic maintenance, lubrication and adjustments. CURTAIN HANGER SIDE FRAME END PLATE TO ADJUST END CLEARANCE SPACING OF CURTAIN SLATS, PRY GENTLY ON METAL ENDS TO CORRECT. USE A SMALL PRY BAR AGAINST THE SIDE FRAMES. Figure 45: Curtain Alignment TOP SUPPORT TUBE AND ROLLER ASSEMBLY /4" BETWEEN CURTAIN AND GUIDE ROLLER WITH DOOR 75% CLOSED LINTEL BRUSH SEAL OUTSIDE OF DOOR Figure 46: Lintel Brush and Roller Installation Manual Part Number: 7A ASI Technologies, Inc. Page 9

30 INSTALLATION Reversing Photoeyes. Mount one photoeye transmitter sensor and one photoeye receiver sensor on the door side using supplied hardware (Figure 47). Mount the second photoeye transmitter and receiver to the side frame using existing photoeye bracket and supplied hardware (Figure 47).. Run cabling from all four photoeyes to the ASI control panel. 3. Make the electrical connections as shown on the electric schematic supplied with the door. 4. Loosen the screws on the photoeye transmitter and receiver brackets. Adjust the photoeye transmitter until it is aligned with the receiver. Tighten screws. A status indicating light will be lit on the amplifier when the transmitter and receiver are aligned. 5. While operating the door to close, interrupt the beam for each set of photoeye sensors. The door should stop and reverse it s direction to fully open. Repeat the alignment procedure described above for each set of photoeyes until the desired door operation is achieved. 6. Test this operation daily. If the photoeye sensors do not function as described in Step 5, take door out of service until repairs are made. WARNING Remove door from service when reversing photoeyes are not operating as described above. Failure to do so could result in serious injury or death. PHOTOEYE TRANSMITTER PHOTOEYE RECEIVER WALL DOOR OPENING (W.I.C.) WALL SIDE FRAME TAPPED HOLES () IN GUARD ANGLE Figure 47: Photoeye Receiver/Transmitter Sensors Placement (Windlock Curtain Shown) PHOTOEYE TRANSMITTER (IDLER SIDE) DOOR SLAT GUARD ANGLE PHOTOEYE RECEIVER (DRIVE SIDE) SIDE FRAME TAPPED HOLES () IN GUARD ANGLE Page ASI Technologies, Inc. Manual Part Number: 7A

31 Over Travel Limit Switch. Locate over travel switch on operator harness assembly.. Attach over travel limit bracket to limit switch (Figure 48) using #0 4 /" screws, nuts and washers. 3. With door in full open position, attach bracket to horizontal support tube using supplied hardware. 4. Horizontally position the over travel limit switch a minimum of " from the curtain (Figure 48), while still allowing the coil cord to trip the limit switch pivot arm. Tighten mounting hardware. 5. With the door in the open position, vertically position the over travel limit switch with a minimum of " between the coil cord and the pivot arm. Tighten the mounting hardware. 6. Route cabling from limit switch back to the operate plate. Cabling should be kept away from the door and operating components. Cable tie the cable in place to prevent movement. DOOR SLAT INSTALLATION LIMIT SWITCH SIDE FRAME WALL " Minimum HORIZONTAL SUPPORT TUBE LIMIT SWITCH BRACKET PIVOT ARM COIL CORD Figure 48: Attaching the Operator Shroud Manual Part Number: 7A ASI Technologies, Inc. Page 3