ASI DOORS 209 User manual

MANUAL PART #: A
OWNER’S MANUAL
MODEL 
Full Aluminum
MODEL 
Full Vision

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GENERAL
INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 3-6
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crates and Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
 MANUAL INSTALLATION
. . . . . . . . . . . . . . . . . . . . . 7-38
Un-Bolt Lifing Cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Opening Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting Face Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting Header Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Un-Rolling Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Light Curtains/Photo-Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Mounting Face Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mount Chain Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Mount Spreader Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Routing Sensor Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Wiring Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mount Lintel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shroud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Controller Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setting Door Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pair Transmitter & Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-47
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Preventative Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . 48-55
Instructions for Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Door Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ID Tag Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Le hand Face Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Right Hand Face Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Header Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Gear Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Curtain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ADDENDUM’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-78
Hybrid & Adjustable Link Assembly Replacement . . . . . . . . . . . . . . . . . . . 56-63
Reversing Edge & Wireless Transmitter Replacement . . . . . . . . . . . . . . . . . 64-72
Slat & Hinge Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 73-78

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Safety Practices
This is a safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury.
CAUTION used without a safety alert symbol indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
NOTE explains general information.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
NOTE
GENERAL
INFORMATION

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Read these safety practices before installing, operating or servicing the SLIDING door. Failure
to follow these safety practices could result in property damage, death or serious injury.
READ AND UNDERSTAND ALL WARNING LABELS AND OPERATING INSTRUCTIONS IN THIS
MANUAL 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 (cont’d)
1. Do not operate the door while under the influence of drugs or alchohol.
2. Do not use the door if it looks broken or does not seem to work properly. Advise your supervisor at
once.
3. Stay clear of the door when it is moving
4. Keep hands, feet and head clear of the door at all times.
5. Do not operate the door with equipment, material or people directly inside door opening.
6. Disconnect power before performing any electrical or mechanical service, cleaning or other mainte-
nance on the door. OSHA requires disconnect to be properly tagged and locked out during all mainte-
nance or service of equipment. With the power supply disconnected, always verify using a volt meter.
7. All electrical troubleshooting or service must be completed by a qualified electrician or service
person and must meet all applicable local, state, federal, international and other governing agency
codes.
8. When it is necessary to service the control box with power on, USE EXTREME CAUTION. Do not place
fingers or uninsulated tools inside the control box. Touching wires or other parts inside the enclosure
may cause electrical shock, serious injury or death.
9. It is your responsibility to keep all warning labels and instructional literature legible, intact and kept
with the door. Replacement labels and literature are 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.
12. Failure to operate the door as intended, as described, or heed any warning may result in equipment
damage, property damage, serious bodily injury or death.
GENERAL
INFORMATION

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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
adjustment of the Door System as described in the ASI Owner’s Manual are the sole responsibility of the
customer. All claims for defects must be made to ASI within thirty 30 days aer the defect is discovered
or should, with reasonable care, have been discovered. The foregoing limited warranty constitutes the
exclusive warranty of asi with respect to the door system. Asi expressly disclaims all other guarantees or
warranties—whether express, implied, or statutory—including but not limited to any implied warranty of
merchantability and fitness for a particular purpose.
If a Door System does not comply with the foregoing limited warranty, and a claim is made by customer
within the one year for labor and two years for parts, ASI will, at the option of ASI, either repair or replace
any defective equipment or parts free of charge, and pay the reasonable labor costs to repair or replace
the defective equipment or parts. The remedy of repair or replacement shall be the exclusive and sole
remedy for any breach of the foregoing limited warranty.
Asi shall not in any event be liable for any incidental, indirect, special, exemplary or consequential
damages of any kind, including without limitation any lost profits, arising from the sale or use of the door
system, or from any other cause whatsoever, whether the claim giving rise to such damages is based
upon breach of warranty (expressed or implied) breach of contract, tort, strict liability or any other theory
of liability, even if a party has been advised of the possibility thereof, and regardless of any advise or
representation that may have been rendered by asi concerning the sale or use of the door system.
At ASI’s request, customer shall return to ASI for inspection any Door System for which a warranty claim has
been made, F.O.B. ASI’s facility with freight prepaid. The customer is responsible for any removal costs.
The customer shall comply with the following procedures in filing a warranty claim with ASI:
1. Notify ASI of any and all defects in writing. ASI will review the warranty request and issue a Returns Goods
Authorization (RGA) form if the defective parts need to be returned to ASI for inspection and verification.
The RGA form must accompany any materials returned for warranty consideration.
2. All replacement parts or equipment will be invoiced to the customer. Upon verification by ASI that the
Door System is defective, ASI will issue a full credit to customer for the replacement parts or equipment.
3. If outside labor is needed to install the replacement parts or equipment, ASI requires a written estimate
of the labor charges in advance so ASI may approve the labor charges and issue a purchase order. ASI will
not accept any labor charges unless previously approved by ASI and accompanied by the ASI purchase
order number.
4. The ASI extended warranty coverage for hydraulic components does not cover reimbursement of labor
charges for the diagnosis or replacement of hydraulic components. Warranty reimbursement is limited to
credit for replacement parts purchased from ASI.
The customer must file a claim with the shipper for any damage and/or losses that may occur during transit.
Installation hardware and start up of the Door System equipment is the responsibility of the installation
contractor. Periodic adjustments and normal maintenance are the responsibility of the customer.
GENERAL
INFORMATION

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Crates and Contents
GENERAL
INFORMATION
Because of variances in the construction of walls on
which the door will be mounted, fasteners are not
supplied. For proper anchoring of the door, we recom-
mend the use of thru-bolts. DO NOT remove door sec-
tions from crate until you encounter the step in which
they are to be installed.
Unless specically called out as “Provided by ASI”,
installer is to provide all necessary mounting hardware,
anchors, inserts, hangers, supports and equipment
needed to install door in accordance with nal shop
drawings and manufacturer’s instructions.
NOTE
Upon receipt of the shipment, check that you have received the correct number of pieces as shown (gure 1).
Shipping crates will contain the face frame assemblies, the curtain and header
assembly, the shroud components, the loose parts box, and the control box. For your protection, note any
damages or shortages on the carrier’s bill of lading before signing the bill for receipt.
The installation of this door will require at least a two man crew and a fork lift. Wider doors require 2 fork lifts.
Select fork lifts with lifting height based upon the height of the door plus a minimum
additional two feet.
Description Qty.
Installation Instructions 1
Sales Drawing 1
Warning Nameplate Assembly 2
Chain Keeper 1
Hanger, Spreader Bar 2
Bracket, Lintel Seal, Slat Support 1
Filler Block, Lintel Seal, Slat 2
Gusset, Spreader Support 1
Support, End Cover, Long (Shroud Option) 5
Support, End Cover, Short (Shroud Option) 5
Manual/Auto Ext. Cord 10 Meter 1
Chain Extension, 2 Meter As Req
Misc. Hardware Bag 1
Self Expanding Foam (Roll) 1
Loose Parts

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Un-bolt Liing Cradle
INSTALLATION
Liing cradle is attached to shipping crate
with lag bolts in 4 places. Be sure to remove
the lag bolts before attempting to li the
liing cradle & header out of the shipping
crate.
Figure 2: Remove lag bolts
attaching liing cradle to the
shipping crate.
Opening Measurements
Improper installation of anchoring devices, installa-
tion into aged or unsound concrete or mounting to
a non-plumb wall without proper shimming could
result in premature product wear or product failure.
Failure to properly install equipment could result in
property damage, bodily injury or death.
ASI Door assemblies are built to match the dimensions of a
specific size opening and will match the sizes listed on the ASI
Sales Drawing that was created for your specific opening.
Before mounting any components, check opening for width at
top, middle, and bottom, and check square of opening. Check
level of top of opening and plumb of sides. Check mounting
surfaces for any obstructions or surface irregularities.
Mounting surfaces should be free of debris and as flat as
possible before mounting components. Any deviations in the
opening from the dimensions the door was built for will need
to be compensated for when mounting door components.
Mounting hardware must support a minimum of:
• 4000 Lbs Shear Force.
• 1000 Lbs Pull Force.
It is the owner’s and installer’s responsibility to use
fasteners that meet or exceed the minimum forces
listed, and that are appropriate for the wall type that
this door is being mounted to.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.
Check Width Dimension
Check Square
Check Square
Check Width Dimension
Check Width Dimension

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Mounting Face Frames
INSTALLATION
Mounting the face frames incorrectly will result in poor
header location and may adversely aect the operation
and performance of the door. Follow all mounting
Instructions carefully to insure optimum performance.
1. Retrieve frace frame from shipping crate. If covers are at-
tached to face frames, remove covers before mounting face
frames. Note that frace frames are handed, and must be
installed on the correct side of opening. See figure #5 for
orientation.
2. Measure opening for width and height. Note any dierence
in width (WIC) and height (HIC) against those listed on sales
drawings that door was built to. Also note the surface condi-
tion of mounting areas around opening.
3. Figure 5 & 7 show the layout & hardware for mounting face-
frames. 1/2”through bolts with steel backing plates on the far
side of wall are recommended.
4. Measure and hold inside dimension between face frames at
WIC plus zero/minus 1/8” as shown. Header mounts on the
outside surfaces of the face frames so this dimension can’t be
oversize or the header will not fit properly. Outside dimension
is show for reference. This dimension has to be less than the
distance between header plates.
Face frame extrusions will be mounted to both sides of the open-
ing. The header assembly mounts to the face frame extrusions.
At the top of each face frame extrusion, there is a hanger bracket
that holds the top spreader bar of the header assembly.
The position of the hanger brackets on the face frames will
Dictate how the header is positioned, so it is critical to
position and mount the face frames carefully and correctly for
the header to be located correctly.
Hold Inside Dimension
Hold Inside Dimension
Check Square
Check Square
Figure 4: Keep Face Frames Square, And
Hold Width When Mounting To Wall
Figure 5: Face Frame Mounting Dimensions

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Mounting Face Frames Continued
INSTALLATION
5. Header need to be in-line and plumb to the floor (figure #6).
If there are protrusions or obstructions on the wall, or if wall
surface is not straight and plumb, face frames will need to be
shimmed at specific spots to keep them plumb and in-line
with respect to the header.
6. Because the hanger brackets at the tops of the face frames de-
termine the position of the header, the tops of the face frames
need to be level.
7. Position both le and right face frames against the wall. Note
the distance between face frames in figure # 5. Recommend-
ed minimum hardware is 1/2” through bolts (see warning on
page #7). Temporarily secure both face frames to each side of
the opening at their approximate mounting locations using
c-clamps.
8. Go to the top of the opening and laser level across the tops of
both face frames to determine if the tops are level. If not, add
shims to the bottom of the low face frame & re-check until
they are level at the tops of the face frames.
9. Note that face frame assemblies with the covers on will proj-
ect out from wall 4-5/8” when assembled (figure # 10). If floor
is sloped away from wall, face frames need to be shimmed
so that the bottoms of the installed face frame covers will sit
flush with the bottoms of the face frames, and will not inter-
fere with the floor surface.
10. Check plumb of mounting surfaces of both face frames. Add
shims to low areas to keep face frames plumb and straight.
Areas of face frames at through bolt mounting holes need
to be flush with wall or shimmed properly so the face frame
doesn’t distort when through bolts are tightened. Distorting
the face frame will prevent the face frame covers from mount-
ing correctly later.
11. When face frames are plumb, and tops of face frames levelled,
mount with hardware appropriate for wall at install location.
Only the top 2 mounting holes are pre-drilled in face frames
(holes for spreader bar hanger). Drill remaining holes for
mounting through face frames & wall per dimensions in figure
# 8, 36” spacing maximum.
12. Hand tighten fasteners. Check distance between face frames
at top, middle, and bottom. Check diagonals for square and
adjust if necessary. Aer all checks have been made, tighten
fasteners except for top 3 fasteners on each frame. These will
be tightened aer mounting header. Making sure face frames
are not distorting while tightening bolts.
13. Note: do not allow fasteners to protrude more than 11/16”
(0.69”) From face frame surface. Curtain chain links move in
this area and bolts that are protruding too high will interfere
with them potentially causing damage to the curtain compo-
nents if fasteners are longer than this dimension.
Shim if needed to keep face frame
mounting surface plumb.
High Point
Shim
Shim
Face Frame
Through Bolt
Face Frame
Mounting
Surface
High Point
Figure 6: Face Frame Mounting Surface Detail
Figure 7: Face Frame Mounting Detail

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Mounting Face Frames Continued
Figure 9: Projection Of Face Frame
Assemblies From Wall
2-9/16”
(4-5/8” with Face
Frame Cover)
True Level
Actual Floor
Shim
Figure 10: Projection of face frame
assembly with cover from wall
Figure 8: Projection Of Face Frame
Fastener Layout
It is important that tops of face frames are mounted level with each other. The header will rest on
the spreader bar hangers at the top of the face frames and the header will not be level if face frames
are not level. Use a laser level to insure tops of face frames are level.
If oor is not level, mount 1st face frame on high side of opening, and shim bottom of other face
frame to keep them level with respect to each other.
Face frames get mounted rst, 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.
NOTE
INSTALLATION

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Mounting Header Assembly
INSTALLATION
1. Locate crated header & curtain assembly. The header & curtain assembly is packaged sitting on top of and is attached
to a liing frame (figure #10). Remove all other packaging but leave assembly attached to the liing frame
2. Using fork lis, carefully li liing frame and header assembly, and move to a position directly in front of, and
centered on the opening. Raise header & curtain assembly so rear spreader bar of header is above hanger brackets
located at the tops of the face frames. Level forks and slowly move assembly towards wall. Use helper to help you
guide assembly into position with back of header assembly flat against wall (figure #12). End plates of header should
fit outside of outer surfaces of face frame extrusions.
3. Slowly lower liing frame & header assembly until rear spreader bar of header fits into hanger brackets on face
frames.
Figure 11: Li Header Assembly
Into Position On Li Frame
Hanger Brackets
on Face Frames
Keep weight supported by fork lis until
header is securely mounted to face frames.
On wide doors, use 2 fork lis, one per side
when liing and mounting header.
Figure 12: Mounting Header On Face Frame Hanger
Brackets.

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Mounting Header Assembly Continued
INSTALLATION
Do NOT remove fork li support of header &
liing frame until header is securely anchored
both face frames.
Figure 14: Attach Header
Assembly To Face Frames
Figure 13: Mounting Header On Face Frame Hanger Brackets
Tighten nuts at
top of header
Figure 16: Remove Banding
From Rolled Curtain
Remove Banding
(6) 3/8”-16 x 0.75”
(P/N 41A1073)
screws per side
“Pry Point” Slot
Figure 15: Remove Liing Frame From Header
4. While header is in position and still supported
by fork lis, add 3/8”-16 x 0.75” Screws to attach
header to face frames, 6 per side. Tighten all 12
screws securely. Use “pry point” slot to help align
holes with threaded track in face frame extrusion if
needed (figure # 13).
5. Tighten top nuts on each face frame that were
lehand tight from previous step. If you can’t reach
bottom nuts with curtain rolled up, tighten the
ones you can reach. Aer curtain is unrolled in a
later step you will check & re-tighten all mounting
hardware.
6. Aer header is securely mounted to both face
frames, liing frame may be removed.
7. With li frame still supported by fork li, remove all
bolts and fasteners holding header assembly to li
frame.
8. Slowly lower li frame out and away from header
assembly and wall.
9. Carefully remove banding straps on curtain, and
any other shipping materials protecting curtain
(figure #16).

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
Unroll Curtain
INSTALLATION
1. To allow switching of manual operation of door from ground level, manual operation cord extensions need to be
installed to both red and green pull handles on motor (found in loose parts box) see figure 17 & 18. Install cord
extensions to allow manual control from floor level.
2. Pull red handle on manual release pull cord to put motor in manual operation mode (figure #18).
3. Use manual drive chain to lower curtain to the halfway point.
4. Check if the curtain chain links are true with the channel openings in both face frame extrusions (figure #19).
5. If curtain is not centered, loosen the two adjustment bolts on the operator mounting bracket (figure # 20)
Figure 19: Alignment Of Ends
Of Curtain Into Face Frames
Figure 20: Adjust Position Of
Operator & Curtain Assembly
Figure 18: Manual Operation Pull Cords
Red “Manual Drive
Mode” Pull Cord
Green “Power Drive
Mode” Pull Cord
Manual Release
Unroll Curtain
down to halfway
point manually
Manual Drive Chain
Figure 17: Unroll Curtain Halfway
Into Opening
Curtain ChainLinks
Should be Center
in Face Frame
Extrusions.
Operator mounting
bracket bolts

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Unroll Curtain Continued
INSTALLATION
6. With these bolts loosened, move operator, and curtain assembly horizontally to center curtain links in face frame
extrusion channels.
7. Retighten adjustment bolts on operator mounting bracket.
8. If curtain is not hanging parallel and true to face frame extrusions;
9. Roll curtain down all the way.
10. Rotate torque tube until the adjustable link (always on le side) is accessible.
11. Tighten or loosen nut on adjustable link to raise or lower le side of curtain until curtain is straight and true with
face frame extrusions (figures 21 & 22).
12. With curtain in completely unrolled position, check and tighten any nuts at tops of face frames that were le
hand tight from previous install steps.
Figure 21: Adjustable Link Location
Adjustable link for
leveling curtain
Adjustable link for
adjusting curtain.
Adjusting Nut
Figure 22: Adjustable Link Detail Views

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Light Curtains & Photo-Eyes
INSTALLATION
Figure 25: Light Curtain & Photo-Eye Detail
If a light curtain or photo-eye option was ordered, light cur-
tains or photo-eyes will be installed at the factory. Light cur-
tains are held in position with two locking cams at the top &
bottom (figure 23).
Light curtains are mounted in the face frame covers in a
channel on the opening side of the extrusion. Photo-eyes are
mounted in a channel in the face frame base extrusion (figure
24).
Wire leads from the light curtains or photo-eyes will be run up
the length of the face frame, and out the top of the channel.
Wire these leads into the control system for photoeye control,
per the schematic for the door.
Light curtains or photo-eyes can also be added to an existing
door in the field. If you are field installing light curtains or
photo-eyes, install per (figure 23 & 24), and wire them to the
control system per the schematic for the door.
Channel
Cover
Leads from Light
Curtains / Photo-Eye(s)
Figure 24: Photoeye And Light
Curtains Installation Options
Light curtain installed in
face frame cover
extrusion.
Single or dual photo-eye(s)
installed in face frame base
extrusion.
Channel
Cover
Light
curtain
in face
frame
cover
Figure 23: locking cam for light
curtain installation.
End of light
curtain
Locking cam in
extrusion slot.
Locking
cams
Single or
dual pho-
to-eye(s)
in face
frame

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Mounting Face Frame Covers
INSTALLATION
Aer curtain is unrolled and adjusted, use the following steps
to install Face Frame Covers:
1. Retrieve face frame covers from shipping crate. Note that
covers are handed and need to be installed on the cor-
rect side (see figure # 26). Tops of covers will have a plas-
tic curtain guide inserted in the end of the extrusion.
2. Face frame cover extrusion profile mates with extrusion
profile of face frame (see figures 27 & 29) and is attached
with 3/8-16 x 3/4 button head screws. The face frame
extrusions have a threaded slot that runs the entire
length of the extrusion and the screws will thread into
that slot at any position.
3. Put door in full open position with curtain completely up.
4. Li face frame cover into vertical position and guide into
position with mating face frame extrusion. Rotate face
frame cover into position from curtain side to outside as
shown in figure # 29 to insure that tab in cover extrusion
seats into base extrusion properly. Align holes in face
frame cover with threaded slot in face frame extrusion.
5. Hold in position and starting from bottom, add fasteners
(p/n 41a1029) to each hole in face frame covers.
6. Hand tighten each fastener as it is added and when all
fasteners are in, tighten them all down.
Figure 29: Rotate Face Frame
Cover Into Position
Tab in cover
extrusion
Figure 28: Position And Mount Face
Frame Covers To Face Frames
If you are installing face frame covers with light bar
option installed, use care not to pinch cable from
light bar protruding from top end of cover.
NOTE
Face Frame
Cover
Plastic curtain
guide
Figure 27: Face Frame
Cover Install Detail
Curtain
Face frame cover
Face frame
3/8-16 X 3/4 (P/N
41A1029)
screw
Figure 26: top of face
frame covers.

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Mounting Chain Bracket
INSTALLATION
Figure 31: Chain Lock Bracket # 13b1773NN
Mount the chain lock bracket (packed in hardware
bag in loose parts box) to the wall so that the slot-
ted opening on the bracket is positioned as shown
in figure 29 & 30.
Figure 32: Mount Spreader Support Gusset To
Center Support
Mounting Spreader Support Gusset
Figure 33: Mount Spreader Support Gusset To
Wall
With the curtain completely lowered, mount the
spreader support gusset(s) (packed in hardware bag
in loose parts box) to the center support(s) on the
header frame ( figure 32).
Doors will have 0, 1, or 2 sets of stieners mounted
on the header, depending on the width of the open-
ing, and whether or not the door was ordered with
a shroud.
Install (1) spreader support gusset for each set of
stieners on header.
Li the header frame at the center support as need-
ed so the rear spreader bar is level and secure to the
wall through the 3 holes in the flange of the spread-
er support gusset as shown in figure 33.
(2) 5/16”-18 x 0.50”
Screws
(P/N 41A1075)

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Routing Sensor Wires
INSTALLATION
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
be routed up through the pocket in the extrusion and out to the control box.
There are 4 possible routings for sensors depending on whether they are in the face frames, or covers, and whether
they are on the drive or idler side of the door. All leads need to be routed to the control box which is normally
mounted on the drive side of the door.
For sensors on idler side, leads will be routed through slots & holes in the header end plate and through the top rear
spreader bar, across to the drive side of door. There should be a length of string routed through the top rear spreader
bar to aid you in routing cables through it. Tie the string to the cables to be routed and pull them through the
spreader bar from the other side of the header.
Drive side face frame sen-
sor wires. Routed through
hole in top of header end
plate.
Cables routed down to
control box
Drive Side Cover sensor
wires. Routed through
slot in bottom of Header
End Plate.
Idler side face frame sensor wires. Routed
through hole in top of header end plate,
back through hole in center of top rear
spreader bar, and over to the drive side of
the door.
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 34: Routing Sensor Wires

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Rounting Sensor Wires Continued
INSTALLATION
Sensors In Drive Side Face Frame:
Leads will come out of the top of the face frame where the face frame meets the top rear cross tube. Route lead
through hole in upper rear corner of header end plate, and down to control box.
Sensors In Drive Side Face Frame Cover:
Leads will come out of the top of the cover at the bottom of the header end plate. Route lead through slot in lower
rear corner of header end plate, and down to control box.
Sensors In Idler Side Face Frame:
Leads will come out of the top of the face frame where the face frame meets the top rear cross tube. Route lead
through hole in upper rear corner of header end plate to the outside of the header end plate. Route leads through
center hole through center of top rear cross tube, to drive side of door, and down to control box.
Sensors In Idler Side Face Frame Cover:
Leads will come out of the top of the cover at the bottom of the header end plate. Route lead through slot in lower
rear corner of header end plate to the outside of the header end plate. Route leads up to and through the center hole
of top rear cross tube, over to drive side of door, and down to control box.
Drive side face frame sensor
wires. Routed through hole
in top of header end plate.
Cables routed down to
control box
Idler side face frame sensor wires. Routed
through hole in top of header end plate,
back through hole in center of top rear
cross tube, and over to drive side of door.
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

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Wiring Layout
INSTALLATION
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.
Figure 36: 209 Electrical Routing Detail..
All wiring and connections are detailed on and must
conform to, the electrical schematic drawing that was
shipped with your 209 door. The electrical schematic
drawing is specific to your door and any options chosen
for your application.
NOTE
208v power requires the use of a boost box to
convert the voltage from 208v to 230v.