Janus AstaAmerica 500 Series User manual

FIRE DOOR 500 SERIES
BASE INSTALLATION MANUAL
READ ENTIRE MANUAL BEFORE
BEGINNING INSTALLATION
FEBRUARY 2020 CARTERSVILLE,GA
astadoor.com
FIRE DOOR 500 SERIES
BASE INSTALLATION MANUAL
FEBRUARY 2020
ASTA DOOR CORPORATION
638 Cassville White Rd NW
Cartersville, GA 30121
P.O. Box 639
Cassville, GA 30123
Office: 770-974-2600
Fax: [phone]
www.astadoor.com

A rolling door is a large heavy object that moves
with the help of springs under extreme tension and
follow these instructions.
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,
WARNING!
Use proper lifting equipment and correct
lifting procedures to avoid damage or injury.
CAUTION
SAFETY INFORMATION
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR
ELECTRICAL SHOCK
HIGH SPRING TENSION
WARNING
Could result in death
or serious injury
Keep people clear of opening while Door is moving.
DO NOT allow children to play with the Door Operator.
DO NOT operate a Door 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 Door
spring parts are fastened, such as steel brackets or other like items.
Repairs and adjustments must be made by a trained door 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
Overhead doors 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:
if not avoided, may result in injury or property damage.
which, if not avoided, could result in death
if not avoided, will result in death or serious injury.
or serious inury.
Door must be fully opened when making adjustments.
Repairs and adjustments must be made by a trained rolling door systems
technician using proper tools and instructions.
WARNING
Could result in death
or serious injury
PAGE 1 ASTA DOOR CORPORATION
DANGER: Indicates an imminently hazardous situation which,
WARNING: Indicates a potentially hazardous situation
CAUTION: Indicates a potentially hazardous situation which,
FIGURE C-1
PAGE C-1 ASTA DOOR CORPORATION
Appendix "C"
1. Verify the barrel and guide assemblies are properly installed and that all
fasteners are tightened securely.
2. Procedure for installation of motor operator.
a. Attach the operator to bracket using the supplied hex bolts,
flat washers, lock washers and hex nuts as shown in Figure C-1.
b. Install motor operator and bracket assembly to the drive side headplate
with two 1/2" -13 NC X 1 1/4" carriage bolts as shown in Figure C-1.
c. Push the assembly toward wall as far as possible for drive chain
installation, and temporarily secure the two carriage bolts as shown in
Figure C-1.
d. Install the drive shaft sprocket with supplied key way.
e. Align the drive shaft and operator sprockets and tighten set screws.
f. Size & install the supplied #50 roller chain and secure with #50 master link.
g. Loosen the operator carriage bolts and tighten the roller chain by pulling
the assembly away from the wall leaving approximately 3/4" slack in chain.
h. Tighten operator bracket carriage bolts and set screw to lock the bracket
in place and to retain roller chain setting during future operation.
MOTOR OPERATOR
OPERATOR BRACKET
SET SCREW
1/2" CARRIAGE BOLT
PIVOT BOLT
OPERATOR FASTENERS
KEY WAY
DRIVE SPROCKET
OPERATOR SPROCKET
#50 ROLLER CHAIN
ASTA Door Corporation 500 Series FIRE DOOR
Motor Operator Installation

PAGE 2
FIGURE 1
TYPICAL FIRE DOOR
RH Drive Shown
LH Drive Opposite
DESCRIPTIONQTY
ITEM
DRIVE SIDE HEAD PLATE
11
TENSION SIDE HEAD PLATE12
DRIVE SHAFT
1
3
MOUNTING FASTENER (SEE FIG. 3)
X4
BARREL ASSEMBLY
15
HOOD
16
TENSION SHAFT
17
8
TENSION WHEEL
1
9
BELLMOUTH/HEADSTOP
1
10
SERVICE CUT-OUT
2
11
BOTTOM BAR ASSEMBLY
2
12
CURTAIN ASSEMBLY
1
13
GUIDE ANGLE ASSEMBLY
1
14 2
PVC SPACER
1
2
3
5
6
7
8
9
12
10
13
4
11
14
ASTA DOOR CORPORATION
PAGE B-1
DROP TESTING ASTA FIRE DOORS:
Appendix "B"
ASTA fire doors require that the door be placed in a permanent out-of balance condition to allow the
door to reliably close from any normal operating position when activated by alarm, notification or release
device.
This out of balance condition will not affect normal operation. It is a standard procedure for ASTA fire
doors and is necessary to enable the door to drop test correctly and to close reliably in the event of
a fire or alarm.
1. Clear the path of the doorway and barricade from passage of personnel or vehicular traffic.
2. With curtain in the fully open position, install locking pliers on each guide approximately 4" - 6"
below curtain stops to arrest downward curtain travel as shown in Figure 18.
3. Disengage the test handle, or operator release mechanism at this time.
4. Begin releasing spring preload tension using winding bars and the tension wheel, in reverse order
as shown in Figure 18, until barrel begins to rotate towards the closed position.
a. Release enough preload tension to allow the curtain to readily move downward and come
to a stop on the locking pliers.
b. Minimum preload is zero tension plus 1/8 turns on the tension wheel.
c. Install tension pin to secure tension wheel.
5. Re-engage test handle or motor release mechanism, and operate door to full open position.
6. You may now drop test the door per supplemental operator instructions.
a. If you wish to initially drop test the door to stop on the locking pliers, you may do so at this time.
If not, you may remove the locking pliers from the guide angles.
b. If you desire to drop test the door with the curtain position closer to the floor to more fully
familiarize yourself with the procedure, you may do so at this time. ASTA fire doors may be
released from any normal operational position with no harm to the fire door or operational
assemblies.
7. Drop test the door from the fully open position by releasing the test handle or motor release mechanism
at this time.
a. Door should start downward readily and close completely to the floor in a safe and controlled manner.
b. Curtain speed shall average not less than 6" per second and not more than 24" per second from
the time of release to reaching the floor.
c. Repeat steps #1 through #6 on this page for further out of balance adjustments.
d. Complete all instructions and documentation on drop test form and apply date.
Creating and Adjusting the Out of Balance Condition
Please follow the following out-of-balance procedure carefully.
ASTA DOOR CORPORATION

NUT WITH
FLAT WASHER
NUT & 2 FLAT HDG WASHERS
UNFILLED CONCRETE
(CMU) SHOWN
ALL THREAD
STUD THRU WALL
3" X 3" CRUSH PLATE
FOR SOFT BRICK
OR UNFILLED CMU
CONCRETE ANCHOR
FILLED CONCRETE
MASONRY UNIT
(CMU) SHOWN
& 2 FLAT HDG WASHERS
(1/4" SETBACK) (1/4" SETBACK)
MASONRY UNIT
STEEL JAMB
THREAD CUTTING SCREW
& 2 FLAT HDG WASHERS
(1/4' SETBACK)
CONCRETE JAMB
(1/4' SETBACK)
CONCRETE ANCHOR
& 2 FLAT HDG WASHERS
FILLET WELDS PER SPEC.
PAGE 3
FIGURE 2
FIGURE 2.A FIGURE 2.B
FIGURE 2.C FIGURE 2.D
ASTA DOOR CORPORATION
GUIDE MOUNTING DETAILS
PAGE A-2
Three fusible links, cable, ferrules, S hooks and a test handle are provided with each ASTA door.
Fusible links are attached to the cable by fashioning a loop in the cable and attaching this loop with an
S hook as shown in Figure A-2.
FIGURE A-3
FIGURE A-2
STEEL CABLE
1/2" EMT CONDUIT
3/4" SET COLLAR - RED
3" O.D. FLAT WASHER
CONCRETE, MASONRY, OR
OR APPROVED NON-MASONRY
FUSIBLE LINK
S HOOK
FERRULE
The upper fusible link locations, per NFPA-80 are shown in Figure A-2. A third fusible
link is located near the drive side headplate close to the opening height.
ASTA DOOR CORPORATION

PAGE 4
FASTENER DRILL
STEEL
NOTES
SIZE
JAMB
OR
CONCRETE
FILLED BLOCK
OR
UNFILLED BLOCK
SOFT BRICK
3/8-16 X 1" TYPE 23 THD CUT SCREW
3/8-16 X 1-1/4" HEX BOLT AND NUT
1/2-13 X 1-1/4" TYPE F THD CUT SCREW
1/2-13 X 1-1/2" HEX BOLT AND NUT
3/8" X 4" DEWALT SCREW-BOLT+
1/2" X 3" DEWALT SCREW-BOLT+
3/8" THREADED ROD & NUTS
1/2" THREADED ROD & NUTS
7/16"
29/64"
9/16"
3/8" ANSI B212.15
7/16"
9/16"
CLEAR HOLES OF CONCRETE DUST
FIGURE 3
FIGURE 5
OPENING WIDTH
OPENING
HEIGHT
HEADER
JAMB
SILL
JAMB
FIGURE 4
"E" GUIDE
STEEL JAMB
"Z" GUIDE
CONCRETE OR MASONRY JAMB
"W"
WALL ANGLE
OUTER ANGLE
INNER ANGLE
C
L
2 HDG
FLAT WASHERS
2 HDG
FLAT WASHERS
1/2" ANSI B212.15
3/16" THICK STEEL JAMB MINIMUM
INSTALL CRUSH PLATES ON
OPPOSITE SIDE OF WALL
ASTA DOOR CORPORATION
11/32"
BEFORE INSTALLING FASTENER
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 door 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 floor using center line of opening, and
clearly mark floor at each jamb.
d. Jamb floor marks should precisely equal "W" dimension and
reflect the location of the wall angle's perpendicular
leg as shown in Figure 5.
STRUCTURAL ANGLE GUIDES - FACE OF WALL
FASTENER CHART
PAGE A-1
FIGURE A-1
The upper fusible link locations, per NFPA-80 are shown in Figure A-1. A third fusible
link is located near the drive side headplate close to the opening height.
Route the cable in such a manner that the separation of any fusible link, or release by a release device,
will allow the cable to completely slack and allow the fire door to close by releasing the fire door
operator, as instructed in the supplemental operator instruction manual. See Figure A-1.
4"
4"
RED ZONE. DO NOT PLACE
LINKS IN THESE ZONES
APPROVED LOCATION
FOR FUSIBLE LINK
CONDUIT OR SLEEVE
12"
MAXIMUM
12" MAXIMUM
APPROVED LOCATION
FOR FUSIBLE LINK
Appendix "A"
ASTA DOOR CORPORATION

b. Measure the distance from each level reference mark to the floor to determine if the floor is level.
If there is a difference in measurements from the marks to the floor,
the floor is not level. You must shim the wall angle with the
longest reference measurement to verify that both wall angles
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.
Be positive about the accuracy of your level elevation reference marks!
FIGURE 6
PAGE 5
are mounted to the same elevation.
LEVEL
REFERENCE
MARK
ASTA DOOR CORPORATION
ü
ü
?
?
INTERMEDIATE
CHALK LINE
TENSION SIDE
HEADPLATE
Page 14
FIGURE 20
d. Attach top hood flange securely to the wall with installer supplied fasteners, 2" from ends
Use masonry fasteners for masonry walls.
On non-masonry walls install hood flange to each available wall stud with 1/4" min. diameter
The use of fire caulk may be required to eliminate gaps unsuitable to contractor or the
Authority Having Jurisdiction.
ü
ü
ü
SECURE HOOD
FLANGE TO WALL
TENSION
PIN
TENSION LABEL
HOOD SUPPORT
FIGURE 19
Note: You may now proceed with drop testing. See Appendix B for further instructions.
ASTA DOOR CORPORATION
2
2
24"
MAX
@ 24" max centers.
fasteners x length appropriate to extend thru substrate.

Page 13
WARNING: Use two solid steel winding bars of a diameter matching the tension wheel lugs.
Use of undersized or non-solid steel winding bars will result in component failure, injury,
or death.
d. Bottom bar should rise from locking pliers and come to rest touching head stops when full
preload tension has been applied.
e. Insert tension wheel pin as shown in Figure 20.
f. You may now remove slings.
11. Procedure for checking correct operation
a. Clear the doorway and closing path of the door.
NOTE: You must re-engage test handle or operator at this time to allow operation of the door.
b. Lower and raise the door several times.
c. Inspect curtain to certify that the endlocks or windlocks at each end of the curtain
are centered and do not rub on the headplates.
d. Make any necessary tension adjustments, hoist adjustments or operator limit adjustments
in order to achieve reliable operation and complete range of travel with no binding or dragging.
e. Verify that all fasteners are correctly installed and secured tightly.
f. Attach the product safety labels as directed on labels.
g. Apply sensing edge warning label if applicable.
Important Notes for a correctly balanced and functional door:
The bottom bar must fully rest on the floor when in the closed position.
The bottom bar must rest on the stops when in the fully open position.
The bottom bar must be level in both the open and closed position.
Procedure for installation of the Hood(s)
12.
b. Attach hood to headplate hood bands with self-drilling fasteners provided and approved by
a. If provided, mount intermediate hood support to a structurally stable location on wall
as shown in Figure 19 using installer supplied fasteners.
ASTA Door Corporation. Use two fasteners per flat hood surface as shown in Figure 20.
c. Overlap multiple hood segments and attach to center hood supports with self-drilling
fasteners.
ü
ü
ü
ASTA DOOR CORPORATION
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. Locate wall angle masonry anchors or machine screws in the TOP of each slot
PAGE 6
Two hot dipped galvanized washers must be installed under the head of each jamb fastener as shown in Figure 7.
USE ONLY HOT DIPPED GALVANIZED WASHERS PROVIDED BY ASTA. DO NOT SUBSTITUTE
WASHERS OF ANY OTHER TYPE OR SOURCE!
FIGURE 7
It is the manufacturers intent that E-type guides be disassembled prior to installation for
attachment by machine screws, masonry anchors or weldments.
Wall angles may extend above steel jambs onto masonry. In this case, attach with masonry
anchors of size and type recommended by manufacturer. Mount in the top of each slot as
shown in Figure 7. Shim with washers as required to maintain a flush mounting surface for
the wall angle. Use anchors that match the diameter of headplate bolts.
ü
ü
INSTALL SHIM
WASHERS UNDER
MACHINE
SCREW OR
WELDMENT
WALL ANGLE
IF NECESSARY
USE MASONRY ANCHORS
OF THE SAME DIAMETER
AS THE HEADPLATE BOLTS.
USE THROUGH BOLTS AND
CRUSH PLATES IF MASONRY
STEEL
JAMB
IS HOLLOW AS SHOWN
IN FIGURE 2.A.
as shown in Figure 7.
ASTA DOOR CORPORATION
*IMPORTANT*
NOTE:
NOTE:
NOTE:

NOTE: Procedure for welding wall angles to steel jambs.
Create weldments consistent only with the specifications shown in Figures 8 and 9.
FACE WALL MOUNT SHOWN
PAGE 7
BETWEEN JAMBS MOUNT SHOWN
FIGURE 8
ü
4. Procedure for installing wall angles
b. Install first wall angle plumb vertically at the correct elevation, and at the correct "W"
dimension floor mark.
c. Install second wall angle by placing it at the "W" dimension marked on the floor at the
second jamb as shown in Figure 10. Shim if necessary.
This is an upward expanding fire door. Guide angles are designed to be set upon the floor
ü
unless one angle requires the use of steel shims at the floor level to create level guide
elevations as shown in Figure 10.
Verify that the low side wall angle is shimmed to the correct height before permanent
ü
attachment to the jamb.
a. Use a plumb bob or level reference device to establish a true plumb reference.
FIGURE 9
JAMB ANGLE
BETWEEN
SLOT
SPACING
LENGTH OF
ONE SIDE
OF SLOT
T 1 1/2"
T
NOTE: USE E6010/E6011/E7014 ELECTRODES
OR ELECTRODES OF EQUIVALENT STRENGTH
T = JAMB ANGLE THICKNESS
MIN 3/16" THICK STEEL ANGLE,
BENT PLATE, OR STRUCTURAL
CHANNEL (BY OTHERS)
T = JAMB ANGLE THICKNESS
MIN 3/16" THICK STEEL ANGLE,
BENT PLATE, OR STRUCTURAL CHANNEL
(BY OTHERS)
BETWEEN
SLOT
SPACING
LENGTH OF
ONE SIDE
OF SLOT
T 1 1/2"
T
NOTE: USE E6010/E6011/7014 ELECTRODES
OR ELECTRODES OF EQUIVALENT STRENGTH
ASTA DOOR CORPORATION
FACE OF JAMB WELDED GUIDE WALL ANGLE BETWEEN JAMB WELDED GUIDE JAMB ANGLE
Page 12
FIGURE 17
i. Install guide service cutouts with previously installed head stops as shown in Figure 17.
j. Tighten guide assembly fasteners securely with two hot dipped galvanized washers per bolt as
shown in Figure 11.
FIGURE 18
a. Install locking pliers to service cutouts approximately 4" down from head stops
to arrest any downward curtain travel as shown in Figure 18.
b. Release and lower the curtain to rest slack upon the locking pliers. Barrel should be free
10. Procedure for applying tension preload to barrel assembly
to rotate at this time.
c. Apply tension from the top, downward, as shown in Figure 18 to the preload amont shown
on tension label and on barrel sticker.
CAUTION
TENSION
LABEL WIND IN A
DOWNWARD
HEADSTOP
LOCKING
PLIERS
DIRECTION
BOTTOM BAR STOP AND ANGLE GUIDE ASSEMBLY
(LEFT SIDE SHOWN)
OUTER ANGLE GUIDE
(SERVICE CUT-OUT)
INNER ANGLE GUIDE
HEADSTOP
INNER ANGLE GUIDE
ASTA DOOR CORPORATION
WINDING BAR
USE ONLY HOT DIPPED GALVANIZED WASHERS PROVIDED BY ASTA.
DO NOT SUBSTITUTE WASHERS OF ANY OTHER TYPE OR SOURCE!

Page 11
9. 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 guides in the service cutout portion
of the guide assembly as shown in Figure 16.
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 Door Corporation supplied cap head screws and
remove locking pliers.
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 barrel lugs into position
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 guide throats as you slowly rotate the barrel
and roll the curtain onto the barrel.
g. Transfer the entire curtain assembly onto the barrel, but leave the bottom bar hanging
3"-4" below the head stop location.
h. Secure curtain at this time to prevent downward rotation.
with segmented starter slats.
Use only straight-eye choker style slings with a minimum 5,000 lb weight rating.
SLINGING: IMPORTANT SAFETY PRECAUTIONS
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!!
ü
ü
FIGURE 16
CAUTION
ASTA DOOR CORPORATION
STARTER SLATS
ATTACHMENT LUGS
PAGE 8
6. Procedure for installing guide angle fasteners
a. Use two hot dipped galvanized washers under each nut as shown in Figure 11.
b. Install the head stops to the service cut-outs. See Figure 17.
c. Do not install guide angle service cut-outs at this time.
FIGURE 11
FIGURE 10
"W" DIMENSION
MARKS ON
FLOOR
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 10.
WALL ANGLE
INNER ANGLE
OUTER ANGLE
TWO HOT DIPPED
GALVANIZED WASHERS
TAPE MEASURE
ASTA DOOR CORPORATION

Page 9
FIGURE 13
7. Procedure for installing barrel and headplate assemblies to wall angles
a. Proceed at ground level and identify components as shown in Figures 12 and 13.
b. Install drive side headplate with mounted bearing as far as possible
onto drive shaft. Install sprocket and keystock onto drive shaft and tighten set screws
c. Install PVC spacer, headplate, tension wheel and keystock on Tension Shaft as shown
FIGURE 14
FIGURE 12
TENSION SIDE
HEADPLATE
DRIVE SIDE
HEADPLATE
HEADPLATES
RH DRIVE SHOWN
LH DRIVE OPPOSITE
TENSION
WHEEL
OUTSIDE
INSIDE
IDENTIFIED BY
MOUNTED FLANGE
BEARING
TENSION END DRIVE END
BARREL ASSEMBLY
KEYSEAT
WELDED
DRIVE
SHAFT
BEARING
ROTATING
SHAFT WITH
KEYSEAT
RH DRIVE SHOWN
LH DRIVE OPPOSITE
PVC SPACER
TENSION
WHEEL
SHAFT COLLAR FACTORY
WELDED TO HEADPLATE
TENSION SIDE
HEADPLATE
BARREL
PVC SPACER
KEYSTOCK
TENSION
STOP
TENSION SIDE HEADPLATE
WELDED DRIVE SHAFT
KEYSTOCK
TENSION
WHEEL
TENSION
WHEEL STOP PVC SPACER
DRIVE SIDE HEADPLATE
RH DRIVE SHOWN
LH DRIVE OPPOSITE
ASTA DOOR CORPORATION
on sprocket at this time as shown in Figure 13.
in Figure 14. Tighten set screws on Tension wheel.
DRIVEN
SPROCKET
KEYSTOCK
TENSION SHAFT
TENSION SHAFT
WHEEL STOP
Page 10
8. 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 inside of wall angles as shown in Figure 15.
c. Verify that barrel is unrestricted and free to rotate before proceeding.
WARNING
At this time, you may refer to the specific operator instructions provided
to install the operator bracket, operator, test handle and cable assemblies.
Refer to the Appendix "A" for related fusible link and cable routing drawings.
FIGURE 15
WALL
ANGLE
TENSION SIDE
HEADPLATE
HEADPLATE BOLTS
KEYSTOCK
TENSION
WHEEL
HOOD BAND
TENSION
LABEL
ASTA DOOR CORPORATION
b. VERIFY THAT BARREL IS DEAD LEVEL BEFORE TIGHTENING HEADPLATE BOLTS!
TENSION SIDE ASSEMBLY
ü
NOTE:
Refer to the Appendix "C" & the provided owners manual for motor operators.
ü

Page 9
FIGURE 13
7. Procedure for installing barrel and headplate assemblies to wall angles
a. Proceed at ground level and identify components as shown in Figures 12 and 13.
b. Install drive side headplate with mounted bearing as far as possible
onto drive shaft. Install sprocket and keystock onto drive shaft and tighten set screws
c. Install PVC spacer, headplate, tension wheel and keystock on Tension Shaft as shown
FIGURE 14
FIGURE 12
TENSION SIDE
HEADPLATE
DRIVE SIDE
HEADPLATE
HEADPLATES
RH DRIVE SHOWN
LH DRIVE OPPOSITE
TENSION
WHEEL
OUTSIDE
INSIDE
IDENTIFIED BY
MOUNTED FLANGE
BEARING
TENSION END DRIVE END
BARREL ASSEMBLY
KEYSEAT
WELDED
DRIVE
SHAFT
BEARING
ROTATING
SHAFT WITH
KEYSEAT
RH DRIVE SHOWN
LH DRIVE OPPOSITE
PVC SPACER
TENSION
WHEEL
SHAFT COLLAR FACTORY
WELDED TO HEADPLATE
TENSION SIDE
HEADPLATE
BARREL
PVC SPACER
KEYSTOCK
TENSION
STOP
TENSION SIDE HEADPLATE
WELDED DRIVE SHAFT
KEYSTOCK
TENSION
WHEEL
TENSION
WHEEL STOP PVC SPACER
DRIVE SIDE HEADPLATE
RH DRIVE SHOWN
LH DRIVE OPPOSITE
ASTA DOOR CORPORATION
on sprocket at this time as shown in Figure 13.
in Figure 14. Tighten set screws on Tension wheel.
DRIVEN
SPROCKET
KEYSTOCK
TENSION SHAFT
TENSION SHAFT
WHEEL STOP
Page 10
8. 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 inside of wall angles as shown in Figure 15.
c. Verify that barrel is unrestricted and free to rotate before proceeding.
WARNING
At this time, you may refer to the specific operator instructions provided
to install the operator bracket, operator, test handle and cable assemblies.
Refer to the Appendix "A" for related fusible link and cable routing drawings.
FIGURE 15
WALL
ANGLE
TENSION SIDE
HEADPLATE
HEADPLATE BOLTS
KEYSTOCK
TENSION
WHEEL
HOOD BAND
TENSION
LABEL
ASTA DOOR CORPORATION
b. VERIFY THAT BARREL IS DEAD LEVEL BEFORE TIGHTENING HEADPLATE BOLTS!
TENSION SIDE ASSEMBLY
ü
NOTE:
Refer to the Appendix "C" & the provided owners manual for motor operators.
ü

Page 11
9. 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 guides in the service cutout portion
of the guide assembly as shown in Figure 16.
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 Door Corporation supplied cap head screws and
remove locking pliers.
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 barrel lugs into position
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 guide throats as you slowly rotate the barrel
and roll the curtain onto the barrel.
g. Transfer the entire curtain assembly onto the barrel, but leave the bottom bar hanging
3"-4" below the head stop location.
h. Secure curtain at this time to prevent downward rotation.
with segmented starter slats.
Use only straight-eye choker style slings with a minimum 5,000 lb weight rating.
SLINGING: IMPORTANT SAFETY PRECAUTIONS
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!!
ü
ü
FIGURE 16
CAUTION
ASTA DOOR CORPORATION
STARTER SLATS
ATTACHMENT LUGS
PAGE 8
6. Procedure for installing guide angle fasteners
a. Use two hot dipped galvanized washers under each nut as shown in Figure 11.
b. Install the head stops to the service cut-outs. See Figure 17.
c. Do not install guide angle service cut-outs at this time.
FIGURE 11
FIGURE 10
"W" DIMENSION
MARKS ON
FLOOR
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 10.
WALL ANGLE
INNER ANGLE
OUTER ANGLE
TWO HOT DIPPED
GALVANIZED WASHERS
TAPE MEASURE
ASTA DOOR CORPORATION

NOTE: Procedure for welding wall angles to steel jambs.
Create weldments consistent only with the specifications shown in Figures 8 and 9.
FACE WALL MOUNT SHOWN
PAGE 7
BETWEEN JAMBS MOUNT SHOWN
FIGURE 8
ü
4. Procedure for installing wall angles
b. Install first wall angle plumb vertically at the correct elevation, and at the correct "W"
dimension floor mark.
c. Install second wall angle by placing it at the "W" dimension marked on the floor at the
second jamb as shown in Figure 10. Shim if necessary.
This is an upward expanding fire door. Guide angles are designed to be set upon the floor
ü
unless one angle requires the use of steel shims at the floor level to create level guide
elevations as shown in Figure 10.
Verify that the low side wall angle is shimmed to the correct height before permanent
ü
attachment to the jamb.
a. Use a plumb bob or level reference device to establish a true plumb reference.
FIGURE 9
JAMB ANGLE
BETWEEN
SLOT
SPACING
LENGTH OF
ONE SIDE
OF SLOT
T 1 1/2"
T
NOTE: USE E6010/E6011/E7014 ELECTRODES
OR ELECTRODES OF EQUIVALENT STRENGTH
T = JAMB ANGLE THICKNESS
MIN 3/16" THICK STEEL ANGLE,
BENT PLATE, OR STRUCTURAL
CHANNEL (BY OTHERS)
T = JAMB ANGLE THICKNESS
MIN 3/16" THICK STEEL ANGLE,
BENT PLATE, OR STRUCTURAL CHANNEL
(BY OTHERS)
BETWEEN
SLOT
SPACING
LENGTH OF
ONE SIDE
OF SLOT
T 1 1/2"
T
NOTE: USE E6010/E6011/7014 ELECTRODES
OR ELECTRODES OF EQUIVALENT STRENGTH
ASTA DOOR CORPORATION
FACE OF JAMB WELDED GUIDE WALL ANGLE BETWEEN JAMB WELDED GUIDE JAMB ANGLE
Page 12
FIGURE 17
i. Install guide service cutouts with previously installed head stops as shown in Figure 17.
j. Tighten guide assembly fasteners securely with two hot dipped galvanized washers per bolt as
shown in Figure 11.
FIGURE 18
a. Install locking pliers to service cutouts approximately 4" down from head stops
to arrest any downward curtain travel as shown in Figure 18.
b. Release and lower the curtain to rest slack upon the locking pliers. Barrel should be free
10. Procedure for applying tension preload to barrel assembly
to rotate at this time.
c. Apply tension from the top, downward, as shown in Figure 18 to the preload amont shown
on tension label and on barrel sticker.
CAUTION
TENSION
LABEL WIND IN A
DOWNWARD
HEADSTOP
LOCKING
PLIERS
DIRECTION
BOTTOM BAR STOP AND ANGLE GUIDE ASSEMBLY
(LEFT SIDE SHOWN)
OUTER ANGLE GUIDE
(SERVICE CUT-OUT)
INNER ANGLE GUIDE
HEADSTOP
INNER ANGLE GUIDE
ASTA DOOR CORPORATION
WINDING BAR
USE ONLY HOT DIPPED GALVANIZED WASHERS PROVIDED BY ASTA.
DO NOT SUBSTITUTE WASHERS OF ANY OTHER TYPE OR SOURCE!

Page 13
WARNING: Use two solid steel winding bars of a diameter matching the tension wheel lugs.
Use of undersized or non-solid steel winding bars will result in component failure, injury,
or death.
d. Bottom bar should rise from locking pliers and come to rest touching head stops when full
preload tension has been applied.
e. Insert tension wheel pin as shown in Figure 20.
f. You may now remove slings.
11. Procedure for checking correct operation
a. Clear the doorway and closing path of the door.
NOTE: You must re-engage test handle or operator at this time to allow operation of the door.
b. Lower and raise the door several times.
c. Inspect curtain to certify that the endlocks or windlocks at each end of the curtain
are centered and do not rub on the headplates.
d. Make any necessary tension adjustments, hoist adjustments or operator limit adjustments
in order to achieve reliable operation and complete range of travel with no binding or dragging.
e. Verify that all fasteners are correctly installed and secured tightly.
f. Attach the product safety labels as directed on labels.
g. Apply sensing edge warning label if applicable.
Important Notes for a correctly balanced and functional door:
The bottom bar must fully rest on the floor when in the closed position.
The bottom bar must rest on the stops when in the fully open position.
The bottom bar must be level in both the open and closed position.
Procedure for installation of the Hood(s)
12.
b. Attach hood to headplate hood bands with self-drilling fasteners provided and approved by
a. If provided, mount intermediate hood support to a structurally stable location on wall
as shown in Figure 19 using installer supplied fasteners.
ASTA Door Corporation. Use two fasteners per flat hood surface as shown in Figure 20.
c. Overlap multiple hood segments and attach to center hood supports with self-drilling
fasteners.
ü
ü
ü
ASTA DOOR CORPORATION
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. Locate wall angle masonry anchors or machine screws in the TOP of each slot
PAGE 6
Two hot dipped galvanized washers must be installed under the head of each jamb fastener as shown in Figure 7.
USE ONLY HOT DIPPED GALVANIZED WASHERS PROVIDED BY ASTA. DO NOT SUBSTITUTE
WASHERS OF ANY OTHER TYPE OR SOURCE!
FIGURE 7
It is the manufacturers intent that E-type guides be disassembled prior to installation for
attachment by machine screws, masonry anchors or weldments.
Wall angles may extend above steel jambs onto masonry. In this case, attach with masonry
anchors of size and type recommended by manufacturer. Mount in the top of each slot as
shown in Figure 7. Shim with washers as required to maintain a flush mounting surface for
the wall angle. Use anchors that match the diameter of headplate bolts.
ü
ü
INSTALL SHIM
WASHERS UNDER
MACHINE
SCREW OR
WELDMENT
WALL ANGLE
IF NECESSARY
USE MASONRY ANCHORS
OF THE SAME DIAMETER
AS THE HEADPLATE BOLTS.
USE THROUGH BOLTS AND
CRUSH PLATES IF MASONRY
STEEL
JAMB
IS HOLLOW AS SHOWN
IN FIGURE 2.A.
as shown in Figure 7.
ASTA DOOR CORPORATION
*IMPORTANT*
NOTE:
NOTE:
NOTE:

b. Measure the distance from each level reference mark to the floor to determine if the floor is level.
If there is a difference in measurements from the marks to the floor,
the floor is not level. You must shim the wall angle with the
longest reference measurement to verify that both wall angles
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.
Be positive about the accuracy of your level elevation reference marks!
FIGURE 6
PAGE 5
are mounted to the same elevation.
LEVEL
REFERENCE
MARK
ASTA DOOR CORPORATION
ü
ü
?
?
INTERMEDIATE
CHALK LINE
TENSION SIDE
HEADPLATE
Page 14
FIGURE 20
d. Attach top hood flange securely to the wall with installer supplied fasteners, 2" from ends
Use masonry fasteners for masonry walls.
On non-masonry walls install hood flange to each available wall stud with 1/4" min. diameter
The use of fire caulk may be required to eliminate gaps unsuitable to contractor or the
Authority Having Jurisdiction.
ü
ü
ü
SECURE HOOD
FLANGE TO WALL
TENSION
PIN
TENSION LABEL
HOOD SUPPORT
FIGURE 19
Note: You may now proceed with drop testing. See Appendix B for further instructions.
ASTA DOOR CORPORATION
2
2
24"
MAX
@ 24" max centers.
fasteners x length appropriate to extend thru substrate.

PAGE 4
FASTENER DRILL
STEEL
NOTES
SIZE
JAMB
OR
CONCRETE
FILLED BLOCK
OR
UNFILLED BLOCK
SOFT BRICK
3/8-16 X 1" TYPE 23 THD CUT SCREW
3/8-16 X 1-1/4" HEX BOLT AND NUT
1/2-13 X 1-1/4" TYPE F THD CUT SCREW
1/2-13 X 1-1/2" HEX BOLT AND NUT
3/8" X 4" DEWALT SCREW-BOLT+
1/2" X 3" DEWALT SCREW-BOLT+
3/8" THREADED ROD & NUTS
1/2" THREADED ROD & NUTS
7/16"
29/64"
9/16"
3/8" ANSI B212.15
7/16"
9/16"
CLEAR HOLES OF CONCRETE DUST
FIGURE 3
FIGURE 5
OPENING WIDTH
OPENING
HEIGHT
HEADER
JAMB
SILL
JAMB
FIGURE 4
"E" GUIDE
STEEL JAMB
"Z" GUIDE
CONCRETE OR MASONRY JAMB
"W"
WALL ANGLE
OUTER ANGLE
INNER ANGLE
C
L
2 HDG
FLAT WASHERS
2 HDG
FLAT WASHERS
1/2" ANSI B212.15
3/16" THICK STEEL JAMB MINIMUM
INSTALL CRUSH PLATES ON
OPPOSITE SIDE OF WALL
ASTA DOOR CORPORATION
11/32"
BEFORE INSTALLING FASTENER
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 door 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 floor using center line of opening, and
clearly mark floor at each jamb.
d. Jamb floor marks should precisely equal "W" dimension and
reflect the location of the wall angle's perpendicular
leg as shown in Figure 5.
STRUCTURAL ANGLE GUIDES - FACE OF WALL
FASTENER CHART
PAGE A-1
FIGURE A-1
The upper fusible link locations, per NFPA-80 are shown in Figure A-1. A third fusible
link is located near the drive side headplate close to the opening height.
Route the cable in such a manner that the separation of any fusible link, or release by a release device,
will allow the cable to completely slack and allow the fire door to close by releasing the fire door
operator, as instructed in the supplemental operator instruction manual. See Figure A-1.
4"
4"
RED ZONE. DO NOT PLACE
LINKS IN THESE ZONES
APPROVED LOCATION
FOR FUSIBLE LINK
CONDUIT OR SLEEVE
12"
MAXIMUM
12" MAXIMUM
APPROVED LOCATION
FOR FUSIBLE LINK
Appendix "A"
ASTA DOOR CORPORATION

NUT WITH
FLAT WASHER
NUT & 2 FLAT HDG WASHERS
UNFILLED CONCRETE
(CMU) SHOWN
ALL THREAD
STUD THRU WALL
3" X 3" CRUSH PLATE
FOR SOFT BRICK
OR UNFILLED CMU
CONCRETE ANCHOR
FILLED CONCRETE
MASONRY UNIT
(CMU) SHOWN
& 2 FLAT HDG WASHERS
(1/4" SETBACK) (1/4" SETBACK)
MASONRY UNIT
STEEL JAMB
THREAD CUTTING SCREW
& 2 FLAT HDG WASHERS
(1/4' SETBACK)
CONCRETE JAMB
(1/4' SETBACK)
CONCRETE ANCHOR
& 2 FLAT HDG WASHERS
FILLET WELDS PER SPEC.
PAGE 3
FIGURE 2
FIGURE 2.A FIGURE 2.B
FIGURE 2.C FIGURE 2.D
ASTA DOOR CORPORATION
GUIDE MOUNTING DETAILS
PAGE A-2
Three fusible links, cable, ferrules, S hooks and a test handle are provided with each ASTA door.
Fusible links are attached to the cable by fashioning a loop in the cable and attaching this loop with an
S hook as shown in Figure A-2.
FIGURE A-3
FIGURE A-2
STEEL CABLE
1/2" EMT CONDUIT
3/4" SET COLLAR - RED
3" O.D. FLAT WASHER
CONCRETE, MASONRY, OR
OR APPROVED NON-MASONRY
FUSIBLE LINK
S HOOK
FERRULE
The upper fusible link locations, per NFPA-80 are shown in Figure A-2. A third fusible
link is located near the drive side headplate close to the opening height.
ASTA DOOR CORPORATION

PAGE 2
FIGURE 1
TYPICAL FIRE DOOR
RH Drive Shown
LH Drive Opposite
DESCRIPTIONQTY
ITEM
DRIVE SIDE HEAD PLATE
11
TENSION SIDE HEAD PLATE12
DRIVE SHAFT
1
3
MOUNTING FASTENER (SEE FIG. 3)
X4
BARREL ASSEMBLY
15
HOOD
16
TENSION SHAFT
17
8
TENSION WHEEL
1
9
BELLMOUTH/HEADSTOP
1
10
SERVICE CUT-OUT
2
11
BOTTOM BAR ASSEMBLY
2
12
CURTAIN ASSEMBLY
1
13
GUIDE ANGLE ASSEMBLY
1
14 2
PVC SPACER
1
2
3
5
6
7
8
9
12
10
13
4
11
14
ASTA DOOR CORPORATION
PAGE B-1
DROP TESTING ASTA FIRE DOORS:
Appendix "B"
ASTA fire doors require that the door be placed in a permanent out-of balance condition to allow the
door to reliably close from any normal operating position when activated by alarm, notification or release
device.
This out of balance condition will not affect normal operation. It is a standard procedure for ASTA fire
doors and is necessary to enable the door to drop test correctly and to close reliably in the event of
a fire or alarm.
1. Clear the path of the doorway and barricade from passage of personnel or vehicular traffic.
2. With curtain in the fully open position, install locking pliers on each guide approximately 4" - 6"
below curtain stops to arrest downward curtain travel as shown in Figure 18.
3. Disengage the test handle, or operator release mechanism at this time.
4. Begin releasing spring preload tension using winding bars and the tension wheel, in reverse order
as shown in Figure 18, until barrel begins to rotate towards the closed position.
a. Release enough preload tension to allow the curtain to readily move downward and come
to a stop on the locking pliers.
b. Minimum preload is zero tension plus 1/8 turns on the tension wheel.
c. Install tension pin to secure tension wheel.
5. Re-engage test handle or motor release mechanism, and operate door to full open position.
6. You may now drop test the door per supplemental operator instructions.
a. If you wish to initially drop test the door to stop on the locking pliers, you may do so at this time.
If not, you may remove the locking pliers from the guide angles.
b. If you desire to drop test the door with the curtain position closer to the floor to more fully
familiarize yourself with the procedure, you may do so at this time. ASTA fire doors may be
released from any normal operational position with no harm to the fire door or operational
assemblies.
7. Drop test the door from the fully open position by releasing the test handle or motor release mechanism
at this time.
a. Door should start downward readily and close completely to the floor in a safe and controlled manner.
b. Curtain speed shall average not less than 6" per second and not more than 24" per second from
the time of release to reaching the floor.
c. Repeat steps #1 through #6 on this page for further out of balance adjustments.
d. Complete all instructions and documentation on drop test form and apply date.
Creating and Adjusting the Out of Balance Condition
Please follow the following out-of-balance procedure carefully.
ASTA DOOR CORPORATION

A rolling door is a large heavy object that moves
with the help of springs under extreme tension and
follow these instructions.
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,
WARNING!
Use proper lifting equipment and correct
lifting procedures to avoid damage or injury.
CAUTION
SAFETY INFORMATION
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR
ELECTRICAL SHOCK
HIGH SPRING TENSION
WARNING
Could result in death
or serious injury
Keep people clear of opening while Door is moving.
DO NOT allow children to play with the Door Operator.
DO NOT operate a Door 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 Door
spring parts are fastened, such as steel brackets or other like items.
Repairs and adjustments must be made by a trained door 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
Overhead doors 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:
if not avoided, may result in injury or property damage.
which, if not avoided, could result in death
if not avoided, will result in death or serious injury.
or serious inury.
Door must be fully opened when making adjustments.
Repairs and adjustments must be made by a trained rolling door systems
technician using proper tools and instructions.
WARNING
Could result in death
or serious injury
PAGE 1 ASTA DOOR CORPORATION
DANGER: Indicates an imminently hazardous situation which,
WARNING: Indicates a potentially hazardous situation
CAUTION: Indicates a potentially hazardous situation which,
FIGURE C-1
PAGE C-1 ASTA DOOR CORPORATION
Appendix "C"
1. Verify the barrel and guide assemblies are properly installed and that all
fasteners are tightened securely.
2. Procedure for installation of motor operator.
a. Attach the operator to bracket using the supplied hex bolts,
flat washers, lock washers and hex nuts as shown in Figure C-1.
b. Install motor operator and bracket assembly to the drive side headplate
with two 1/2" -13 NC X 1 1/4" carriage bolts as shown in Figure C-1.
c. Push the assembly toward wall as far as possible for drive chain
installation, and temporarily secure the two carriage bolts as shown in
Figure C-1.
d. Install the drive shaft sprocket with supplied key way.
e. Align the drive shaft and operator sprockets and tighten set screws.
f. Size & install the supplied #50 roller chain and secure with #50 master link.
g. Loosen the operator carriage bolts and tighten the roller chain by pulling
the assembly away from the wall leaving approximately 3/4" slack in chain.
h. Tighten operator bracket carriage bolts and set screw to lock the bracket
in place and to retain roller chain setting during future operation.
MOTOR OPERATOR
OPERATOR BRACKET
SET SCREW
1/2" CARRIAGE BOLT
PIVOT BOLT
OPERATOR FASTENERS
KEY WAY
DRIVE SPROCKET
OPERATOR SPROCKET
#50 ROLLER CHAIN
ASTA Door Corporation 500 Series FIRE DOOR
Motor Operator Installation

FIRE DOOR 500 SERIES
BASE INSTALLATION MANUAL
READ ENTIRE MANUAL BEFORE
BEGINNING INSTALLATION
FEBRUARY 2020 CARTERSVILLE,GA
astadoor.com
FIRE DOOR 500 SERIES
BASE INSTALLATION MANUAL
FEBRUARY 2020
ASTA DOOR CORPORATION
638 Cassville White Rd NW
Cartersville, GA 30121
P.O. Box 639
Cassville, GA 30123
Office: 770-974-2600
Fax: [phone]
www.astadoor.com