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ASI DOORS 209 Owner's Manual

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OWNER'S MANUAL
MODEL 209
MODEL 209
Full Vision
Full Aluminum
MANUAL PART #: 17A235

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Summary of Contents for ASI DOORS 209

  • Page 1 OWNER’S MANUAL MODEL 209 MODEL 209 Full Vision Full Aluminum MANUAL PART #: 17A235...

  • Page 2: Table Of Contents

    GENERAL INFORMATION Safety Practices Warranty Policy Crates and Contents 209 MANUAL INSTALLATION 7-38 Un-Bolt Lifing Cradle Opening Measurements Mounting Face Frames Mounting Header Assembly Un-Rolling Curtain Light Curtains/Photo-Eyes Mounting Face Frame Covers Mount Chain Brackets Mount Spreader Support Routing Sensor Wires...

  • Page 3: General Information

    CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury CAUTION used without a safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage NOTE NOTE explains general information ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 4 Replacement labels and literature are availale from ASI Doors, Inc or its representatives 10 If you have any questions, contact your supervisor or your local ASI Doors, Inc representative for assistance 11 Train all service and personnel using or near door on intended use(s) and operation of the door...

  • Page 5: Warranty Policy

    Warranty Policy ASI Doors, Inc (herein called “ASI”) warrants solely for the benefit of its customer that each door system manufactured by ASI (each a “Door System”) will be free from defects in material and manufacture for a period of two 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...

  • Page 6: Crates And Contents

    Manual/Auto Ext. Cord 10 Meter needed to install door in accordance with final shop Chain Extension, 2 Meter As Req drawings and manufacturer’s instructions. Misc. Hardware Bag Self Expanding Foam (Roll) ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 7: 209 Manual Installation

    Failure to do so could result in property damage, bodily injury or death Figure 3: Check plumb, square, and width when mounting face frames to wall ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 8: Mounting Face Frames

    Hold Width When Mounting To Wall and performance of the door Follow all mounting Instructions carefully to insure optimum performance Figure 5: Face Frame Mounting Dimensions ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 9 Figure 7: Face Frame Mounting Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 10 Face frames get mounted first, then the header assembly. Face frame covers get mounted AFTER header. DO NOT mount face frame covers before mounting header assembly. If the door operator is left hand mounted, the door operator will be mounted opposite than views shown. ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 11: Mounting Header Assembly

    On wide doors, use 2 fork lifts, one per side when lifting and mounting header Hanger Brackets on Face Frames Figure 12: Mounting Header On Face Frame Hanger Brackets ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 12 Slowly lower lift frame out and away from header assembly and wall Carefully remove banding straps on curtain, and Remove Banding any other shipping materials protecting curtain (figure #16) Figure 16: Remove Banding From Rolled Curtain ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 13: Un-Rolling Curtain

    Into Opening Curtain ChainLinks Should be Center in Face Frame Extrusions Operator mounting bracket bolts Figure 19: Alignment Of Ends Figure 20: Adjust Position Of Of Curtain Into Face Frames Operator & Curtain Assembly ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 14 12 With curtain in completely unrolled position, check and tighten any nuts at tops of face frames that were left hand tight from previous install steps Adjustable link for leveling curtain Figure 21: Adjustable Link Location Adjusting Nut Adjustable link for adjusting curtain Figure 22: Adjustable Link Detail Views ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 15: Light Curtains/Photo-Eyes

    Light curtain Locking in face cams Light curtain installed in frame face frame cover cover extrusion Channel Figure 24: Photoeye And Light Figure 25: Light Curtain & Photo-Eye Detail Cover Curtains Installation Options ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 16: Mounting Face Frame Covers

    Figure 26: top of face frame covers Face frame cover Curtain 3/8-16 X 3/4 (P/N 41A1029) screw Face frame Tab in cover extrusion Figure 29: Rotate Face Frame Figure 27: Face Frame Cover Into Position Cover Install Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 17: Mount Chain Brackets

    Mounting Spreader Support Gusset er support gusset as shown in figure 33 (2) 5/16”-18 x 0 50” Screws (P/N 41A1075) Figure 32: Mount Spreader Support Gusset To Figure 33: Mount Spreader Support Gusset To Center Support Wall ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 18: Routing Sensor Wires

    Routing Sensor Wires Refer to figures 34 – 35 for wire routing for the 209 door light curtains or photo eyes Leads from the light curtain or photo eye sensors come out at the top ends of the face frames or covers and need to...
  • Page 19 Idler side cover sensor wires Routed through slot in bottom of header end plate, through hole in center of top rear cross tube, and over to drive side of door Figure 35: Routing Sensor Wires ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 20: Wiring Layout

    Wiring Layout Figures 36 -38 show a general wiring layout for power and signal wire routing to the 209 door, between the door motor and encoder, light curtains or photoeyes, the control box, and incoming power. NOTE All wiring and connections are detailed on and must...
  • Page 21 Wiring Layout Continued Figure 38: 209 Electrical Routing, Motor Connections Detail Figure 37: 209 Electrical Routing Detail, Side View ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 22: Mount Lintel Seal

    Insert one end of the lintel seal into the light curtain channel in the face frame extrusion, above the end of the channel ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 23 Figure 43: Positioning Lintel Seal Curtain channel in face frame extrusion Lintel seal assembly Lintel seal filler block Figure 42: Lintel Seal And Clip Detail Figure 44: Lintel Seal Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 24: Shroud Installation

    Idler side end cover supports supports Figure 45: Mounting Shroud Components NOTE Shroud install steps show install for a RH door. Install for a LH door is the same, but mirrored to the opposite side. ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 25 3 screws, p/n 41a1075 (see figure #46) On the other end of the lower shroud support(s), Figure 47: Mounting there is a small hole for attaching to the extrusion of panel #1 (the bottom panel) Clip Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 26 #2 and push into place to fully seat the panel into the slot in the extrusion (figure #51) and fasten using three 1/4-20 x 1/2” screws (P/N 41A1074) Figure 49: Mounting Panel #1 (Bottom Panel) ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 27 (Figure #54). Figure 52: Mounting Panel #4 (Front Top Panel) Center mounting clips attach to holes in spreader bar stiffeners Figure 50: Mounting Panel #2 (Front Bottom Panel) Figure 53: Mounting 5th (Top) Panel ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 28 Peel off the protective coating and discard End cover with velcro pads Velcro pads on end cover supports Score protective coating on each panel along extrusions & remove coating Figure 55: Mount End Covers, And Remove Protective Coating On Panels ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 29: Electrical Startup

    Provides programming and setup menus, and provides error indications OPEN Button Display (visible through window STOP Button in enclosure) CLOSE Button Wall-Mounted Enclosure Power Disconnect Figure 56: Control Enclosure Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 30 Up Button Down Button Standard Inputs Encoder Connection RS 485 COM Terminal Block Configurable Inputs Terminal Block Control Output Power Output Relay Terminal Terminal Block Block Motor Connection Braking Resistor Figure 57: Controller Features Connection ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 31 Terminal blocks for connecting the motor are located on Motor Connections the bottom of the controller The braking resistor is supplied in the enclosure, Braking Resistor Connection pre-wired behind the subpanel ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 32: Controller Functions

    The code request screen shown at left appears when a menu is protected by an access code Use the ▲ and ▼ buttons to enter the code, then press the Menu/Enter button to accept the code ASI DOORS, INC. (800) 558-7068...
  • Page 33 The table at the right refers to the numbers by each Tech Support Level 1 menu item Different menu items have different levels Tech Support Level 2 of security, and higher level items require a higher OEM Level level password to access ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 34 To edit the time interval, use the ▲ and ▼ buttons to select the desired value, then press the menu/enter button to store it The message stored is briefly displayed, then the screen returns to the express menu Setting the value to zero disables the manual close timer ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 35 Provides the ability to jog the door using the ▲ and ▼ buttons Any connected safety inputs are ignored to allow unrestricted door movement Any connected safety devices are ignored to allow unrestricted door movement ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 36: Setting Door Limits

    Adjust position and press Menu/Enter Repeat as needed for either position When complete the controller must be returned back to the main screen Press and HOLD the Menu/Enter button until on the main screen ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 37: Warning Labels

    (Figure 62) The bottom of the warning label should be approximately 60” from the floor Figure 62: Warning Label Installation, Figure 61: Warning Label Installation, Wall Mount Face Frames ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 38: Pair Transmitter & Controller

    It is recommended that you mount it with the button against the bottom bar to prevent accidental un-pairing “Pairing” button on Transmitter Wireless Transmitter (23B154) Figure 64: Wireless Transmitter Detail Figure 65: Controller Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 39: Maintenance

    Do not clean Acrylic polycarbonate in direct sunlight or at high temperatures as this can lead to staining • For all mentioned chemicals consult the manufacturer’s material safety data sheet (MSDS) for proper safety pre- cautions • Do not use alcohols ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 40: Preventative Maintenance

    Inspect Bottom Bar Inspect Electrical Control Box and Terminal Connection (4.4 Lbs. of Torque) Inspect Windows Door Lubrication and Cleaning Inspect Bearings and Locking Collars Inspect Operator Assembly Braking Inspection Inspect Curtain Connecting Links ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 41: Preventative Schedules

    The cycle counter is located in the control box. signs of wear or damage Replace as needed Recording daily inspections is usually not necessary. ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 42: Troubleshooting

    4 Ensure correct line voltage 1 Brake lining completely worn 1 Replace brake assembly G Door does not stop consistently 2 Air gap has increased to point 2 Reset brake where adjusting nuts are up tight ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 43: Error Codes

    Decrease the acceleration ramps Overcurrent DC/ View the Motor Current display to see the current Brake (Medium Over current while DC braking delivered to the motor Decrease the DC brake Priority) level ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 44 View the System Status - Int Levels to check Low internal 24V (Top The internal 24VDC power supply that the voltage is within range Check I/O Priority) voltage is too low wiring for shorts ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 45 Check the connections from the reversing edge to the Safety Edge Test Fail The reversing edge test controller If using the SeyWave wireless system, check (Medium Priority) has failed operation of connected host and remote door sensor ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 46 Communication with the Check the connections between the encoder and the Comm Loss (Top absolute encoder has been controller Priority) lost Installation Fault An error occurred during Re-perform quick setup (Low Priority) quick setup ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 47 Can also be reset by higher priority reset Activation input conditions Can also be reset by higher priority reset Medium Stop, E-Stop or Menu/Enter button pressed conditions High Menu/Enter button pressed Priority Reset Limits Successful quick setup ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 48: Replacement Parts

    For more specific parts information, please contact an authorized representative or consult the factory’s customer service or engineering departments Asi doors reserves the right to discontinue any part and make design changes without notice...

  • Page 49: Door Identification

    Manufacture Date Figure 66: ASI Door Label ID Tag Location ASI Doors ID Tag Figure 67: Label Location When ordering parts, have your ASI job number and door number available. ASI DOORS, INC.

  • Page 50: Left Hand Face Frames

    ASM, BASE, SIDE FRM, LH, W/ DUAL P/E 76B0056LV EXTRUSION, VERTICAL COLUMN 44B0056 HANGER, SPREADER BAR 13B2736NN10 WEAR STRIP, SIDE COLUMN, 209, HIC + 25 31” 11B0314 GASKET, 1 0”,GREY VINYL, HIC + 25 31” 15A009 PHOTOEYE, TRANSMITTER 23B0124-T PHOTOEYE, RECEIVER...

  • Page 51: Right Hand Face Frames

    ASM, BASE, SIDE FRM, RH, W/ DUAL P/E 76B0056RV EXTRUSION, VERTICAL COLUMN 44B0056 HANGER, SPREADER BAR 13B2736NN10 WEAR STRIP, SIDE COLUMN, 209, HIC + 25 31” 11B0314 GASKET, 1 0”,GREY VINYL, HIC + 25 31” 15A009 PHOTOEYE, TRANSMITTER 23B0124-T PHOTOEYE, RECEIVER...

  • Page 52: Header Assembly

    ASM, TORQUE TUBE, RH, 2” DRIVE 2 24B0952NN ASM, CAM FOLLOWER NOTE When ordering parts, specify Torque tube assemblies are sub-components of Job Number, Door Number the header assemblies listed, and are listed for and Manufacture Date reference ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 53: Gear Motor Assembly

    2.0” 1.5” 1.5” DESCRIPTION PART # ITEM # OPTION, DRIVE, 1 5” DRIVE, RH, 209 G2 55B0149F01 OPTION, DRIVE, 1 5” DRIVE, LH, 209 G2 55B0149F02 OPTION, DRIVE, 2” DRIVE, RH, 209 G2 55B0150F01 OPTION, DRIVE, 2” DRIVE, LH, 209 G2 55B0150F02 GEARMOTOR, 1 5”...

  • Page 54: Curtain Assembly

    Curtain Assembly ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 55 AR ASSEMBLY, VISION SLAT 24B0959NV AR ASSEMBLY, ENDCAP LINK 24B0824NN AR ASSEMBLY, ADJUSTABLE LINK 24B0945NN AR ASSEMBLY, HYBRID LINK CAP 24B0935NN ASSEMBLY, TOP SLAT, 209 24B0971NV ASSEMBLY, BOTTOM BAR, 209 24B0970NV END CAP, BOTTOM BAR, MACHINED 14B0324NN AR SEAL, SLAT HINGE 15B0062 EXTRUSION, LIVE EDGE ADAPTER, WIC + 3 03”...

  • Page 56: Addendum's

    Assembly Replacement This bulletin is an addition to the standard owner’s manual for the 209 apex dura & vision doors All warranties, safety practices and warning descriptions pertaining to this door can be found in on page xx, and apply to procedures and instructions contained in this bulletin...
  • Page 57 Adjustable Link on Hybrid Link on right left side of Header side of Header DO NOT remove vertical guide covers Covers need to remain in place to hold curtain in position Figure 3: Link Assembly Locations ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 58 Temporarily use a piece of tape to hold the hybrid link assembly against the wall and away from the barrel assembly Secure hybrid link assembly in vertical position, away from barrel assembly Figure 5: Unattach Hybrid Link Assembly From Slat Wheel ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 59 Make sure you are moving barrel assembly OUT not IN Figure 6: Mark reference line on drive sprocket Mark sprocket in-line with Manual operation rib on motor casting pull cords Manual operation drive chain Figure 7: Manual Operation Controls ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 60 Hole in top link of curtain on right side of header (Adjustable link assembly side) Figure 9: Top Link Of Curtain, Left Side Of Header ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 61 (3 full links, & hybrid link) to the top slat link on the curtain Unattach hybrid link from top link on curtain and remove Figure 11: Remove Hybrid Link Assembly From Curtain ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 62 Attach new adjustable link assembly to curtain on left side of header Figure 13: Top Link of Curtain, Right Side of Header Figure 14: Move Barrel Back To Original Position ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 63 Use the following hardware to attach the adjustable link assembly to the slat wheel: 5/16” x 3/4” shoulder screw (P/N 41A1056) Figure 17: Attach Hybrid Link Assembly To Slat Wheel Figure 18: Adjustable Link Hardware ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 64: Reversing Edge & Wireless Transmitter Replacement

    Wireless Transmitter Replacement This bulletin is an addition to the standard owner’s manual for the 209 apex dura & vision doors All warranties, safety practices and warning descriptions pertaining to this door can be found in the original owner’s manual, and apply to procedures and instructions...
  • Page 65 Block curtain for easier access to components Figure 2: Block Curtain ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 66 5/16 x 3/4 shoulder screws (41a1056) in endcap links from both ends of slat (figure # 4) Remove entire slat assembly and lay on a work surface with the transmitter facing up 5/16 x 3/4 Figure 4: Remove Bottom Bar Assembly Shoulder Screws (41A1056) ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 67 & blue wires for connection To be able to make connections, you may need to pull the wire-nuts off the tape that is holding them in place while you are working ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 68 “T” profile with a soap water solution to make sliding it into the extrusion easier. Pull the wires of the new reversing edge through the hole for the transmitter. Figure 7: Reversing Edge Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 69 (2) 1/4-20 X 2 00” screws (41A1070), and tighten If you also replaced the wireless transmitter, go to the “pairing” procedure before re-mounting the wireless transmitter Figure 9: Channel Cut in End Cap ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 70 It is recommended that you mount it with the button against the bottom bar to prevent accidental un-pairing “Pairing” Button on Transmitter Wireless Figure 11: Controller Detail Transmitter (23B154) Figure 10: Wireless Transmitter Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 71 Slide along the gasket for a short distance (12” or so) Switch sides and work from center in the opposite direction roughly the same distance until the center 2 ft Or so of the gasket is seated ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 72 11 Replace face frame covers, replace screws holding covers in place, and tighten Hinge gasket inserted between 2 slats Squeeze triangular ribs together when inserting gasket This side to outside Gasket Rib of Slat Figure 14: Hinge Gasket Detail Figure 15: Hinge Gasket and Slat Detail ASI DOORS, INC. (800) 558-7068 asidoors.com...

  • Page 73: Slat & Hinge Gasket Replacement

    Slat & Hinge Gasket Replacement This bulletin is an addition to the standard owner’s manual for the 209 apex dura & vision doors All warranties, safety practices and warning descriptions pertaining to this door can be found in the original owner’s manual, and apply to procedures and instructions...
  • Page 74 (Figure 2) Side Frame Extrusion Covers Figure 1: Remove Side Frame Covers Block curtain for easier access to components Figure 2: Block Curtain ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 75 On slat(s) to be replaced, loosen and remove two ¼”-20 screws in end cap links from both ends of slat(s) (Figure 4) Endcap Link Remove 1/4”-20 Screws Figure 4: Remove Screws from End Cap Links ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 76 (Figure 5) If slat is too tight to remove, loosen (but do not remove) screws on endcap links of slats above and below slat to be removed Be sure to re-tighten these screws after replacing slat(s) Figure 5: Remove Slat ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 77 Replace ¼”-20 screws, and tighten Tighten ¼”-20 screws on adjacent slats above and below if they were loosened in removing slat Repeat on other side Figure 6: Slat and Endcap Link Profile Figure 7: Install New Slat ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 78 10 Check and re-tighten any screws on endcap links loosened in Figure 10: Hinge Gasket and Slat Detail previous steps 11 Replace face frame covers, replace screws holding covers in place, and tighten ASI DOORS, INC. (800) 558-7068 asidoors.com...
  • Page 79 ASI DOORS, INC. 5848 North 95th Court, Milwaukee, WI 53225 (800) 558-7068...

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