SPIRIT HIGH SPEED FABRIC ROLL-UP DOOR OWNER S MANUAL

Transcription

1 SPIRIT HIGH SPEED FABRIC ROLL-UP DOOR OWNER S MANUAL MODEL ELECTRIC NEW DESIGN DOOR MODEL: 9D522 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. 2004, ASI Technologies, Inc. Manual Part number: 7A

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. 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: 7A

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, death or serious injury. READ AND UNDERSTAND ALL LABELS AND 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.. 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. 0. If you have any questions, contact your supervisor or your local ASI Technologies, Inc. representative for assistance.. Train all service and personnel using or near door on intended use(s) and operation of the door. 2. 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: 7A 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 () 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 applicable 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:. 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. 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: 7A

5 GENERAL INFORMATION Marathon Spirit High Speed Fabric Roll-Up Door General Information Begins on Page 2 Safety Practices Page 2 Warranty Policy Page 4 Crates and Contents Page 6 Maintenance Begins on Page 34 Resetting Bottom Bar Page 34 Troubleshooting Page 35 Preventative Page 36 Installation Begins on Page 8 Door Measurements Page 8 Side Support Assembly Page 9 Barrel Seal Page Barrel Assembly Installation Page 2 Attaching Counterweight Page 4 Over-Travel Bracket & Warning Labels Page 6 Electrical Controls Page 7 PLC Inputs Page 22 PLC Outputs Page 24 Other Electrical Functions Page 26 Start-Up Page 28 Electrical Start-Up Page 29 Shroud Installation (Optional) Page 32 Final Checks Page 33 Replacement Parts Begins on Page 38 Instructions for Ordering Page 38 Door Identification Page 39 ID Tag Location Page 39 Door Assembly Page 40 Header Assembly Page 4 Electric Bottom Bar Assembly Page 42 Pneumatic Bottom Bar Assembly Page 43 Idler Side Column Assembly Page 44 Drive Side Column Assembly Page 45 Panel Assembly Page 46 Panel Assembly 2-Speed Door Page 48 Operator Assembly Page 50 Labels Page 5 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: 7A ASI Technologies, Inc. Page 5

6 GENERAL INFORMATION Crates and Contents HEADER ASSEMBLY AND MOTOR SHROUD BARREL SEAL DRIVE GUIDE IDLER GUIDE CONTROL BOX COUNTERWEIGHT LOOSE PARTS BOX CRATE Figure : Crates and Contents Page ASI Technologies, Inc. Manual Part Number: 7A

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 ). Crate one will contain the side frame assembly, the curtain and barrel assembly, the loose parts box, the operator, control box, barrel seal and counterweight. 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. Loose Parts Box: DESCRIPTION QTY. DESCRIPTION QTY. Installation Instructions Sales Drawings Warning Nameplate Assembly..2 Misc. Activation Devices Manual Part Number: 7A ASI Technologies, Inc. Page 7

8 INSTALLATION Door Measurements. Find the door centerline by measuring the width of the door opening in inches and dividing by two (Figure 2). Mark the door centerline on the floor. 2. The area around the opening must be a finished, flat surface. As shown in Figure 2, the finished surface must extend 7 /4" beyond the opening on the idler side, and 9-3 /4" on the drive side and 9 /2" at the header. 3. For proper operation of the breakaway bar, reference the centerline found in step. Mark a line on the wall at a distance /2 width in clear (W.I.C.) plus 7 /4" on the idler side, and /2 width in clear (W.I.C.) plus 9 3 /4" on the drive side from the center of the doorway. HEADER 8" for no shroud 8" for 0º shroud 25" for 30º shroud ADDITIONAL 2" HEIGHT ON DRIVE SIDE C L /2 W.I.C /4" DRIVE SIDE 9 3 /4" /2 W.I.C. + 7 /4" IDLER SIDE 7 /4" Figure 2: Door Measurements RECOMMEND BLOCK WALL STEEL TUBE OR STEEL ANGLE TO SUPPORT BOLTED HEADER ASSEMBLY 7 /4" 9 3 /4" min min IDLER BARREL HEADER BRACKET 5 3 /4" WIC 2 3 /4" 5" OPERATOR BARREL HEADER BRACKET 2 5 /8" 6" 2 3 /4" 8" 0" 9 /2" Figure 3: Marking Bolt Holes BOLT HOLE LOCATIONS 9 3 /8" NOTE: ALL BARREL HEAD ATTACHMENT HOLES ARE 9 /6" DIA. SLOT HOLES DOOR HEAD WIC DOOR JAMB HIC 6" HIC Figure 4: Marking Bolt Holes (Also see Figures 2 & 3) Page ASI Technologies, Inc. Manual Part Number: 7A

9 INSTALLATION Side Support Assembly. Uncrate and remove covers from each side frame. 2. Stand each side frame up against the wall referencing the lines shown on Page 8, Figure 2. Check to make sure the side frames are plumb. Note that the wider side frame is on the drive side. Using the side frames as templates, mark the placement of holes (Page 8, Figures 3 & 4). 3. Using the hole positions marked on the wall, drill all holes for 3 /8" diameter thru-bolt fasteners. FOR HEADER ATTACHMENT ATTACH TO WALL WITH HOLES FROM HERE DOWN GUIDE TO FLOOR LINE We strongly recommend that thru-holes be drilled for proper anchoring of the door to the wall. Figure 5: Drive Side Frame 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. 4. Install both idler and drive side frames to the wall. Do not use the two top most holes at this time (Figures 5 & 6). These will be used for header attachment on Page 0. Frames should be approximately /4" from the edge of the doorway. Use barrel seal assembly for proper spacing between side frames. Distance between the frames should be W.I.C. plus /2". Be sure both frames are straight, plumb and square. FOR HEADER ATTACHMENT ATTACH TO WALL WITH HOLES FROM HERE DOWN GUIDE TO FLOOR LINE Figure 6: Idler Side Frame Manual Part Number: 7A ASI Technologies, Inc. Page 9

10 INSTALLATION Side Support Assembly Continued 5. Attach idler side and drive side cover using the fasteners supplied (Figure 7). Welding galvanized metal may result in minor or moderate injury. IDLER SIDE FRAME IDLER SIDE COVER COVER BOLTS Figure 7: Attaching Side Cover Page ASI Technologies, Inc. Manual Part Number: 7A

11 M AN U AL R E L E A S E Barrel Seal. Check to see if the sideframes are positioned properly withing the opening (Page 8, Figure 4). 2. Attach barrel seal between sideframes using the fasteners supplied (Figure 8). 3. Make sure when barrel is installed, seal rests on top of curtain (Figure 9). INSTALLATION SHROUD CLIP BARREL SEAL BARREL SEAL BARREL SEAL SUPPORT CURTAIN HEIGHT IN CLEAR (H.I.C.) Figure 8: Barrel Seal Installation Figure 9: Barrel Seal Installation Manual Part Number: 7A ASI Technologies, Inc. Page

12 INSTALLATION Barrel Assembly 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.. If door has an optional operator or barrel shroud, remove these shrouds before installation. Using a forklift, pick up the barrel assembly through the harness and raise into position (Figure 0). 2. Rotate the operator and header mounting plate so that the mounting holes line up with the holes in the side frame and index barrel to have bottom bar breakaway tabs in line with side column guide rail. Thru bolt or fasten securely to the wall using 3 /8" fasteners (Figure 0). Level the header before final tightening of bolts. Mark and drill holes for two slots at top of side guide and attach to wall with 9/6" thru-bolts (Figure ). BARREL STRAPS HARNESS ROTATE TO MOUNT Figure 0: Lifting Header THRU BOLTS OPPOSITE VIEW DRIVE CHAIN BOTTOM BAR LIMIT SWITCH BOX DRIVE SIDE COVER Figure : Header Installation Page ASI Technologies, Inc. Manual Part Number: 7A

13 INSTALLATION Barrel Assembly Installation Continued 3. Make sure the drive chain is properly tensioned. NOTE: Do not overtighten chain. Adjust the chain using the mounting bolts on the operator so the drive chain has a maximum 3 /8" deflection on the one side (Figure 2). Tension is preset at the factory, but may change during shipping. Periodically check the tension. 3 /8" MAXIMUM Do not remove barrel straps until drive chain is attached and proper chain tension is achieved. Failure to do so may result in minor or moderate injury. Figure 2: Drive Chain Adjustment 4. Remove shipping barrel straps (Figure 3). Figure 3: Removing Barrel Straps Manual Part Number: 7A ASI Technologies, Inc. Page 3

14 R E L E A S E INSTALLATION Attaching Counterweight. Release the brake by pulling down the brake release handle. Place the bottom bar into guide (Figure 4) while pulling down on the door. Be careful not to scratch or tear fabric on edge of front guide when inserting curtain into guide. 2. Position door all the way open with mechanical stop hooked against door stop pin. 3. Open drive side hinged cover and unwind the counterweight strap found on the drive side of the barrel do not rotate the barrel. IMPORTANT two dead wraps must remain on the barrel. Bottom bar must be in the UP position at this time. Run the strap past the header roller guide. Lead the strap between the inside of the guide and the roller (Figure 5). PLACE BOTTOM BAR INTO SIDE GUIDE BOTTOM BAR MECHANICAL STOP SIDE GUIDES M AN U AL BRAKE RELEASE PULL DOWN TO RELEASE BRAKE Figure 4: Leading Curtain Into Guide Counterweight could fall during assembly. Use extreme caution during the following steps. Failure to stay clear of counterweight or use of caution could result in death or serious injury. 4. Position counterweight into side frame and raise counterweight (using shims) 4" to 6" above the floor. HEADER ROLLER GUIDE Figure 5: Leading the Strap Past the Header Roller Page ASI Technologies, Inc. Manual Part Number: 7A

15 INSTALLATION Attaching Counterweight Continued 5. Insert clevis through counterweight attachment bracket. 6. Loop counterweight strap and attach strap clamps. Beveled edges of strap clamps should be towards strap (Figure 6). 7. Insert clevis pin through strap and clevis and secure with cotter pin. Adjust strap to insure counterweight does not rest on ground when door in full open position. 8. Pull brake release and operate door manually through fully closed and fully opened positions. Check for proper tracking of counterweight strap and curtain fabric to ensure desired counterweight travel: when door is at full HIC --- the counterweight should not touch floor; and when door is fully closed --- the counterweight and clamp should not interfere with header roller guide (Figure 6). CUT STRAP " ABOVE STRAP CLAMP HEADER ROLLER GUIDE STRAP LOOP STRAP CLAMP COTTER PIN CLEVIS PIN COUNTER WEIGHT CLEVIS SIDE VIEW OF STRAP BEVELED EDGE (TOWARDS STRAP) Figure 6: Attaching the Counterweight to Strap Manual Part Number: 7A ASI Technologies, Inc. Page 5

16 INSTALLATION Over-Travel Bracket & Warning Labels. Install over-travel bottom bar bracket on cord assembly bracket and secure with bolts (Figure 7). 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. 2. Inspect Warning Labels on side frame covers (Figure 8). Mount Warning Labels provided on other side of the wall opposite the side covers (Figure 9). The bottom of the Warning label should be approximately 60" from the floor. Figure 7: Over-Travel Bracket Installation CAUTION Connect Reversing edge switch. Test edge daily. See Instructions. EMERGENCY MANUAL RELEASE In the event of a power outage pull handle down while lifting bottom of door. Release handle when door approaches full open. CAUTION HIC " 78" 60" 60". Read, study and understand all warning labels, operating instructions and installation manual furnished with this equipment prior to use. If any portion of this material is unclear, contact your factory representative for clarification. 2. This is a high speed door designed for vehicular traffic. Operation may be automatic. Keep doorway clear at all times. Door impact may cause personal injury or property damage. 3. Do not start door downward unless doorway is clear. Once door has begun closing Do Not Enter Doorway! 4. Check reversing edge, photoeye and any other activation device for proper operation daily. See operating instructions for procedure. 5. Do not operate door with side columns open or without factory provided shrouds properly installed. 6. Mount door operator more than 8 feet (2.44 M) above the floor. 7. It is your responsibility to keep all warning labels and instructional literature legible and intact. Replacement labels and literature are available from the factory. 8. Failure to heed these warnings may result in equipment and/or personal or fatal injury. ASI TECHNOLOGIES, INC.. Read, study and understand all warning labels, operating instructions and installation manual furnished with this equipment prior to use. If any portion of this material is unclear, contact your factory representative for clarification. 2. This is a high speed door designed for vehicular traffic. Operation may be automatic. Keep doorway clear at all times. Door impact may cause personal injury or property damage. 3. Do not start door downward unless doorway is clear. Once door has begun closing Do Not Enter Doorway! 4. Check reversing edge, photoeye and any other activation device for proper operation daily. See operating instructions for procedure. 5. Do not operate door with side columns open or without factory provided shrouds properly installed. 6. Mount door operator more than 8 feet (2.44 M) above the floor. 7. It is your responsibility to keep all warning labels and instructional literature legible and intact. Replacement labels and literature are available from the factory. 8. Failure to heed these warnings may result in equipment and/or personal or fatal injury. ASI TECHNOLOGIES, INC. Figure 8: Warning Label Installation Side Frames Figure 9: Warning Label Installation Wall Mount Page ASI Technologies, Inc. Manual Part Number: 7A

17 Electrical Controls INSTALLATION FOR CLARITY COVER AND GUIDE NOT SHOWN 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. 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.. Make sure prewired cable supplied is of sufficient length to enable location of control box where desired. Mount control box to a convenient location, leaving sufficient room for control box door to be opened. CAUTION Wiring must be completed by a licensed electrician. All wiring connections must be in accordance with all local, state, federal, NEC or other governing agency codes. Reference electrical drawings shipped with door. Figure 20: Control Lead Connection Manual Part Number: 7A ASI Technologies, Inc. Page 7

18 L L2 L3 NC A T T2 T3 NC A2 STOP 95 NC NC 98 T OPEN W RESET A T2 T3 NC A2 RESISTOR L L2 L3 NC A CLOSE L L2 L3 NC A T T2 T3 NC A2 T T2 T3 NC A2 SIMATIC S7-200 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 GND GND L L2 L3 T T2 T3 B 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. 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. Prewired control leads should be connected to the plug in the side column. They are tagged and marked for ease of installation. Open side column cover. Route pre-wired multi-conductor cable from control box to connector inside side column. Remove plastic shipping covers, align pins on plug and receptacle, then twist collar on plug until it clicks in place (Page 6, Figure 20). 4. Close drive side guide cover and secure with fasteners. 5. Motor wires should be marked T, T2, T3 and ground. (B & 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. 6. From a fused disconnect, route power supply wires to the control panel and connect to terminal blocks L, L2, L3 (Figure 2). Also attach a ground to control panel terminal. 7. All connections should be made per the schematic. All wiring connections from harness MUST be terminated in control box INTLK BRAKE REV EDGE E-STOP PHOTOEYE LOOP GND GND L L2 L3 T T2 T3 B B2 Figure 2: ASI Control Panel Page ASI Technologies, Inc. Manual Part Number: 7A

19 INSTALLATION Electrical Controls Continued 8. 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 inside the drive side column (Figure 23). COIL CORD CONNECTION CAUTION 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. 9. Drill 3 /6" hole through front face midway up the counter weight shroud (HIC/2) as shown in Figure Secure coil cord to shroud with coil cord clamp and self-tapping screw.. 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. 2. 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). M A N U A L R E L E A S E COIL CORD CLAMP M A N U A L R E L E A S E LIMIT SWITCH PLUG SELF-TAPPING SCREW FLOOR H.I.C./2 Figure 22: Connecting Limit Switch Figure 23: Connecting Coil Cord Manual Part Number: 7A ASI Technologies, Inc. Page 9

20 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 could 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 20 VAC (for the PLC) and 24 VAC (for other sensing and electrical) devices. SIMATIC S7-200 SF RUN STOP L L L R N L AC QO Q CPU AC/DC/RELAY Run Term Stop IO I M M M PORT 0 Figure 24: PLC Layout Page ASI Technologies, Inc. Manual Part Number: 7A

21 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 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 Input LED's Figure 25: PLC Description 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 2

22 INSTALLATION PLC Inputs (4) 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 I.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. 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 55 LSO LSC M M I0.0 OPEN I0. CLOSE I0.2 OPEN/CLOSE I0.3 PARTIAL OPEN I0.4 E-STOP I0.5 OPEN LIMIT I0.6 CLOSE LIMIT I0.7 M 2M CR2 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, death or serious injury. 6 JUMPER P.E. 62 (2) (4) EXT. CUTOUT 63 JUMPER 64 I. REVERSING PHOTOEYE I.2 EXTERNAL CUTOUT I.3 BREAKAWAY TABS 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. I.4 RESET BUTTON I.5 POT MODE PLC 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 NOT USED: Page ASI Technologies, Inc. Manual Part Number: 7A JUMPER FOR PARTIAL OPEN Figure 26: PLC Input Connections (See electrical drawing provided for specific electrical connections.) M M

23 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.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 I.3 BREAKAWAY TABS: This input is connected to a normally open switch (may be normally closed on some products, see electrical drawing provided) that closes 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 installation manual. Input I.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 I.5 POT MODE: This input toggles the door operation between Preannounce to Close mode and Partial Open mode (Figure 28). When to I.5 is open, Preannounce to Close can be used (See Other Electrical Functions for description of this function). When to I.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 Figure 27: Time to Close Settings Manual Part Number: 7A ASI Technologies, Inc. Page 23

24 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. 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 Q0.2 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 I.5). 24 VAC L DOOR CLOSED Q0.0 DOOR OPEN Q0. DOOR CLOSING Q0.2 PREANNOUNCE Q0.3 TO CLOSE PLC 2L OPEN Q0.4 CLOSE Q0.5 Q VAC 3L FAULT/RESET Q0.7 COUNTER Q.0 BRAKE Q. GND N L (20 VAC) (N for 20 VAC) 3 (20 VAC) Figure 28: PLC Output Connections Page ASI Technologies, Inc. Manual Part Number: 7A

25 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. BRAKE: This output relay closes to signal the motor brake. 24 VAC L DOOR CLOSED Q0.0 DOOR OPEN Q0. DOOR CLOSING Q0.2 PREANNOUNCE Q0.3 TO CLOSE 2L OPEN Q0.4 CLOSE Q0.5 Q VAC 3L FAULT/RESET Q COUNTER Q.0 0 BRAKE Q. 8 PLC GND N L (20 VAC) 2 (N for 20 VAC) 3 (20 VAC) Figure 29: PLC Output Connections Fault Condition Motor Run Timer LED Sequence Fault Cause Action to Clear Fault One quick flash every 4 seconds The motor ran continuously for greater than 0 seconds. Correct problem, then cycle Power off and on or cycle E-Stop off and on. Start-Up Fault Two quick flashes every 4 seconds PLC receives open, close, open/close, partial open, reversing edge or reversing photoeye signal at power up. Correct problem, then cycle Power off and on or cycle E-Stop off and on. 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 (Page 32), then press Fault/Reset button. Manual Part Number: 7A ASI Technologies, Inc. Page 25

26 INSTALLATION Other Electrical Functions TIME TO CLOSE: This is a rotary pot (pot 0) used to set a 2 20 second timer (Figure 30). 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 2 to 20 seconds. Rotating 0% clockwise will set the timer to 2 seconds, 50% clockwise will set the timer to 0 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. NOTE: PLC must be in run mode for door to operate. Run Term Stop 0 Figure 30: Time to Close Settings Adjust pot lightly and do not rotate past 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 ) 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 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. Page ASI Technologies, Inc. Manual Part Number: 7A

27 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 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 I0.2. 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 27

28 INSTALLATION Start-Up 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.. 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 3: ASI Limit Switch ALIGN CHAIN Be sure to close drive side support cover 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 3). 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 32). 5. Check tension of limit switch drive chain and allow /4" maximum deflection (Figure 33). /4" MAXIMUM 3/8" BOLTS (BEHIND LIMIT BOX) Figure 32: Alignment of Limit Switch Gear Figure 33: Limit Switch Drive Chain Adjustment Page ASI Technologies, Inc. Manual Part Number: 7A

29 Electrical Start-Up INSTALLATION M M 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.. Position the door at the center 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 by watching the Input Lights I0.5 and I0.6 (Figure 34). 3. Position the door at the center of the opening. CR LSO LSC CR M I0. CLOSE I0.2 OPEN/CLOSE I0.3 PARTIAL OPEN I0.4 E-STOP I0.5 OPEN LIMIT I0.6 CLOSE LIMIT I0.7 2M I.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. 6 P.E. 62 (2) (4) JUMPER EXT. CUTOUT 63 JUMPER JUMPER FOR PARTIAL OPEN I. REVERSING PHOTOEYE I.2 EXTERNAL CUTOUT I.3 BREAKAWAY TABS I.4 RESET BUTTON I.5 POT MODE 4. Turn on power to control panel and wait 0 seconds. Supply any open activation signal. The door should open. If the door starts to close, shut the power off immediately. For a single speed unit, reverse any two L or T lead wires at the terminal strip. For a two speed unit only, reverse any two T leads. Reversing the L will not affect door direction. M M PLC Figure 34: 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 35: ASI Control Panel GND GND L L2 L3 T T2 T3 B B2 Manual Part Number: 7A ASI Technologies, Inc. Page 29

30 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 red light is illuminated. If this light is 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 36). 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 37). 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 36: Limit Switch Adjustment NORM LSC OPEN NORM CLOSED NORM CLOSED LSO CAM NYLOCK NUT OPEN NORM COMMON SPROCKET Figure 37: 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. Page ASI Technologies, Inc. Manual Part Number: 7A

31 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 38). 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. 0. 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 39). 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 38 Testing Reversing Edge CAUTION 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. Figure 39 Testing Reversing Photoeye Manual Part Number: 7A ASI Technologies, Inc. Page 3

32 M AN U AL R E L E A S E INSTALLATION Shroud Installation (Optional) OPERATOR SHROUD DO NOT put door into operation until all required shrouding is put in place. See OSHA standards for proper guarding requirements. All doors with a height in clear (HIC) of less than 8'-0" require operator shrouding. Failure to do so could result in property damage, death or serious injury.. Assemble barrel and operator shrouding together using provided hardware (Figure 40). 2. Raise barrel and operator shrouding over barrel and attach back return lip of shroud assembly to barrel seal wall clip (Figure 4). 3. Pull manual release cable thru hole in bottom of the operator shroud. 4. Lower shroud into place. 5. Attach shroud to both drive side and idler side frames. BARREL SHROUD Figure 40 Assembly of Barrel and Operator Shrouding BACK RETURN LIP SHROUD ASSEMBLY SHROUD CLIP Figure 4 Raising Barrel and Operator Shrouding Into Place Page ASI Technologies, Inc. Manual Part Number: 7A