Airlift Doors XRS Series User manual

XRS Parts List
A: Door Assembly
B: Left Hand Track
C: Right Hand Track
D: Aluminum Cover w/Support Bar
E: Vinyl Cover w/Support Bar
F: Single Support Bar
G: Double Support Bar w/Seal
H: Bearings
I: XRS Opener
J: Opener Mounting Brackets (2)
K: Shaft Collar
L: PVC Shaft Spacer
Not Pictured
M: XRS Fastener Kit
Optional Accessories
N: Motor Cover
A
B
C
DEFG
H
I
L
N
JK

****CAUTION****
Please read through these instructions before beginning
installation of the door. Only trained professional door
installers should attempt installation of the XRS series doors
from Airlift Doors, Inc.
Some steps in this process require lifting up to 200 lbs and we
strongly recommend using a mechanical lift or 3 people with
proper lifting and safety equipment.
Always inspect your tools and equipment such as ladders and
be sure all are in proper working operation before beginning
the installation.
Only a licensed electrician should make the necessary
connections to the controls & motor and you should never attempt to
service the motor without first disconnecting the power supply
to the motor. Performing service on this motor without
disconnecting the power supply may result in serious injury or
death.
All components of this door have been engineered according to
measurements provided to Airlift Doors, Inc. Do not attempt
to modify any components or use any substitute parts without
first consulting a factory representative of Airlift Doors, Inc.
Failure to do so may alter the operation of the door and may
create dangerous scenarios upon installation or normal
operation that could result in personal injury or death. Any
modifications to the product without factory approval will void
all factory warranties.
For all XRS Plus models, both Premium and Elite, 120v power
will need to be run to the control box. Furthermore, wiring
capable of supporting 3phase/230v power will need to be run
from the control box to the door opener.

CAUTION
Please read all instructions prior to beginning installation. Use caution, improper
installation of door can cause severe injury or death. Door to be installed by qualified
personnel utilizing proper safety equipment.
STEP 1 - MEASURE DOOR OPENING AND FLOOR TO CEILING HEIGHT
The door tracks have been pre-cut at the factory to match ceiling measurements given to us at the time
of the order. DO NOT CUT TRACKS WITHOUT CONSULTING THE FACTORY FIRST!! IF TRACKS
WILL NOT FIT OR YOU FEEL THEY NEED TO BE CUT, PLEASE CALL TECH SUPPORT AT
1-888-368-4403 BEFORE PROCEEDING.
STEP 2 - UNPACK HARDWARE
Unpack door and all hardware. Confirm all parts listed in the parts list have been included.
STEP 3 - DETERMINE LH & RH TRACKS
3-1: The left hand track will have the the bearing plate at the top and the brush seal pointed to the right
towards the center of the door opening.
3-2: The right hand track will have the bearing plate at the top and the brush seal pointed to the left
towards the center of the door opening.
3-3: For each track, the fastening portion of the track with the pre-drilled holes will be pointed away from
the door opening.
STEP 4 - MOUNT LEFT HAND TRACK
4-1: Place track against the wall so the stainless steel reset bracket is against the inside of the door jamb
and the brush seal is pointed towards the center of the opening. (FIG. 4A & 4B)
Stainless reset
bracket flush against
inside of door jamb.
FIG. 4A FIG. 4B 1

STEP 4 - MOUNT LEFT HAND TRACK cont...
4-2: Level the track and mount to the door jamb at the midpoint of the track using only 1 anchor at this time.
The remaining anchors will be used in a later step.
STEP 5 - MOUNT RIGHT HAND TRACK
5-1: Repeat step 4 for the right hand track assembly.
STEP 6 - MOUNT TOP COVER
6-1: Using two people, lift the aluminum top cover assembly onto the top of the bearing plates. Make sure
the square support bar is on the bottom of the cover and is towards the wall. (FIG. 6A)
6-2: Using two 5/16” x 1” bolts, attach the cover support bar to each bearing plate. Use the inner most
pre-drilled hole at the top of the bearing plates. (FIG. 6B)
FIG. 6A FIG. 6B
STEP 7 - MOUNT VINYL COVER SUPPORT BAR
7-1: Unroll vinyl cover from aluminum support bar as shown in FIG. 7A below.
FIG. 7A

STEP 7 - MOUNT VINYL COVER SUPPORT BAR cont...
7-2: Using two people, lift the support bar with the cover attached and fasten it to each bearing plate using
two 5/16” x 1” bolts. The bar will mount to the outer most mounting hole at the top of each plate.
DO NOT TIGHTEN BOLTS AT THIS POINT. Leave them slightly loose until you complete step 15.
(FIG. 7B)
FIG. 7B
STEP 8 - COMPLETE TRACK MOUNTING
8-1: Check that both tracks are level and square with the mounting surface.
8-2: Complete the mounting of the track by fastening the track to the wall through the remaining pre-drilled
holes in both the track and the bearing plates. (FIG. 8A)
Fasten tracks and bearing plates
to wall through all remaining pre-drilled
holes.

STEP 9 - INSTALL DOOR ASSEMBLY
CAUTION
DO NOT REMOVE THE ROPES FROM THE DOOR ASSEMBLY YET. THE DOOR NEEDS
TO REMAIN ROLLED UP UNTIL A LATER STEP!!
**IMPORTANT** USE EXTREME CAUTION WHEN LIFTING THE ROLLED DOOR ASSEMBLY
INTO PLACE. DOOR WEIGHT IS APPROXIMATELY 160-200 LBS. LIFTING THE DOOR
IMPROPERLY AND/OR USING LESS THAN THE RECOMMENDED NUMBER OF PEOPLE
CAN RESULT IN SERIOUS INJURY OR DEATH.
9-1: Lift vinyl cover on top of the door assembly so it is not in the way. (NOTE, the vinyl cover has been
removed from the figures below for clarity.)
9-2: Slide one 3-1/8” PVC shaft spacer on each end of the shaft. (FIG. 9A)
9-2: Remove rolled door assembly from box. Using 3 people or a mechanical lift, lift the door assembly
into place and slide the exposed ends of the shaft into the slots at the front of each bearing plate.
9-3: **IMPORTANT** Be sure to orient the door so the yellow bottom edge is closest to the wall. The
door panels will unroll on the wall side of the tube.
SEE FIGURES 9A & 9B BELOW
FIG. 9A
FIG. 9B
PVC Shaft
Spacer
9-4: Lift the rolled door assembly into place by
sliding the ends of the shaft into the slots at
the front of each bearing plate.
(FIG. 9C)
FIG. 9C

STEP 10 - INSTALL BEARINGS
10-1: Slide bearing onto shaft. LIft the shaft slightly to align the the bearing mounting holes with the
pre-installed 3/8” bolts. Slide the bearing onto the mounting bolts until it is against the retaining nut.
(FIG. 10A
10-2: Use (2) 3/8” lock washers and (2) 3/8” nuts to fasten the bearing to the bearing plate.
(FIG. 10B)
10-3: Repeat steps 10-1 and 10-2 for the opposite side of the door.
FIG. 10A FIG. 10B
STEP 11 - SET DOOR OPENING HEIGHT
11-1: Have one person place a vice grip on the door shaft on the side opposite to where the opener will
be installed. This person must hold the vice grip firmly to prevent the door from unrolling.
11-2: While the vice grip is being held, have another person untie the ropes from the door assembly.
11-3: **IMPORTANT** Guide the edges of the door into each track and lower the door by hand until
the bottom edge is at the desired opening height. For instance, if you have a 10’ high opening,
but only want the door to open to 8’, you must lower it to 8’ before proceeding.
(FIG’s. 11A & 11B)
11-4: Once the door at the desired opening height, place the vice grip on the shaft and against the wall so
the door remains in that position and doesn’t unroll. Be sure to place the vice grip on the side of the
door that the opener WILL NOT be mounted on. (FIG. 11C)
FIG. 11A (Door set to open to 10’) FIG. 11B (Door set to open to 8’) FIG. 11C

STEP 12 - MOUNT BOTTOM SUPPORT BAR
12-1: Install the outer, bottom support bar to each bearing plate using (2) 5/16” x 1” bolts. (FIG. 12A)
FIG. 12A
STEP 13 - INSTALL COVER BOLTS
13-1: Lay the double wide support bar flat on the ground with the black rubber seal on top.
13-2: Slide (5) 1/4”X1/2” hex head bolts into the slot next to the rubber seal as shown below. (FIG. 13A)
13-3: Space the bolts evenly along the length of the support bar.
FIG. 13A
STEP 14 - MOUNT DOUBLE SUPPORT BAR
14-1: Flip the double support bar over so the rubber seal is on the bottom.
14-2: Mount the double support bar to the slot in the bottom of each bearing plate using (4) 5/16” x 1” bolts.
14-2: Do not tighten these bolts yet. Leave them loose so the bar can slide in the slot.
5/16” x 1” bolts
(Do not tighten yet)
Black rubber seal
on bottom

STEP 15 - COMPLETE VINYL COVER INSTALL
15-1: Pull the front vinyl cover down and wrap it around the bottom support bars. (FIG. 15A)
15-2: Adjust the location of the 1/4” bolts in the bottom slot of the double support bar so they are aligned with
the 5 grommets in the bottom edge of the vinyl cover.
15-3: Using (5) 1/4” x 1/2” hexhead bolts, fasten the vinyl cover to the double support bar. **NOTE: Be
sure to stretch the vinyl cover as you go to prevent a wrinkled appearance. (FIG. 15B)
FIG. 15A FIG. 15B
FIG. 15C FIG. 15D
PULL SEAL
TOWARDS
DOOR
TIGHTEN
5/16” X 1” BOLTS
FASTEN VINYL
COVER TO DOUBL
SUPPORT BAR
WRAP VINYL
COVER AROUND
BOTTOM SUPPORT BAR
STEP 16 - INSTALL POLY INTO BEARING PLATE SLOTS
16-1: Slide one of the 2” x 5” pieces of polycarbonate into the slot in each bearing plate as shown.
(FIG’s. 16A & 16B)
FIG. 16A FIG. 16B
15-4: Once the vinyl cover is fastened to
the double support bar, slide the black
rubber seal in towards the door until the
rubber seal just touches the vinyl. (Fig. 15C)
15-5:While holding the rubber seal in place
tighten the (4) 5/16”x1”bolts that fasten the bar
to the bearing plate. Next rotate the upper support
bar until the vinyl cover is tight. Tighten the (2)
5/16”bolts holding the upper support bar. (Fig. 15D)

STEP 17 - OPENER INSTALLATION
17-1: Unpack the opener and lay it flat on the ground.
17-2: Determine which side of the opener to attach the mounting brackets. **NOTE** When the opener
is mounted, the black electronics cover will be facing away from the wall. (FIG’s. 17A & 17B)
17-3: Attach the opener brackets to the correct side of the opener using (4) M8 x 1/2” bolts.
**NOTE** The opener brackets mount to the opener through the smaller round holes, NOT the
larger slotted holes.
17-4: Slide the opener onto the end of the shaft making sure the brackets are towards the bearing
plate and the black opener cover is facing away from the wall. (FIG. 17C)
**OPTIONAL** Apply Anti-Seize to the door shaft before installing the motor. (Not supplied)
17-5: Align the slotted holes in the mounting brackets with the bolts on the bearing plate. Slide the
opener onto the bolts. Fasten the mounting brackets to the bearing plate using 3/8” lock washers
and 3/8” nuts. (FIG. 17D)
FIG. 17A (Right Hand Motor Mount) FIG. 17B (Left Hand Motor Mount
FIG. 17C
FIG. 17D

STEP 17 - OPENER INSTALLATION continued.......
17-6: Rotate the door shaft with a vice grip until the keyway of the shaft is in line with the key slot in
the opener. (FIG. 17E)
17-7: Insert the opener key into the keyway and key slot and push it in until approximately 1/4” is
sticking out. (FIG’s. 17F & 17G)
17-8: Slide the 1” shaft collar onto the end of the shaft. Push it against the key and tighten the collar
set screw. (FIG. 17H)
FIG. 17E FIG. 17F
FIG. 17G
FIG. 17H

STEP 17 - OPENER INSTALLATION continued.......
17-9: Mount and wire your door control according to the wiring insert included in your installation
packet.
17-10: Proceed to step 18 when wiring is complete.
STEP 18 - INSTALL PHOTO EYES
18-1: Using the aluminum mounting brackets provided, first mount each photo eye to a bracket.
18-2: Next, mount the brackets to the door track approximately 2 ft above the floor as shown below.
(FIG. 18A or 18B)
18-3: Wire the photo eyes to the controls as specified in the wiring diagram included with this guide.
FIG. 18A (Banner Eyes) FIG. 18B (Telco Eyes)
STEP 19 - OPENER ADJUSTMENTS
The opener limits are set by adjusting two of the four plastic cams at the top of the opener.
- The green cam closest to the opener sets the open limit.
- The white cam, 2nd closest to the opener sets the close limit.
The opener limits were preset at the factory to allow the door to travel within 1-2 ft of the floor at
20% opener speed. Follow these steps to set the door to open and close to the desired position.
The XRS Roll Up Door Opener allows the user to adjust the overall speed of the opener by using the arrow buttons
on the VFD inside the control box. PLEASE NOTE that adjustments to the opener speed will require adjustments to
the open and close limits on the opener. This is due to the fact that as the opener runs at a faster speed, the
momentum of the door and the time it takes to slow the door down both increase. In other words, the faster the
door moves, the more it will “coast”to a stop. Please use the following step by step instructions to properly set the
opener limits.
**CAUTION** During this entire procedure you must be ready to press the STOP button on the control box to prevent
the door from travelling too far in either the open or close direction. Failure to do so may result in
damage to the door and may require replacement or disassembly in order to fix the problem.

STEP 19 - OPENER ADJUSTMENTS continued........
19-1: The first step is to adjust the opener run at the desired speed. This is done by using the UP/DOWN
arrows on the face of the VFD inside the control box. (FIG. 19A)
UP arrow increases opener speed
DOWN arrow decreases opener speed
Digital readout shows current opener speed as a
percentage of the maximum speed. The range is from
0% to 100%. A setting of 100% is equal to approximately
30” per second of door travel.
**NOTE** The remaining buttons on the VFD
are NOT USED.
OPEN AND CLOSE SPEED ARE NOT INDIVIDUALLY
ADJUSTABLE
Fig. 19A - VFD
19-2: Adjust the VFD to a desired speed using the UP/DOWN arrows and press CLOSE on the control
box. **REMEMBER TO BE READY TO PRESS STOP**
19-3: Adjust the door speed as needed.
19-4: Once the desired opener speed has been set, press the open button and stop the door when it is
approximately 12” below the desired opening height.
**The opener limits are set by adjusting the Open and Close limit cams inside the gear head portion of the
motor. Before proceeding, remove the black plastic cover from the opener so you have access to the
Limit Assembly.

STEP 19 - OPENER ADJUSTMENTS continued........
19-5: Press the open button and then stop the door approximately 12” below the desired opening height.
19-6: Loosen the set screw on the Open Limit Cam (Innermost Green Cam) and rotate it clockwise until
the limit switch is pressed in from below. Retighten the set screw. (FIG. 19B)
19-7: Now press the close button and stop the door when it is approximately 12” above the floor.
19-8: Loosen the set screw on the Close Limit Cam (Inner White Cam) and rotate it counterclockwise until
the limit switch is pressed in from above. Retighten the set screw. (FIG. 19C)
19-9: Depending on the speed you have chosen for the opener, you may have to fine tune adjust the limit
cams. This is due to the coasting nature of the opener.
Run the door open and closed and adjust the fine tuning screw on the Open/Close limit cams until the
door stops at the desired open and close positions.
Limit Switch
Fig. 19B
Limit Switch
Fig. 19C
**IMPORTANT**
Once the opener limits have been set, any adjustment to the opener speed will
require that you adjust the opener limits as well.
STEP 20 - MOTOR COVER INSTALL
20-1: Thread a 3/8” nut on the two outer mounting bolts located on the motor side bearing plate.
(FIG. 20A)
20-2: Remove the front panel of the motor cover.
20-3: Lift the motor cover up and around the motor and align the slots in the mounting bracket with the
mounting bolts that you threaded a nut onto. Push the motor cover onto the bolts until it is snug
against the wall. (FIG. 20B)

STEP 20 - MOTOR COVER INSTALL (OPTIONAL)
20-4: Level the motor cover and fasten the mounting bracket to the mounting bolts using a large 1-1/2”
washer, a 3/8” lock washer, and a 3/8” nut.
20-5: Drill a 1/4” hole through the side of the door track using the hole in the 90 deg mounting bracket
as a guide. Fasten the bottom 90 deg bracket to the track using a 1/4” bolt and nut. (FIG. 20D)
20-5: Re-install the front panel on the motor cover.
FIG. 20A FIG. 20B
FIG. 20C FIG. 20D

XRS Plus Model Wiring Instructions
1. Each control must be supplied by its own 20amp / 120v power. Wire this power directly to
the 120v terminals at the bottom right hand of the terminal block.
2. 3~240v wiring from control box to motor must be minimum 12AWG / Stranded wire. This
wire is not included with the opener system and must be supplied by others.
3. Low voltage wiring is pre-wired to control box but may be extended if necessary. See wiring
schematic for wire placements.
4. All high voltage input and output wiring MUST BE INSTALLED BY A LICENSED ELECTRICIAN.
5. Photo eye interrupt wiring. **OPTIONAL**
- Wiring the photo eyes in this manner will disable the photo eyes when the door is
fully closed. This does not affect the normal operation of the photo eyes. If the door is
in transit, the photo eyes will still reverse the door. This is simply to prevent a closed
door from being opened by a blocked photo eye.
- The wiring instructions for this are shown on the wiring schematic (Orange and Red
wires from the opener limit assembly).
- If this feature is used, the outer Green Limit Cam (3rd from wall) must be matched to
the inner White Limit Cam (2nd from wall) so both cams are pushing in their respective
switches when the door is closed.
- If you need the photo eyes to open the door even if the door is closed, you can bypass
this feature by wiring the white wire from the receiver photo eye directly to the open
terminal on the terminal block.
6. Accessory Contacts
- A separate set of N/O & N/C contacts are available to provide a door position
indication to an outside source such as a car wash controller. If the car wash controller
needs to know the position of the door, use the following wires:
- Blue (Common), Brown (N/O), Yellow (N/C)
- If this feature is used, the outer White Limit Cam (4th from wall) will need to be
matched to either the inner Green Limit Cam (To signal door is open) or the inner
White Limit Cam (To signal door is closed).

Black To “DN Limit”
White To COMMON
Green To“UP Limit”
Terminal Block in Control Box
*Please hook only one wire per terminal*
Green To Ground
Black To “W”
White To “V”
Red To “U”
Red
White
Black
Green
120v Ground
120v Neutral
120v Hot
XRS Plus Model Wiring Schematic
(See attached instructions for additional information)
Prewired“Pigtail”
Supplied By Airlift
Motor Wiring Must Be
Minimum 12ga Stranded Wire
**Supplied By Others**
120v Power requires
20amp circuit per
opener
Minimum 12ga Wire
**Supplied By Others**
**Yellow, Blue, Brown, Red, & Orange Wires are only
used when additional inputs are required. If
additional inputs regarding door position are needed
please contact our technical support department for
wiring instructions.

Banner Infrared Safety Eyes
QS303E
Emitter Eye
QS30VR3R
Receiver Eye
BLUE
BLUE
BROWN
BROWN
YELLOW
WHITE
BLUE (24V+)
BROWN (24V-)
YELLOW (COMM)
WHITE (OPEN)