JANUS INTERNATIONAL ASTA AMERICA 700 Series Instruction Manual

COUNTER SHUTTERS 700 SERIES
BASE INSTALLATION MANUAL
READ ENTIRE MANUAL BEFORE
BEGINNING INSTALLATION
APRIL 2020
ASTA AMERICA
by Janus International
CARTERSVILLE,GA
astaamerica.com

WARNING!
CAUTION
SAFETY INFORMATION
POTENTIAL HAZARD EFFECT PREVENTION
WARNING
Could result in death
or serious injury
Keep people clear of opening while Counter Shutter is moving.
DO NOT allow children to play with the Operator.
DO NOT operate a Shutter that jams or one that has a broken spring.
Turn off power before removing operator cover.
When replacing operator cover, make sure wires are not pinched or near
moving parts.
Operator must be properly grounded.
DO NOT try to remove, repair or adjust springs or anything to which Shutter
spring parts are fastened, such as steel brackets or other like items.
Repairs and adjustments must be made by a trained shutter system
technician using proper tools and instructions.
OVERVIEW OF POTENTIAL HAZARDS
WARNING
Could result in death
or serious injury
WARNING
Could result in death
or serious injury
Counter Shutter must be fully opened when making adjustments.
Repairs and adjustments must be made by a trained rolling shutter systems
technician using proper tools and instructions.
WARNING
Could result in death
or serious injury
PAGE 2 ASTA AMERICA
Counter Shutters are large, heavy objects that move with the help of springs under high tension and electric motors. Since
moving objects, springs under tension, and electric motors can cause injuries, your safety and the safety of others depend
on you reading the information in this manual. If you have questions or do not understand the information presented, call
your nearest service representative.
In this section, and those that follow, the words "Danger", "Warning", and "Caution" are used to emphasize important safety
information. For example:
A Counter Shutter is a large heavy object that moves
with the help of springs under extreme tension and
electric motors. Moving objects and springs under
tension and electric motors can cause serious injuries
or death. For your safety and the safety of others,
follow these instructions.
Use proper lifting equipment and correct
lifting procedures to avoid damage or injury.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous
situation which, if not avoided, could result in death or
serious inury.
CAUTION: Indicates a potentially hazardous situation which, if
not avoided, may result in injury or property damage.

FIGURE 1
PAGE 3 ASTA AMERICA
DESCRIPTIONQTY
ITEM
DRIVE SIDE HEAD PLATE
11
TENSION SIDE HEAD PLATE
1
2
DRIVE SHAFT1
3
MOUNTING FASTENER (SEE FIG. 3)
X
4
BARREL ASSEMBLY
15
HOOD
1
6
TENSION SHAFT
27
8
TENSION WHEEL
1
9
BELLMOUTH/HEADSTOP
1
10 2
11 BOTTOM BAR ASSEMBLY 2
12 CURTAIN ASSEMBLY1
13
FRONT GUIDE
2
14 2
TYPICAL COUNTER SHUTTER
1
2
3
4
5
6
WALL GUIDE
END COVERS
7
8
910
11
12
14
13

(1/4" SETBACK)
TUBE - 3/16" MINIMUM
THREAD CUTTING SCREW
LAG BOLT (3/8" X 3")
THREAD CUTTING SCREW
(1/4" SETBACK)
(1/4" SETBACK) (1/4" SETBACK)
(1/4" SETBACK)
TUBE - 3/16" MINIMUM
NUT WITH
FLAT WASHER
UNFILLED CONCRETE
ALL THREAD
STUD THRU WALL
3" X 3" CRUSH PLATE
FOR SOFT BRICK
OR UNFILLED CMU
CONCRETE ANCHOR
FILLED CONCRETE
MASONRY UNIT
MASONRY UNIT
STEEL JAMB - 3/16" MIN
THREAD CUTTING SCREW
LAG BOLT (3/8" X 3")
FIGURE 2
14 GAUGE MIN
NON MASONRY JAMB
THREAD CUTTING SCREW
NON MASONRY JAMB
BETWEEN JAMB MOUNT
MANUAL OPERATION
BETWEEN JAMB MOUNT
CRANK / MOTOR
PAGE 4 ASTA AMERICA

STEEL JAMB CONCRETE FACE OF WALL
FASTENER DRILL
STEEL
NOTES
SIZE
JAMB
OR
CONCRETE
FILLED BLOCK
OR
UNFILLED BLOCK
SOFT BRICK
3/8-16 X 1-1/4" TYPE 23 THD CUT SCREW
3/8-16 X 1-1/4" HEX BOLT AND NUT
3/8" X 1-7/8" SLEEVE ANCHOR
3/8" THREADED ROD & NUTS
1/2" THREADED ROD & NUTS
7/16"
1/8"
3/8"
7/16"
9/16"
CLEAR HOLES OF CONCRETE DUST
3/16" THICK STEEL JAMB MINIMUM
INSTALL CRUSH PLATES ON
OPPOSITE SIDE OF WALL
11/32"
BEFORE INSTALLING FASTENER
FASTENER CHART
3/8 LAG SCREW
NON
MASONRY
3/8 X 3 LAG BOLT 7/16"
3/8 X 3 LAG BOLT 1/4"
14 GAUGE STEEL STUD MINIMUM
WOOD STUD
PAGE 5 ASTA AMERICA
FIGURE 3
OPENING WIDTH
OPENING
HEIGHT
HEADER
JAMB
SILL
JAMB
FIGURE 4
1. Pre-Installation Evaluation
a. Verify that your measurements match the opening width, height,
headroom, sideroom and backroom dimensions shown on shop
drawing.
b. Verify that jamb construction is the same as shown in shop
drawing and that construction is suitable for mounting guides.
c. Verify that guides can be mounted plumb.
d. Verify that all shutter parts are available.
2. Procedure for laying out guides
a. Find and mark centerline of opening and mark as shown in
Figure 5.
b. Determine "W" dimension from the shop drawing.
c. Center "W" dimension on sill using center line of opening and
clearly mark at each jamb.
d. Sill marks should precisely equal "W" dimension and
reflect the location of the wall angle's perpendicular
leg as shown in Figure 5.
FIGURE 5
EXTRUDED ALUMINUM GUIDES - FACE OF WALL

PAGE 6 ASTA AMERICA
Be positive about the accuracy of your level elevation reference marks!
FIGURE 6
LEVEL
REFERENCE
ü
ü
3. Procedure for shooting level reference marks
a. Create level elevation marks at left and right jamb faces using a level reference device or
survey instrument as shown in Figure 6.
b. Measure the distance from each level reference mark to the sill to determine if the sill is level.
If there is a difference in measurements from the marks to the sill,
the sill is not level. You must shim the wall angle with the longest
reference measurement to verify that both wall guides are
mounted to the same elevation.
4. Procedure for installing wall angles
a. Use a plumb bob or similar device to establish a true plumb reference.
b. Install first wall angle plumb vertically at the correct elevation, and at the correct "W"
dimension sill mark.
c. Install second wall angle by placing it at the "W" dimension marked on the sill at the
second jamb as shown in Figure 7. Shim if necessary.

ü
"W" DIMENSION
MARKS ON SILL
SILL
ü
PAGE 7 ASTA AMERICA
TAPE MEASURE
FIGURE 7
d. Use a tape measure while attaching the second wall angle to maintain a
consistent "W" dimension all the way to the top as shown in Figure 7.
Verify that the low side wall angle is shimmed to the correct height before permanent
attachment to the jamb.
Top two holes where wall guide fastens to jamb above header; fasteners to be installed
through headplate slots, through wall guide into jamb as shown in figure 10 on page 9.
NOTE: Use only fasteners provided and approved by ASTA Door Corporation.
Reference Figure 3 to determine correct jamb fastener type for your application, and
for drill bit size, etc.

FIGURE 9
FIGURE 8
HEADPLATES BARREL ASSEMBLY
WELDS
WELDED
DRIVE
SHAFT
TENSION END DRIVE SIDE
BEARING
ROTATING
SHAFT
TENSION SIDE
HEADPLATE
DRIVE SIDE
HEADPLATE
TENSION SIDE HEADPLATE
INSIDE TENSION WHEEL
BEARING
CLEVIS PIN
CLEVIS HAIR PIN
DRIVE SIDE
WELDED DRIVE
SHAFT
DRIVE SIDE HEADPLATE
DRIVE SIDE BEARING
(MANUAL OPERATION ONLY)
RH DRIVE SHOWN - LH DRIVE OPPOSITE
FACTORY
TENSION RECEIVER
INSTALLED
TENSION PIN
FACTORY INSTALLED
TENSION PIN
OUTSIDE
BEARING
IF MANUAL
PAGE 8 ASTA AMERICA
RH DRIVE SHOWN - LH DRIVE OPPOSITE
MANUAL NO KEYWAY
CRANK WITH KEYWAY
RH DRIVE SHOWN - LH DRIVE OPPOSITE
5. Procedure for assembling barrel and headplate assemblies.
a. Proceed at ground level and identify components as shown in Figures 8, 9 and 10.
b. Install tension wheel and tension headplate. Tension detail shown in Figure 9.
c. Install drive side headplate as shown in Figure 9 for manual operation.
d. Install drive side headplate as shown in Figure 15 on Page 12 for optional hand crank
operation.

FIGURE 10
PAGE 9 ASTA AMERICA
WARNING
HEADPLATE SHOULD
BE FLUSH WITH TOP OF
WALL ANGLE.
TENSION HEADPLATE
TENSION RECEIVER
HOODBAND
INSIDE TENSION
WHEEL
TENSION SHAFT
7. Procedure for slinging curtain to barrel
a. Using hoisting equipment, suspend the curtain assembly below the barrel on two or more slings.
b. Center the factory rolled curtain assembly between the guides as shown in Figure 11.
c. Use locking pliers to temporarily fasten two or more segmented starter slats to slings.
d. Roll curtain, slings and barrel as one unit in order to pull the starter slats and curtain over the
top of the barrel.
e. Attach segmented starter slats to barrel using ASTA supplied button head screws and remove
locking pliers.
6. Procedure for installing barrel and headplates to guide assembly
a. Carefully secure barrel to hoisting equipment and raise into position at top of
wall angles. Attach headplate brackets to wall angles as shown in Figure 10.
b. VERIFY THAT BARREL IS DEAD LEVEL BEFORE INSTALLING WALL &
HEADPLATE FASTENERS.
c. Headplate should be flush with top of wall angle.
d. Set spacing between headplates adequate for later hood installation.
e. Verify that barrel is unrestricted and free to rotate before proceeding.
SLINGING: IMPORTANT SAFETY PRECAUTIONS
Use only straight-eye choker style slings with a minimum 5,000 lb weight rating. Use slings of
a length that keeps the factory rolled curtain as close to the barrel assembly as possible.
Close and secure sling ends with a clevis or chain shackle of adequate size that features a
SCREW-IN STYLE PIN ONLY. DO NOT USE A CLIP RETAINED SHACKLE OR CLEVIS PIN!!

FIGURE 12
WALL GUIDE
FRONT GUIDE
BELL MOUTH
SELF TAPPING SCREW
BELL MOUTH
FASTENER HOLE
PAGE 10 ASTA AMERICA
ü
ü
FIGURE 11
CAUTION
It may be necessary to use the hoisting equipment to lift the weight of the curtain
enough to allow rotation of the barrel to bring the attachment lugs into position with
segmented starter slats.
When starter slats are attached to the barrel lugs, you may lower the hoisting equipment
and proceed with the next step.
f. Center curtain slats individually between the wall angles as you slowly rotate the barrel and roll the curtain
onto the barrel.
g. Install front guide angles as shown in Figure 12 using supplied fasteners.
h. Tighten guide assembly fasteners securely.
i. Snap front bellmouth in place and secure to headplate with supplied fastener.

FIGURE 14
SECURE HOOD
FLANGE TO WALL
INSTALL ENDCAPS UNDER HOOD
BEFORE INSTALLING FASTENERS.
PAGE 11 ASTA AMERICA
FIGURE 13
9. Procedure for installing hood flange, hood and endcovers.
a. Attach top hood flange securely to the wall with installer supplied fasteners.
b. Insert end covers underneath hood and fasten hood to headplate hood bands with self drilling fasteners.
8. Procedure for applying preload to barrel assembly
a. Roll curtain to fully closed position.
b. Apply tension from the top, downward, as shown in Figure 13 to the preload amount shown on
tension headplate label, barrel sticker, or shop drawing.
c. Raise curtain and check balance.

FIGURE A-1
3- 1/4 X 1-1/4
CARRIAGE BOLT 1/4" X 1/4" X 1" KEYSTOCK
NUTS &
LOCK WASHER
3-BOLT
AWNING CRANK
BRONZE
BEVELED
GEAR
Installing Awning Crank Assembly To
DRIVE SIDE
HEADPLATE
Drive Side Headplate and Shaft
PAGE A-1 ASTA AMERICA
Appendix "A"
9. Procedure for Installing (optional) Awning Crank
a. Insert 1/4" x 1" key stock into key seat on drive shaft.
b. Align bevel gear key way with key stock and slide awning crank onto drive shaft until awning
crank back is seated against head plate.
c. Align mounting holes in awning crank with mounting holes in head plate. Insert (3) 1/4" x 1-1/4"
carriage bolts from inner side of head plate through holes in head plate and awning crank.
d. Using the (3) supplied 1/4" lock washers and hex nuts securely tighten nuts to attach awing crank
to head plate.
638 Cassville White Rd NW
Cartersville, GA 30121
P.O. Box 639
Cassville, GA 30123
Office: 770-974-2600
Fax: [phone]
www.astadoor.com