I ARTING LEANROOM OORS - Construction

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2

reversing photoeye 2

3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C

24 VDCsensor outside

emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery m

odule 50motor rot. direction

jumper C9–C10 = clockwise (EB/ER)

no jumper

= anticlockwise (EL)

A = with

B = without

J1AB automatic system configuration

A = yes (run system reset)

B = no

Art. KAU0005

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery m

odule 50motor rot. direction


no jumper

= anticlockwise (EL)

A = with

B = without



B = no

Art. KAU0005

1-800-558-7068www.asidoors.com© 2004, ASI Technologies, Inc. Manual Part number: 17A225-061009

BI-PARTING LXP CLEANROOM DOORS

OWNER’S MANUAL

MODELS

170 LXPMANUAL – BI-PARTING

160 LXPPOWER – BI-PARTING

Do not install, operate or service this product unless you have read and understand the SafetyPractices, Warnings, Installation and Operating Instructions contained in this manual. Failureto do so could result in property damage, death or serious injury.

Page 2 ©2004 ASI Technologies, Inc. Manual Part Number: 17A225-0610091-800-558-7068

170 LXP Manual & 160 LXP Power – Bi-Parting

GENERAL INFORMATION

Safety PracticesThis is the safety alert symbol. It is used to alert you topotential personal injury hazards. Obey all safety messagesthat follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situationwhich, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situationwhich, 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 apotentially hazardous situation which, if not avoided, mayresult in property damage.

NOTE explains general information.

Manual Part Number: 17A225-061009 ©2004 ASI Technologies, Inc. Page 31-800-558-7068


GENERAL INFORMATION

1. Do not operate the SLIDING 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 properly. Advise yoursupervisor at once.

3. Stay clear of the door when it is moving.

4. Keep hands, feet and head clear of the door at all times.

5. Do not operate the door with equipment, material or people directly inside door opening.

6. Disconnect power before performing any electrical or mechanical service, cleaning or othermaintenance on the door. OSHA requires disconnect to be properly tagged and locked out duringall maintenance or service of equipment. With the power supply disconnected, always verify usinga volt meter.

7. All electrical troubleshooting or service must be completed by a qualified electrician or serviceperson and must meet all applicable local, state, federal, international and other governingagency codes.

8. When it is necessary to service the control box with power on, USE EXTREME CAUTION. Do notplace fingers or uninsulated tools inside the control box. Touching wires or other parts inside theenclosure may cause electrical shock, serious injury or death.

9. It is your responsibility to keep all warning labels and instructional literature legible, intact andkept with the door. Replacement labels and literature are available from ASI Technologies, Inc.or its representatives.

10. If you have any questions, contact your supervisor or your local ASI Technologies, Inc.representative for assistance.

11. Train all service and personnel using or near door on intended use(s) and operation of the door.

12. Failure to operate the door as intended, as described, or heed any warning may result inequipment damage, property damage, serious bodily injury or death.

Read these safety practices before installing, operating or servicing the SLIDING door. Failureto follow these safety practices could result in property damage, death or serious injury.

READ AND UNDERSTAND ALL WARNING LABELS AND OPERATING INSTRUCTIONS IN THISMANUAL BEFORE OPERATING THE SLIDING DOOR. If you do not understand the instructions,ask your supervisor to teach you how to use the SLIDING door.

Safety Practices Continued



GENERAL INFORMATION

ASI Technologies, Inc. (herein called "ASI") warrants solely for the benefit of its customer that each doorsystem manufactured by ASI (each a "Door System") will be free from defects in material and manufacture fora period of one (1) year from the date of original shipment by ASI. The foregoing limited warranty shall notapply to defects which result from improper installation, abuse, misuse, alteration, modification or failure tomaintain the Door System in accordance with the ASI Owner's Manual. Periodic lubrication and adjustment ofthe Door System as described in the ASI Owner's Manual are the sole responsibility of the customer. Allclaims for defects must be made to ASI within thirty (30) days after the defect is discovered or should, withreasonable care, have been discovered. THE FOREGOING LIMITED WARRANTY CONSTITUTES THEEXCLUSIVE WARRANTY OF ASI WITH RESPECT TO THE DOOR SYSTEM. ASI EXPRESSLYDISCLAIMS ALL OTHER GUARANTEES OR WARRANTIES—WHETHER EXPRESS, IMPLIED, ORSTATUTORY—INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE.

If a Door System does not comply with the foregoing limited warranty, and a claim is made by customer withinthe applicable warranty period, ASI will, at the option of ASI, either repair or replace any defective equipment orparts 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 foregoinglimited warranty.

ASI SHALL NOT IN ANY EVENT BE LIABLE FOR ANY INCIDENTAL, INDIRECT, SPECIAL, EXEMPLARYOR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING WITHOUT LIMITATION ANY LOSTPROFITS, ARISING FROM THE SALE OR USE OF THE DOOR SYSTEM, OR FROM ANY OTHER CAUSEWHATSOEVER, WHETHER THE CLAIM GIVING RISE TO SUCH DAMAGES IS BASED UPON BREACHOF WARRANTY (EXPRESSED OR IMPLIED) BREACH OF CONTRACT, TORT, STRICT LIABILITY OR ANYOTHER 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 ASICONCERNING 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 hasbeen made, F.O.B. ASI's facility with freight prepaid. The customer is responsible for any removal costs.

The customer shall comply with the following procedures in filing a warranty claim with ASI:

1. Notify ASI of any and all defects in writing. ASI will review the warranty request and issue a ReturnsGoods Authorization (RGA) form if the defective parts need to be returned to ASI for inspection andverification. 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 DoorSystem 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 ofthe labor charges in advance so ASI may approve the labor charges and issue a purchase order. ASI willnot accept any labor charges unless previously approved by ASI and accompanied by the ASI purchaseorder 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 installationcontractor. Periodic adjustments and normal maintenance are the responsibility of the customer.

ASI Technologies, Inc. Warranty Policy



GENERAL INFORMATION

CleanSeal® Bi-Parting Cleanroom Doors

Do not install, operate or service this product unless you have read and understand the SafetyPractices, Warnings and Installation and Operating Instructions contained in this manual.Failure to do so could result in property damage, death or serious injury.

Warranty

General InformationBegins on Page 2

Safety Practices Page 2Warranty Policy Page 4Crates and Contents Page 6

Installation170 LXP Manual Begins on Page 8

Door Measurements Page 9Frame and Header Assembly Page 10Panel Installation & Adjustment Page 12

160 LXP Power Begins on Page 14Door Measurements Page 15Frame and Header Assembly Page 16Panel Installation & Adjustment Page 19Warning Label Installation Page 20Electrical Controls Page 21Electrical Equipment Page 25Start-Up Page 26Activator Signals Page 27Control Panel Operation Page 27Setting Operating Modes Page 28Changing Door

Operating Parameters Page 29

MaintenanceBegins on Page 31

Inspection Page 31Preventative Page 31Troubleshooting Page 32Fault Diagnosis Page 32

Replacement PartsBegins on Page 34

Instructions for Ordering Page 34Door Identification Page 35ID Tag Location Page 35Door Assembly Page 36Header Assembly and Shrouds Page 37Door Panel Assembly Page 38Face Frame Assembly Page 39



GENERAL INFORMATION

Crates and Contents

SIDE FRAMES HEADER

SHROUD

CRATE 2

DOOR PANEL

CRATE 1

LOOSE PARTS BOX

Figure 1: Crates and Contents



GENERAL INFORMATION

Crates and Contents Continued

Upon receipt of the shipment, check that you have received the correctnumber of pieces as shown in (Figure 1). Crate one will contain the doorpanels. Crate two will contain the header, shroud, controls and sideframes. For your protection, note any damages or shortages on thecarrier’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 forklift. Select a fork lift with lifting height based upon the height of the doorplus a minimum additional two feet.

Because of variances in the construction of walls on which the doorwill be mounted, fasteners are not supplied. For proper anchoringof the door, we recommend the use of thru-bolts. DO NOT removedoor sections from crate until you encounter the step in which theyare to be installed.

For INSTALLATION of a 170 Manual – Bi-Parting Door turn to page 8.For INSTALLATION of a 160 Power – Bi-Parting Door turn to page 14.

Installation Instructions . . . . . . . .1Warning Nameplate Assembly . .2

Misc. Hardware . . . . . . . . . . . . . .–Misc. Activation Devices . . . . . . –

DESCRIPTION QTY. DESCRIPTION QTY.

Loose Parts Box:

MODEL

170 LXPMANUAL – BI-PARTING

INSTALLATION

170 LXP Manual – Bi-Parting


21/2"

WIDTH(W.I.C. × 2) + 9"

21/2"

OPENING WIDTH(W.I.C.)

HEIGHT(H.I.C.)

CLEARANCE FOR SLIDING(W.I.C. + 31/2")

2

HEIGHT(H.I.C. + 111/2" max. for Standard Panel)

(H.I.C. + 141/2" max. with Breakout Option)

INSTALLATION



Door Measurements1. Measure door opening to verify door

dimensions (Figure 3). Based upon dimensionsin Figure 3, determine that door will havesufficient wall space to open. The side frameswill fit flush to the edge of the opening. Figure 2: Wall Clip Position

W.I.C

WALLCLIP

WALLCLIP

W.I.C. + 3/8"3/16"

Figure 3: Door Measurements

Figure 5: Mounting Headerand Face Frames

Figure 4: Checking Plumb and Square

WALL CLIPS

INSTALLATION



Frame and Header Assembly1. Attach wall clips to the wall, flush with the

edge of the opening, LEAVING THE BOTTOM2 BOLT HOLES OPEN FOR THE FLOORHARDWARE (Page 9, Figure 2).

2. Attach both bottom roller brackets to the wallthrough the two holes in bottom of wall clip(Figure 6).

3. Attach the face frames with 2 screwsper frame (Figure 7).

Recheck wall clips to be sure they are plumband level. Make any necessary adjustments.

Figure 6: Installing Wall Clips and Roller Brackets

WALLCLIPS

ROLLERBRACKETS

Figure 7: Fastening Face Frame to Wall Clip

SCREW

TOP VIEW(LEFT SIDE)

FACEFRAME

WALL CLIP

SCREWLOCATION

INSTALLATION



4. Remove the shroud from the header byremoving 4 screws on top of the shroud and 4screws on the bottom splice bracket.

5. Position the header on top of the side clipsand center it in the door opening. Use thecenter shroud brackets as a guide.

6. Mount the header to the wall. Use the holesprovided in the header to mount it to the wall(Page 12, Figure 9).

Improper installation of anchoring devices,installation into aged or unsound concreteor mounting to a non-plumb wall withoutproper shimming; could result in prematureproduct wear or product failure. Failure toproperly install equipment could result inproperty damage.

We strongly recommend that thru-holes bedrilled for proper anchoring of the door tothe wall.

When mounting rail, keep personnel out of thearea below the header until the rail is securedto the wall. Failure to do so could result inproperty damage, death or serious injury.

Figure 8: Positioning the Header

CL = 1/2 W.I.C.

CL

Frame and Header Assembly Continued

INSTALLATION



Panel Installation and Adjustment

Figure 9: Attaching Panel to Header

SEAL EXTENSION FORBREAKOUT EGRESS

(OPTIONAL)

SEAL EXTENSION FORSTANDARD PANEL

MOUNTING BOLTS(BY OTHERS)

VERTICAL PANELADJUSTMENT BOLT

HORIZONTAL PANELADJUSTMENT BOLT

DOOR PANEL

GASKET

HEADER

END OF TRAVEL BUMPERSHROUD

MOUNTINGBRACKET

1. Loosen the two horizontal panel adjustingbolts on top of each panel(s). These bolts willslide between the two forks on the paneltrolley bracket in the header (Figures 9 & 10).

2. Measure the distance between the mountingbolts on the panel and manually position the paneltrolleys the same distance apart in the header.

3. Manually position the bottom of the panel overthe guide roller. Then move the panel intoposition so the two adjusting bolts are locatedon the forks of the panel trolleys.

4. Position the panel horizontally to provide aconsistent seal and tighten the horizontalpanel adjusting bolts.

5. Back off the roller truck locking bolts on the

INSTALLATION



Panel Installation and Adjustment Continued

Figure 10: Adjusting Bolt Locations

ROLLER TRUCKLOCKING BOLTS VERTICAL PANEL

ADJUSTMENT BOLTS

SLIDEPANEL

panel trolleys and use the vertical paneladjustment bolts to position the panel at thedesired height. The panel gasket should havecontact with the floor for proper sealing.Tighten the locking bolts to secure the panel.

6. Manually operate the door and visually inspectto ensure the gasket is making contact aroundthe perimeter of the opening. Make anyadjustments necessary to maintain a seal.

7. Manually operate the door panels open andclosed. Verify that door panels clear theopening and contact bumpers at the end ofopen and close travel.

8. If bumpers require adjustment, loosen thesocket head set screws on the bumperbracket and slide the bumper into position asneeded. Lock the set screws down.

Minimal contact is all that is necessary toprovide a tight seal. This will also extend thelife of the gasket.

INSTALLATION

160 LXP Power – Bi-Parting


MODEL

160 LXPPOWER – BI-PARTING

INSTALLATION



Door Measurements1. Measure door opening to verify door

dimensions (Figure 12). Based upon dimensionsin Figure 12, determine that door will havesufficient wall space to open. The side frameswill fit flush to the edge of the opening. Figure 11: Wall Clip Position

W.I.C

WALLCLIP

WALLCLIP

W.I.C. + 3/8"3/16"

Figure 12: Door Measurements

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery module 50

motor rot. direction


no jumper = anticlockwise (EL)

A = with

B = without



B = no

Art. KAU0005

WALL CLIPS

Figure 14: Mounting Headerand Face Frames

Figure 13: Checking Plumb and Square

HEIGHT(H.I.C. + 111/2" max. for Standard Panel)

(H.I.C. + 141/2" max. with Breakout Option)

21/2"

WIDTH(W.I.C. × 2) + 10"

21/2"

OPENING WIDTH(W.I.C.)

HEIGHT(H.I.C.)

CLEARANCE FOR SLIDING(W.I.C. + 31/2")

2

INSTALLATION



Figure 16: Fastening Face Frame to Wall Clip

SCREW

TOP VIEW(LEFT SIDE)

FACEFRAME

WALL CLIP

SCREWLOCATION

Frame and Header Assembly1. Attach wall clips to the wall, flush with the

edge of the opening, LEAVING THE BOTTOM2 BOLT HOLES OPEN FOR THE FLOORHARDWARE (Page 15, Figure 11).

2. Attach both bottom roller brackets to the wallthrough the two holes in bottom of wall clip(Figure 15).

3. Remove the shroud from the header byremoving 4 screws from the top of the shroudand 4 screws on the bottom splice bracket.

4. Locate photoeye cables on back of headerand identify each pair of wires by its locationnear the grommeted holes in the bottom edgeof the header. You will be installing one set ofan emitter and receiver on each side frame. Itmust match up with the corresponding emitterand receiver on the other side frame. Removethe emitter and receiver heads from each wirefor installation into face frames .

Recheck wall clips to be sure they are plumband level. Make any necessary adjustments.

Figure 15: Installing Wall Clips and Roller Brackets

WALLCLIPS

ROLLERBRACKETS

INSTALLATION




5. Position the photoeyes in the face frames inpairs of emitter and receiver. The wires arecolor-coded blue or gray. Emitters are grayand receivers are blue. Match wire colors andinstall the photoeyes as shown in Figure 18(Page 18).

6. Use self-adhesive clamps and ties provided tohold the wiring in place and contain any extralength of wire.

7. Position the header on top of the side clipsand center it in the door opening. Use thecenter shroud brackets as a guide (Figure 17).

When mounting rail, keep personnel out of thearea below the header until the rail is securedto the wall. Failure to do so could result inproperty damage, death or serious injury.

The emitter cable (gray) can be shortened orlengthened, the receiver cable (blue) mayonly be shortened but not lengthened.

Figure 17: Positioning the Header

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10





A = with

B = without



B = no

Art. KAU0005

CL = 1/2 W.I.C.

CL

INSTALLATION



Figure 18: Connecting to Photoeyes

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10





A = with

B = without



B = no

Art. KAU0005

BLUE

BLUE

GRAY

GRAY

8. Make sure the photoeye cables come out ofholes provided in the bottom of the header anddo not get cut or pinched during positioning.Mount photoeye sensors as shown inFigure 18. Pay attention to colors of photoeyewires (Figure 18).

9. Mount the header to the wall. Use the holesprovided in the header to mount it to the wall(Page 19, Figure 20).

10. Connect the power cord to the 115VACgrounded power inlet on the TCP-51CONTROL UNIT (Page 23, Figure 25). Verifythat the voltage setting on the control unit isset to 115VAC. Then route the cord throughthe header and out to the power source.

Make sure the edges of all routing holes of thepower cord are smooth and have any burrsremoved. Use tie wraps or clips to make surepower cord is secure inside the header, and willnot contact any moving parts inside the header.

DO NOT plug into 115 VAC power at this time.

Improper installation of anchoring devices,installation into aged or unsound concreteor mounting to a non-plumb wall withoutproper shimming; could result in prematureproduct wear or product failure. Failure toproperly install equipment could result inproperty damage.

We strongly recommend that thru-holes bedrilled for proper anchoring of the door tothe wall.


INSTALLATION



Panel Installation and Adjustment1. Loosen the two horizontal panel adjusting

bolts on top of each panel(s). These bolts willslide between the two forks on the paneltrolley bracket in the header (Figures 19 & 20).

2. Measure the distance between the mountingbolts on the panel and manually position the paneltrolleys the same distance apart in the header.

3. Manually position the bottom of the panel overthe guide roller. Then move the panel intoposition so the two adjusting bolts are locatedon the forks of the panel trolleys.

4. Close both door panels to provide aconsistent center and edge seal and tightenthe bolts.

5. Back off the locking bolts on the panel trolleys

Figure 20: Attaching Panel to Header

SEAL EXTENSION FORBREAKOUT EGRESS

(OPTIONAL)

SEAL EXTENSION FORSTANDARD PANEL

MOUNTING BOLTS(BY OTHERS)

VERTICAL PANELADJUSTMENT BOLT

HORIZONTAL PANELADJUSTMENT BOLT

DOOR PANEL

GASKET

HEADER

END OF TRAVEL BUMPERSHROUD

MOUNTINGBRACKET

Figure 19: Adjusting Bolt Locations

HORIZONTAL PANELADJUSTMENT BOLTS

ROLLER TRUCKLOCKING BOLTS VERTICAL PANEL

ADJUSTMENT BOLTS

SLIDEPANEL

INSTALLATION



1. Install warning label(Figure 21) to wall asshown in Figure 22.

Do not apply where doorpanel will cover whendoor is open. Applywarning label next topush plate.

Figure 22: Warning Label Installation

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10





A = with

B = without



B = no

Art. KAU0005

WARNING

ASI TECHNOLOGIES INC.

17C024

This sliding door is designed

for vehicular and trained

pedestrian traffic. 1.

Operation may be automatic.

Keep doorway clear at all

times. 2.

Door impact may cause

personal injury or property

damage.3.

Failure to head these

warnings may result in

equipment and/or property

damage and/or perosnal or

fatal injury.

4.

58"

LABEL

PUSHPLATE

DOOR OPEN POSITION

Figure 21: Warning Label

WARNING

ASI TECHNOLOGIES INC. 17C024

This sliding door is designed for vehicular and trained pedestrian traffic.

1.

Operation may be automatic. Keep doorway clear at all times.

2.

Door impact may cause personal injury or property damage.

3.

Failure to head these warnings may result in equipment and/or property damage and/or perosnal or fatal injury.

4.

Warning Label Installation

and use the vertical panel adjustment bolts toposition the panel at the desired height. Thepanel gasket should have contact with thefloor for proper sealing. Tighten the lockingbolts to secure the panel.

6. Manually operate the door and visually inspectto ensure the gasket is making contact aroundthe perimeter of the opening. Make anyadjustments necessary to maintain a seal.

7. Manually operate the door panels open andclosed. Verify that door panels clear theopening and contact bumpers at the end ofopen travel.

8. If bumpers require adjustment, loosen thesocket head set screws on the bumperbracket and slide the bumper into position asneeded. Lock the set screws down.

Minimal contact is all that is necessary toprovide a tight seal. This will also extend thelife of the gasket.

Panel Installation and Adjustment Continued

INSTALLATION



OUT 1OUT 2OUT 3OUT 4OUT 5OUT 6

A B

MICROPROCESSORCONTROLLER

P1 P2

A B C D

MAINSCONNECTION

I/OMODULE 1(OPTIONAL)

SEE NOTE 1

MOUNTINGBRACKET

POSITIONENCODER

BRAKE

TRANSFORMER POWERINPUT

MODULE

MOTOR

FUSE

BATTERYBACKUP

CONTROLUNIT

EEPROM

CONTROLPANEL

SERCOMPROGRAMMER

RECEPTICAL

PHOTOEYEMODULE

TERMINALCONNECTOR

INPUT/OUPUTMODULE

Figure 23: TC-P51 Operator

Electrical Controls

The microprocessor control system is designed specifically for ASI Technologies Doors. Themicroprocessor programmed self-diagnostic features convey both door status and troubleshootingindicators through individual LED’s. Additional inputs are available for automatic door opening.Troubleshooting time is significantly reduced since the LED indicator lights direct you to specificproblems. Initial electrical hookup is made easy with conveniently located plug-in type 115 VAC powerconnectors. Individual adjustment of opening and closing speed, automatic “Time to Close” and“Partial Opening” offer flexibility of adjustment for existing or future applications.

INPUT POWERThe nominal supply voltage for the control panel is 115 VAC. Be sure to verify this voltage supply isavailable. The control unit provides 24 VDC for other sensing and electrical devices.

Control box contains HIGH VOLTAGE! The following procedures should be performed byqualified 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.

INSTALLATION



BRANCH CIRCUITPROTECTION AND DISCONNECTING

PROVIDED BY OTHERS

POWER SUPPLYN

PE

L1

IN GN

D

E-S

TOP

C2

C3

INS

IDE

OU

TSID

E

B9

B10

B8

CLO

SE

OU

TOP

EN

TRANSFORMER

4

1

3

6

(ORANGE)

(WHITE)

(YELLOW)

(PURPLE)

(RED)

(RED)

EP1(YEL/GRN)

1

2

5 AMPS

F1

+20...42 VDC (MOTOR, LOCK, BRAKE)

+24 VDC (SENSORS, INPUTS, OUTPUTS)

+5 VDC (PROCESSOR, ENCODER)

PH

20

PH

2A

C

PH

10

PH

1A

C

KLI

XO

N

BR

AK

E

++CONTROL

UNIT4

(WH

ITE)

(BR

OW

N)

2

BRAKE

(BLU

E)7

(GR

EY)

5

(YEL

LOW

)

(PU

RPL

E)

61

(GR

EEN

)

(RED

)

3 8

2 OHMSTH PH 1 PH 2

2 OHMS

MOTOR

(WH

ITE)

(BR

OW

N)

V1

V2

(GR

EY)

(YEL

LOW

)

(GR

EEN

)

V4

V3

V6

CO

IL

CO

IL

LOC

KE

D

UN

LOC

KE

D

GN

D

1 2 3 4 6

I/OMODULE

(E11

)

(E12

)

(E14

)

(E11

)

(E12

)

(E14

)

TERMINAL BLOCKS

B1

B2

B3

B5

B6

GN

D

IN IN IN OU

T

OU

T

OU

T

OU

T

24V

DC

GN

D

IN GN

D

IN E.P

B

C1

C4

24V

DC

24V

DC

GN

D

GN

D

IN IN 24V

DC

D2

D1

C3/C8(RED)

24VDC

C3/C8(RED)

(GR

AY)

SEENOTE 2

SEENOTE 2

RADIO CONTROLS

(OPTIONAL)

(YEL

LOW

)

SEENOTE 2

(YEL

LOW

)

(GR

AY)

C5/C10(BLK)

TOUCHLESS SENSOR

(OPTIONAL)

(RED)

C5/C10

MOTION DETECTOR

(OPTIONAL)

C3/C8 C5/C10

C5

C6

C7

C8

C9

C10

B7

1 2 3 5 6 87 9 10

B4

4

(BLA

CK)

(RED

)

(WH

ITE)

(YEL

LOW

)

(BLU

E)

(GR

EY)

(GR

EEN

)

(BR

OW

N)

(OR

ANG

E)

(PU

RPL

E)

UP

DO

WN

P. L

OC

K

OFF

AU

TO

AU

TOR

ED

EX

IT

OP

EN

CONTROL PANEL

D3

D4

V7

V8

(PIN

K)7 8

(BLU

E)

* *

AC

TIV

ATO

R

AC

TIV

ATO

R

PUSHPLATE

JUMPER

PUSHPLATE

MOTOR CONNECTOR LOCK CONNECTOR

LOCK(OPTIONAL)

DOOROPEN

DOORCLOSED

(OPTIONAL)

BA

SEENOTE 2

REGULATOR

REGULATOR

GND

NOTE:

By Others

Figure 24: TCP-51 Operator Wiring Schematic

Electrical Controls Continued

INSTALLATION




MAIN POWER CONNECTION: The door issupplied with a grounded power cord.

1. Check that all edges of feed-through holes forthe power cable are smooth and have no burrs.

2. Check the correct setting of the voltageselector (Figure 25).

Disconnect power at the fused disconnectduring all electrical or mechanical service.Disconnect must be properly locked out duringmaintenance or service of equipment. Failureto disconnect power could result in death orserious injury.

Control box contains HIGH VOLTAGE! Thefollowing procedures should be performed byqualified electrical personnel only. Wiringmust meet all local, state, federal andinternational, or other governing agencycodes. Failure to do so could result in deathor serious injury.

Art. KAU0005

VOLTAGESELECTOR

(SET TO 115V)

POWER RECEPTACLEON DOOR OPERATOR

INPUT POWER CABLE115 VAC GROUNDED PLUG

(SUPPLIED WITH DOOR)

Figure 25: Power Cable

INSTALLATION




Figure 26: Photoeye Connections

BLK

GRN

YEL

RED

P-2

P-1

BLUGRY

BLU

WHITE

GRY

SHIELD

REVERSING PHOTOEYE:1. Confirm the wiring to the photoeyes is intact

as shown in Figure 26.

2. Confirm jumper for the emergency stop switchis installed as shown in Figure 27.

3. Connect wiring from wall mount push platesas shown in Figure 27.

4. Connect wiring from optional sensors asshown on Page 22, Figure 24.

Remove the jumper between D1 and D2 ifemergency stop switch is used.

The length of the photoeye cables must notexceed 19'. Do not extend the cable suppliedby ASI!

Figure 27: Electrical Connections

1C

Push Plate Push Plate

GN

DIN G

ND

IN +24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

2 3 4 5 6 7 8 9 10

INSTALLATION



Electrical Equipment

TCP-51 CONTROL UNIT: This microprocessorbased control has the ability to automaticallycalibrate door opening and closing functionswithout the need for limit switches. It is aself-contained door operating unit with a powertransformer, motor, brake and clutch. It opensand closes the door panels with a timing beltdrive and provides controlled acceleration anddeceleration of the door panels for long drive life.It also provides 24V DC to operate optionalactivating devices. The microprocessor hasself-diagnostic capabilities to alert the user to anyoperational problems.

FUNCTION CONTROL PANEL: This panel whichis mounted inside the header provides a touchpad for adjusting operating parameters of thedoor opening and closing cycle. This controlpanel allows adjustment to the door opening andclosing speeds, and adjustment of hold-opentime of the door. If the door encounters sometype of operating fault the control panel has5 LEDs that flash to indicate which 1 of 30 faultsthat has occurred.

REVERSING PHOTOEYE: Two photoeye setsare provided standard on all automatic doors.There is a separate control card that powerseach set. The control card is plugged into theTCP-51 CONTROL UNIT and provides a self-checking function at the end of each open cycle.If the door has not been opened in 20 seconds, itwill then automatically run another self-checkingfunction. The green LED on the control cardflashes during each self check function.

ELECTRONIC REVERSING: During opening orclosing, the door is monitored by electroniccircuits. If the door encounters an obstructionduring closing, it reverses and reopens, remainsopen for a short period, then closes again withreduced speed. If the door encounters anobstruction during opening, it reverses and runsin closing direction for a few inches, stops forawhile and closes (opens if an activator signal isreceived) with a reduced speed.

FAULT DIAGNOSIS: The microprocessor controlcontinuously monitors performance and willdisplay operating faults through a combination offlashing LEDs on the control panel. See a listingof fault codes starting on Page 32.

OVERALL DRIVE/CONTROL SYSTEM

1. The TCP-51 control has a limited number ofwiring inputs, since it needs no limit switchesor reversing edge wiring. The terminal stripthat accepts external wiring is located at thebottom right side of the TCP-51 control.

2. Each reversing photoeye set has a circuitcard that plugs into a socket in the TCP-51control. These cards provide a wiringconnection for each photoeye set and havean LED that indicates operating status. If the

photoeye is operating properly a green LEDis on and it will go off if the beam isinterrupted or connected incorrectly.

3. The Function Control Panel provides themeans to make adjustments to the operatingparameters of the door. Since it is remotelylocated from the TCP-51 control, it has acable that plugs into a terminal strip on theright side of the TCP-51 control.

CONTROL INPUTS

INSTALLATION



Start-Up

1. Position the door in the closed position.

2. Locate the Function Control Panel. Plug theconnector into the receptacle in the TCP-51.Secure the excess cable and bracket so thatthe door can be operated without contactingthe bracket or excess cable.

3. Turn on the power disconnect or plug in thepower cord into a grounded outlet. Makesure the cord is routed to prevent contactwith any moving parts.

4. Press the UP or DOWN button on theControl Panel until the LED next to #2 and Tois lit. The door will automatically perform acalibration run to find the end stops. The doorshould open slowly, stop and close slowly. Itis checking travel open and close positions.

5. Supply an activating signal. The door willopen faster and close at a slower speed. Itwill operate at default speeds set duringthe calibration run above. Themicroprocessor senses panel weight andcalculates braking distances.

6. Supply another activating signal. Themicroprocessor calculates required motortorque during opening and closing.

7. If the customer desires to modify the dooroperating parameters such as opening orclosing speed, hold open time or reduceddoor opening width, see the next two sections.

8. Supply another activating signal to testreversing photoeyes by blocking the lightbeam while door is closing. The doorshould open and remain open until theobstruction has been removed, the doorwill automatically close. Cycle the doorseveral times to verify correct operationby all activators, safety devices andproper seal of the gasket. Make anynecessary adjustments.

9. Test the automatic reversing by blocking thedoor during closing. Cycle the door openand closed again. Supply another input andblock the door during opening.

10. Install the shroud. Shrouds over 10' long willbe made in 2 pieces.

11. Mount 4 brackets on top of header inlocations shown with self drilling andtapping screws.

12. Snap function control panel into steelmounting/splice bracket.

13. Loop excess cable from function controlpanel and secure with tie wraps.

All reversing photoeyes have been tested atthe factory and require only field connection.

Read and understand the start-up procedurein this manual before attempting to power-up the door. Failure to do so could result indamage to the door, personal injury and willnullify all warranties.

INSTALLATION



Activator SignalsInputs C1 & C2 – INSIDE ACTIVATOR: Thisinput is connected to a normally open pushbuttonor other momentary contact that when activated,will open the door. As long as the contact isclosed the door will remain open. When thecontact is reopened, then, after a set time, thedoor will close automatically.

Inputs C6 & C7 – OUTSIDE ACTIVATOR: Thisinput is connected to a normally open pushbuttonor other momentary contact that when activated,will open the door. As long as the contact isclosed the door will remain open. When thecontact is reopened, then, after a set time, thedoor will close automatically. If the one-way orEXIT-ONLY operating function is selected by thecontrol panel, this input is defeated.

Inputs C3 & C4 or C8 & C10 – 24VDC POWER– ACTIVATORS: This power supply can be usedfor optional activators and locks.

Inputs D1 & D2 – EMERGENCY STOPSWITCH: This input requires a normally closedcontact, that when opened during door operationwill immediately cause the door to stop byautomatic braking, after which the door panel canbe moved freely. The door will not operate untilthe contact is re-made and the software is resetby selecting the “OFF” operating mode with thefunction control panel. Then, by changing theoperating node back to “ON”, the door functionsnormally.

Inputs D3 & D4 – KEY SWITCH: This input canbe used to allow opening of the door when otherinputs might be shut off by the control panel,such as in the OFF mode.

Control Panel OperationThe most important element for modifying thedoor operation is the Function Control Panel(Figure 28). It can perform the following:

• Selection of operation mode – there are 5different operating modes that determinethe behavior of the door → Page 28.

• Setting of parameters → Page 29.

• Manual operation (free wheeling) → Page 30.

• Reset (calibration run) → Page 30.

• Fault indication → Starts on Page 32.

Tr

1

To

2

Pr

3

Vo

4

Vc

5

SYMBOL FOROPERATING MODE

DOOR PARAMETER(SEE BELOW FOR

DESCRIPTION)LED

UPKEY

OFF

AUTOMATIC

REDUCEDOPENING

EXIT ONLY

HOLD OPEN

5 O

PE

RAT

ING

MO

DE

S

DOWNKEY

Door ParameterTr Hold-open time with

reduced opening widthTo Hold-open time with full

opening width

Pr Reduced opening widthVo Opening speedVc Closing speed

Figure 28: Control Panel Touch Pad

INSTALLATION



Setting Operating ModesSETTING OPERATING MODE:The continuously illuminated LED indicates thecurrently active operating mode.

1. Press UP or DOWN button until desiredoperating mode is indicated on the panel LED.

Operating Mode OFFDoor Closed and Locked: In the operatingmode OFF the door is closed and cannot beopened by the opening activators – except by akey switch. The door panels are closed andalso locked if an optional lock is installed.

The opening activators will immediately bedeactivated if the operating mode OFF isselected while the door is still open. However,safety beams remain functional which ensuresthat the door will not close if any object blocksthe beams.

Operating Mode AUTOAutomatic Operation: AUTO is the mainoperating mode. Upon a door openingcommand the door opens automatically to fullopening width, stays open until the hold-opentime To has elapsed and closes again.

If the top operating mode (OFF) is left inupward direction, the bottom operatingmode (OPEN) is selected and vice versa.An operating mode is only valid if the LEDhas been lit up for at least 1 second.

Operating Mode AUTOREDAutomatic Operation with Reduced OpeningWidth: In operating mode AUTORED, upon adoor opening command, the door opensautomatically to a reduced opening width, staysopen for the hold-open time Tr and then closesagain.

If a sensor or actuator detects an objectapproaching from the opposite direction duringopening, the door opens a little wider toprovide additional clearance.

This mode is useful to reduce loss ofconditioned air.

Operating Mode EXIT ONLYPlant Closing Mode: In this mode, the dooropens only by inputs wired to the inside room(terminals 1A and 2). However, as long as thedoor is not fully closed, the external inputs(terminals 3 and 4) causes a reversal of thedoor movement. The opening width dependson the previously selected operating mode(AUTO or AUTORED).

This mode is used, for example, during closingtime of a plant and is therefore also called plantclosing mode.

Operating Mode HOLD OPENDoor Remains Open: The door opensimmediately and stays open. The opening widthdepends on the previously selected operatingmode (AUTO or AUTORED).

INSTALLATION



Changing Door Operating ParametersADJUSTING PARAMETERS:The door operating parameters areautomatically set to default values when thesystem is started up. They can, however, at anytime be changed to suit individual requirements.

The parameters are shown on the control panelby letters Tr, To, Pr, Vo and Vc). With eachparameter (Figure 28, Page 27) a specific doorbehavior can be adjusted.

1. Select parameter Tr, To, Pr, Vo, or Vc to beadjusted by pressing UP or DOWN key;➞ corresponding LED lights up.

2. Press both UP/DOWN keys on the controlpanel simultaneously for one second;➞ the LED flashes to indicate that thechanges can be made.

3. Adjust respective parameter by pressingthe UP or the DOWN key once orseveral times.

If, for example, the parameter is to beincreased, the UP key is pressed. Theflashing frequency, as well, changesaccordingly.

If no key is pressed within 60 seconds, theadjustment process is terminatedautomatically and the settings remainunchanged.

4. To store the new parameter setting: press both UP/DOWN keys againsimultaneously ➞ now the LED is againcontinuously illuminated. The new setting isnow in effect.

5. Select the original operating mode bypressing the UP or DOWN key.

All other settings, e.g. acceleration and brakingdistances, are optimized by the microprocessorand may not be changed.

HOLD-OPEN TIMES To and Tr:The hold-open time is the time during which thedoor stays in the open position from the timethe sensors no longer receive any signals.

To (Time open) Hold-open time with fullopening width, active inoperating mode AUTO.

Tr (Time reduced) Hold-open time withreduced opening width,active in operating modeAUTORED.

The hold-open time is to be set so that evenslower users have enough time to pass throughthe door.

Significance of LED Flashes Limit ValuesUP key:faster flashing ➞ shorter hold-open time min: 0 sec.DOWN key:slower flashing ➞ longer hold-open time max: 10 sec.

REDUCED OPENING WIDTH Pr:Pr (Position reduced) Position of the open door

with reduced openingwidth, operating modeAUTORED.

If air loss is to be minimized and/or reducedopening width is desired, it is infinitely variablebetween a minimum of 8" per door panel andthe full opening width.

Significance of LED Flashes Limit ValuesUP key:faster flashing ➞ smaller opening width 16"DOWN key:slower flashing ➞ wider opening width max. opening

If the operating mode AUTORED is set beforethe optimization of the reduced opening width,the door panels move to the desired openingwidth simultaneously with the variation in therhythm of flashing.

INSTALLATION



Changing Door Operating Parameters Continued

SPEEDS Vo and Vc:Vo (Velocity open) Opening speed

Vc (Velocity close) Closing speed

Normally, a higher opening speed is desired toavoid slowing down the flow of traffic. Pleaseconsult national regulations regarding theclosing speed.

Significance of LED Flashes Limit ValuesUP key:faster flashing ➞ higher speed See ChartDOWN key:slower flashing ➞ lower speed See Chart

Operating Speeds Min.(in/sec) Max.(in/sec.)Vo Opening 12 30Vc Closing 8 20

MANUAL OPERATION (Free Wheeling)There are 3 ways the door can be put into afree wheel mode:

1. Press and hold for 10 seconds either theUP or DOWN key on the control panel. Theautomatic operation is turned off and thedoor can be moved freely. Fault code 43 isindicated on the control panel. To put thedoor in automatic operation again, pressand hold either the UP or DOWN key for5 seconds.

2. Press EMERGENCY STOP button (ifequipped). The door panel can be movedmanually. Fault code 10 is indicated on thecontrol panel. To put the door in operationagain, reset EMERGENCY STOP buttonand select operation on the control panel.

3. Disconnect main power. The door will bestopped (if moving) by automatic brakingand then the door can be moved manually.

RESET (Calibration Run)To start a reset of the control system, press andhold either the UP or DOWN key for 5seconds. The door will perform a calibrationrun:

1. The door will open slowly to find thebumper stop.

2. After the hold open time has elapsed thedoor will close.

3. During this procedure fault code 2 isindicated on the control panel.

After each change to the system (e.g. doorweight or mechanical adjustments), asystem reset must be effected by pressinga key at the control panel for 5 seconds orby interrupting the power supply;otherwise proper functioning of the dooris not guaranteed.

MAINTENANCE



InspectionMANUAL & POWER

1. CHECK THE CONDITION OF THE MAIN ROLLER WHEELS. Replace if the flange is 1/16" thickor less, and if the roller has excessive foreign debris on the working surface (Figure 26).

2. CHECK GASKETS FOR PROPER SEALING. Look for gasket compression along the entiredoor perimeter.

3. CHECK MAIN DRIVE BELT FOR TENSION. Allow a maximum deflection per chart (Figure 26)on one leg of the belt. If the tension is too loose, loosen and adjust the idler pulley bracket tomaintain the desired tension. Once the proper tension is set, retighten the idler pulley bracket.

POWER1. CHECK OPERATOR MOUNTING BOLTS AND IDLER PULLEY BRACKET BOLTS FOR

PROPER TIGHTNESS. During the initial run in period these items may loosen.

DAILY1. Check for proper operation and inspect all safety devices.

These include all reversing photoeyes and the electronicreversing of the operator while opening or closing.

MONTHLY (Manual & Power)1. Check roller truck and panel mounting bolts.

2. Check for a tight door seal. Make adjustments as shown inSection 2 of this manual.

3. Check gaskets for wear. Replace if torn or worn.

4. Check header mounting bolts and tighten where necessary.

5. Check drive belt tension (Figure 29).

MONTHLY (Power)1. Check operator mounting bolts.

2. Check idler pulley bracket mounting bolts.

3. Check all wiring for loose or sagging wires monthly or every100,000 cycles, whichever comes first.

ANNUALLY (Power)1. Check drive belt for wear. (sides and teeth)

2. Check all wiring for loose or sagging wires.

3. Check photoeye operation.

Preventative

Figure 29: Roller Wheel Inspection

SHOULDBE MORETHAN 1/16"

MAINTENANCE



Probable Cause Corrective MeasuresProblem

Troubleshooting

Fault Diagnosis

Man

ual

Pow

er

B. Inconsistent starting,and stopping &reverse

1. Loose or poor connection. 1. Check connections in control circuit and in all connections on the photoeyes.

D. Door closes andopens immediately

1. Photoeyes signaling to reopen. 1. Check for seals blocking photoeye, or obstruction in doorway.

E. Drive belt “slaps”bottom side of rail

1. Belt is loose. 1. Retension drive belt.

A. Door will not open 1. No power.

2. Loose or disconnected wire.3. Defective actuator.

1. Check power switches, fuses & connections. Verify 115 VAC voltage at poweroutlet.

2. Check wiring and connection.3. Check wiring and actuator with ohmmeter.

A. Door panel difficultto close or open

1. Gasket too tight.2. Gasket sticks.

1. Readjust panel for minimum gasket pressure.2. Apply small amount of lubricant to the header surface only

(Armor All or Automotive Wax).

C. Door opens but willnot close

1. Photoeye malfunction.2. Activator.

1. Realign photoeye, inspect wiring and amplifier, replace if necessary.2. Inspect wiring, replace if necessary.

FAULT DISPLAY: With the occurrence of a fault, thecorresponding fault code is displayed on the controlpanel – in flashing LED combinations form – alternatelywith the display of the active operating mode:

Fault Code 1 to 30:• Fault code flashes for 6 sec.,

• … operating mode is displayed for 10 sec.

The table shows the LED combinations (code) of theindividual faults.

Tr

1

1

To

2

Pr

3

Vo

4

Vc

5

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

flashing LED

From Fault Code 33:• Beginning with operating mode OFF

(LED1), all 5 LED light up shortly oneafter another (named as run light) 1x,

• … fault code flashes for 6 sec.,

• … operating mode is displayed for 10 sec.

The table shows the run light followed bythe LED combination (code) of theindividual faults.

Tr

1

1×

+

To

2

Pr

3

Vo

4

Vc

5

43 45 49

flashing LED

MAINTENANCE



Fault Diagnosis Continued

1. Door lock faulty ➞ check by manual lockdisengagement

2. Calibration run ➞ wait until door is closed

3. Battery operation only; mains power off

4. Light beam 1 faulty




possible reasons:

• transmitter, receiver, wiring or powermodule faulty

• safety beam not properly aligned

• wiring not properly shielded

8. In operating mode OFF: safety beaminterrupted longer than 10 sec.

9. Operator type not defined or processor failure

10. “Emergency-off” is activated ➞ reset push-button and select operating mode OFF

11. Motor overheated ➞ call for assistance

12. Power module faulty or shut down

13. No door movement: encoder, cable, motor orbelt faulty; possibly door blocked

14. Battery failure or signalling device faulty

15. Failure of night duty lock ➞ check by manuallock disengagement

16. Door in reversing mode: door encounteredan obstacle ➞ wait until door is closed

17. Panel key UP gives contact longer than 1min: panel or cable faulty

18. Panel key DOWN gives contact longer than1 min: panel or cable faulty

19. Burglar alarm ➞ reset by means of a keyswitch or system reset

20. Activator 1 gives contact longer than 1 min:




• activator or wiring faulty

24. Safety beam 1 interrupted for more than 1 min:




possible reasons:

• safety beam or wiring faulty

• optical components possibly dirty

28. Key switch gives contact for longer than 1min: key turned

29. External closing reversing

30. External opening reversing

43. Free wheeling mode

45. Support request: system needs maintenance➞ call for assistance

49. System is ready for automatic systemconfiguration

EXPLANATION OF FAULT CODE AND TROUBLE SHOOTING

REPLACEMENT PARTS

General Information


This parts manual is intended to assist in the correctidentification of the more commonly replaced parts; covering,generally, all models and styles offered within the MarathonPharm. line. The manual will also help identify obsolete parts,part design changes and current production parts. For morespecific parts information, please contact an authorizedrepresentative or consult the Factory’s Customer Service orEngineering Departments. ASI Technologies reserves the rightto discontinue any part and make design changes withoutnotice.

Refer to the information tag on your door and record the:

1. Door model number

2. Job number

3. Door number

4. Manufacturing date.

Use part numbers referenced in this manual.

If the item is not found in the manual, the product code on theback of the item is helpful.

If your door has no information label, the approximate purchasedate is helpful.

General Instructions for Ordering Door PartsAccurate information is always necessary to serve you

correctly and promptly. Several steps should be followed todetermine exactly the parts that are needed.

Instructions for Ordering

Once you have gathered the information above, call:

1-800-558-7068

or

Order Parts Online at:

www.asidoors.comand follow the “Parts” link

REPLACEMENT PARTS

General Information


Determining the Job Number, Model and Year ofManufacture of your door is necessary to providequick and accurate parts identification. The followingis a description of labels and their locations.

Door Identification

Product Label

ID Tag Location

When ordering parts, have your ASI job number and door number available.

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10





A = with

B = without



B = no

Art. KAU0005

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10





A = with

B = without



B = no

Art. KAU0005

ASI TECHNOLOGIES, INC.

MILWAUKEE

DOOR MODEL

JOB NUMBER

DOOR NUMBER

WISCONSINMADE IN

USA

MFG. DATE

INSPECTED BY

DRAWING NUMBER

ID TAG LOCATION

ASI TECHNOLOGIES, INC.MILWAUKEE

DOOR MODEL JOB NUMBER DOOR NUMBER

WISCONSIN MADE IN USA

MFG. DATE INSPECTED BY DRAWING NUMBER

When ordering parts, specifyJob Number, Door Number

and Manufacture Date

REPLACEMENT PARTS



MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery m

odule 50motor ro

t. direction

jumper C9–C10 = clockwise (E

B/ER)

no jumper

= anticlockwise (E

L)

A = with

B = without


A = yes (ru

n system reset)

B = no

Art. KAU0005

Door Assembly

NOTE: Subsequent pages showdetailed assemblies with parts lists.

POWER OPERATED MODEL SHOWN



REPLACEMENT PARTS



Header Assembly & Shrouds

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery m

odule 50motor ro

t. direction


B/ER)

no jumper

= anticlockwise (E

L)

A = with

B = without


A = yes (ru

n system reset)

B = no

Art. KAU0005

MOTOR &

BRAKE

FUSE

TRAFO SEC.

BATTERY

ENCODER

LOCK

MODULE

EPROM

TERMINAL

10+24V

OUT

OUT

OUT

OUT

OUT

IN

IN

IN

GND

+24V

open

exit

red

auto

off

p.lock

down

up

GND

shield

987654321

control panel

CONTROL UNIT

TCP-51LC

1 2


3 4 P2

R +

– T

–+

1 2


3 4 P1

R +

– T

–+

1C


emerg.

switch

key op.

switch

activators

sensor inside

24 VDC

GN

DIN

GN

DIN

+24

VG

ND

IN &

RES

GN

DE

.PB

+24

V

23

45

67

89 10

J2AB battery m

odule 50motor ro

t. direction


B/ER)

no jumper

= anticlockwise (E

L)

A = with

B = without


A = yes (ru

n system reset)

B = no

Art. KAU0005

Flat Shroud (Optional)

Sloped Shroud (Standard)

1420

2

22

365

15

1011

1

4

17 1819

21

13

8

8

8

7

65

65

15

10

9

12

16

11

1

23

13

13

13

81D470, Manual, Standard81D471, Power, Standard81D474, Manual, w/Breakout81D475, Power, w/Breakout

1 24B143 Assembly, roller trolley (includes Items 10 & 11)2 24B141 Assembly, idler pulley (includes Items 14 & 23)3 24B142 Assembly, trolley stop bumper4 30D022 Operator, TCP 51 drive, complete5 28B140 Shroud, sloped, stainless steel (standard)– 44B005 Shroud, flat, aluminum (optional)6 24B148 Cover, hold open plate (under shroud)7 13B767 Side cover, header (for flat shroud only)8 24B147 Support, cover, header (for flat shroud only)9 24B145 Kit, guide rail replacement

10 24B143-1 Trolley, upper section11 24B143-2 Trolley, lower section12 13B798 Trolley stop, closed13 13B797 Bracket, shroud (for standard sloped shroud only)

14 24B141-2 Pulley, idler15 24B144 Extrusion, header and buildout16 24B146 Guide rail clamp

The following are on power operated models only17 23A272 TCP programmable controller18 23A279 Flat cable, TCP 51/TCP 101 controller19 23A280 I/O module (optional)20 24B141-1 Bracket, idler pulley21 23A271 Power cord22 50A120 Drive belt23 24B151 Assembly, bracket, with control panel

Not Shown:NS 17A223 Nameplate, warning label

Item Part No. Description Item Part No. Description



REPLACEMENT PARTS



5

14

2

3

20 21

8

3

12

9

16

17

19

18

10

11

13

15

1

76

4

Front View – Right Hand Panel

Door Panel Assembly86D440, Standard86D441, w/Breakout

1 13B756 Capping, top (Note if door has breakout option)2 13B757 Capping, bottom (Note if door has breakout option)3 13B758 Capping, side (Note if door has breakout option)4 13B763 Extrusion, machined, u-channel5 16B036 Handle, pull, recessed6 44A012 Gasket retainer7 15A009 Gasket8 41A133 Rivet, capping, SS

The following are on breakout option models only9 41A733 Bolt, shoulder, 5/8–11 x 31/2", SHSS, S/S

10 16A110 Detent11 41A104 Set screw12 13B765 Extrusion, top13 13B764 Extrusion, bottom14 17B034 Decal15 41A379 Screw, 1/4–20 × 1", SHCS, low head16 11A133 Spacer, breakout17 41A735 T-nut, 5/16–1818 41A620 Screw, 5/16–18 × 1/2", whizlock19 41A740 Screw, set, 5/16–18 × .25", cup point20 24B154 Assembly, breakout roller21 41A659 Screw, #8–32 × 3/8", PH, FHMS, SS

Item Part No. Description



REPLACEMENT PARTS



2

21

1

45

4

3

3

5

4

5

4

5

Face Frame Assembly76D402F1, No Photoeyes76D402F4, RH Dual Photoeyes76D402F5, LH Dual Photoeyes

1 13B760 Cover, side frame2 13B762 Wall clip, side frame3 24B140F1 Bracket, bottom roller, RH– 24B140F2 Bracket, bottom roller, LH

The following are on power operated models only4 22A251 Clip, wire guide5 23A270 Photoeye set

Item Part No. Description



BI-PARTING LXP CLEANROOM DOORS

5848 N. 95th Court • Milwaukee, WI 53225 • (414) 464-6200 • (800) 558-7068 • FAX: (414) 464-9863 • www.asidoors.com

I ARTING LEANROOM OORS - Construction

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