ASTA Door Corporation
4255 McEver Industrial Drive
Acworth, GA 30101
Phone: (770) 974-2600
Fax: (770) 974-1455
Web Site: www.astadoor.com
IMPORTANT REMARKS ALL ASTA PRODUCTS MUST BE
INSTALLED BY A LICENSED, QUALIFIED PROFESSIONAL DOOR
COMPANY TO QUALIFY FOR OUR WARRANTY. INSTALLATION
WITHOUT PROPER TOOLS AND KNOWLEDGE CAN RESULT IN
PERSONAL INJURY. THIS PAMPHLET IS DESIGNED TO ASSIST
A PROFESSIONAL IN THE INSTALLATION OF ASTA MODEL 300
COMMERCIAL SLAT DOORS. SAFETY IS FOREMOST
INSTALLATION SHOULD BE EXECUTED BY LICENSED, QUALIFIED
DOOR PROFESSIONALS. INSPECT ALL OF THE SHIPPED PARTS
AND ACCOUNT FOR EVERYTHING BEFORE COMMENCING
ANY WORK. FOR QUESTIONS AND TECHNICAL ASSISTANCE,
CONTACT ASTA CUSTOMER SUPPORT AT (770) 974-2600.
Installation Instructions
Model 300 Commercial Slat Door
USE ASTA DOOR CORPORATION PARTS ONLY - ALL OTHERS SHALL VOID WARRANTY
WARNING
MOVING DOOR can cause serious injury or death.
Keep clear of opening while door is moving.
SAFETY INSTRUCTIONS
1. Do Not stand or walk under moving door. Keep door in full view and free of obstructions while operating.
2. Do Not allow children to operate the door or automatic operator.
3. Repairs or adjustments should be made by a trained service person using proper tools and instructions.
4. To avoid injury, do not put fingers between door and guides.
5. Read owner’s manual for your door and operator for more information.
CAUTION: USE CORRECT LIFTING PROCEDURES AND EQUIPMENT DURING
INSTALLATION OF THIS PRODUCT TO AVOID INJURY OR DAMAGE.
STANDARD GUIDE
DIAGRAM 3
2.1/16"
2.1/16"
CHAIN CLIP
18
19
DIAGRAM 1
STEEL / WOOD
20-21
5-6
OPTIONAL
3.1/8"
3.1/2"
5.1/2"
3.1/8"
3.1/2"
26-27
2
DIAGRAM 4
CONCRETE / MASONRY
STRUCTURAL GUIDE DETAIL (NON-WINDLOCK)
DIAGRAM 5
22
DIAGRAM 6
5.1/8"
2.3/4"
46
G = 1.1/8"
45
G = 1.1/8"
4"
4"
G
G
3/8"
12-14
3
3/8"
STEEL / WOOD
7-9
DIAGRAM 2
16
CONCRETE / MASONRY
STRUCTURAL GUIDE DETAIL (WINDLOCK)
DIAGRAM 7
DIAGRAM 8
3.1/4"
11
5.1/8"
15
G = 1.1/2"
4.3/4"
G
3/8"
STEEL / WOOD
G = 1.1/2"
4.3/4"
G
3/8"
CONCRETE / MASONRY
PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
CURTAIN SUB-ASSEMBLY:
VARIES
TOPSHEET
190020-1
STARTER SLAT-TOP
VARIES
ENDING SLAT-BOTTOM
VARIES
SLAT, FLAT PROFILE
VARIES
SLAT, CURVED PROFILE
VARIES
ENDLOCK, NYLON
450143-1
ENDLOCK, CAST IRON
450144-1
WINDLOCK, CAST IRON
450141-1
BOTTOM-BAR SUB-ASSEMBLY:
VARIES
STARTER/ENDING SLAT
VARIES
BOTTOM ANGLE, 2" X 1-1/2" X 12 GA GALV. STEEL 190001-1
BOTTOM ANGLE, 2" X 2" X 1/8" STRUC. STEEL
270008-1
BOTTOM ANGLE, 2" X 2" X 3/16" STRUC. STEEL
270007-1
ALUMINUM RETAINER
VARIES
BOTTOM BULB ASTRAGAL
260004-1
AXLE SUB-ASSEMBLY:
VARIES
AXLE PIPE
VARIES
12" BEARING DRUM ASSEMBLY
220300BB-1
SPRING - LH
VARIES
SPRING - RH
VARIES
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
SPRING CLAMP ASSEMBLY
230001-1
NUT, 3/8"-16 SQUARE
740301-1
BOLT, 3/8"-16 X 1-1/2" SQUARE HEAD SET
730501-1
WASHER, 1-7/16" ROUND FLAT
770104-1
GUIDE CHANNEL - 12 GA GALV. HEAVY DUTY - LH
VARIES
GUIDE CHANNEL - 12 GA GALV. HEAVY DUTY - RH
VARIES
3PC GUIDE - NON-WINDLOCK (TYPE 2) - LH
VARIES
3PC GUIDE - NON-WINDLOCK (TYPE 2) - RH
VARIES
3PC WINDLOCK GUIDE (TYPE 5/5M) - LH
VARIES
3PC WINDLOCK GUIDE (TYPE 5/5M) - RH
VARIES
STANDARD SUPPORT BRACKET, LH
310300-1
STANDARD SUPPORT BRACKET, RH
310200-1
HEAVY DUTY SUPPORT BRACKET, LH
310300-1HD
HEAVY DUTY SUPPORT BRACKET, RH
310200-1HD
AXLE CLAMP (STAMPING)
310103-1
STANDARD KEEPER PLATE
310102-1
BOLT, 3/8"-24 X 3-1/2" HEX HEAD
730103-1
NUT, 3/8"-24 HEX
740104-1
WASHER, 3/8" FLAT
750103-1
WASHER, 3/8" LOCK
750203-1
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
EXTENDED KEEPER PLATE
3/8"-16 U-BOLT
NUT, 3/8"-16 HEX
LIFT CLIP - DOOR STOP
SLIDE BOLT LOCK
BOLT, 1/4"-20 X 1-1/4" TRUSS HEAD SLOTTED
NUT, 1/4"-20 SELF LOCKING
NUT, 5/16"-18 HEX
WASHER, 1/4" FLAT
CHAIN HOIST ASSEMBLY (8:1) POCKET WHEEL:
DOOR SPROCKET (9'-72 TOOTH)
HAND CHAIN, OPEN LINK
CHAIN CLIP
CHAIN PACK, #41-78 PITCH
BOLT, 3/8"-16 X 1-1/2" HEX HEAD
CHAIN HOIST ASSEMBLY SINGLE REDUCTION:
CHAIN PACK, #41 - 110 PITCH
ANCHOR, 3/8" X 1-7/8" SLEEVE
STEEL MOUNTING PLATE - STANDARD
STEEL MOUNTING PLATE - HEAVY DUTY
420101-1
770301-1
740103-1
280301-1
280104-1
730301-1
740201-1
740102-1
750101-1
420104-1
440001-1
420299-1
420300-1
420111-1
730100-1
420102-1
420106-1
760101-1
310400-1
310410-1
CAUTION: Do not remove the plastic BANDS which holds the door in a roll. You will be told
at a later time when to remove it. No guarantee will be given or responsibility accepted by
the manufacturer if the door is not installed as instructed. For proper operation, follow the
instructions as given. Please review all the steps before beginning.
NOTE
LEFT HAND SHOWN THROUGHOUT, RIGHT HAND OPPOSITE.
Step #1 - PREPARATION
A. CHECK THE HEIGHT and WIDTH OF THE DOOR OPENING.
B. CHECK IF THE DOOR JAMBS ARE PLUMB.
C. CHECK IF THE FLOOR AND HEADER ARE LEVEL.
D.CHECK THE dimension panel for side room
and head room requirements. (SEE DIAGRAM 9)
DIAGRAM 9
CEILING
(DOOR ASSEMBLY)
OPENING
HEIGHT
SEE
A1
SEE
A2
OPENING
WIDTH
DRIVE
SPROCKET
ASSEMBLY (52)
SET
SCREW
DOOR SUPPORT
BRACKETS
HEADER
b.install electric operator kit (if equipped) as follows:
1.install e.o. sprocket to end drum of door on
preferred side using 3/8" x 1.1/2" hex bolt (56),
3/8" nuts (44) and 3/8" lock washer (41).
2.slide flat round washer (25) and spring clamp
assembly onto door axle and secure set screw with
clamp and washer against bearing of the end drum.
(see diagram 11)
DRIVE
CHAIN (55)
X
20"
21"
23"
OPERATION
ELECTRIC
POCKET WHEEL REDUCTION GEAR
NOTE
Y
9"
10"
11"
Z
11"
11"
12"
A1
9"
10"
A2
7"
7"
DIAGRAM 10
DRIVE
SPROCKET
(52)
DOOR
SHAFT
POCKET
WHEEL
ASSEMBLY
(51)
CLEARANCE REQUIREMENTS
OPENING HEIGHT
up to 8'
UP TO 14'
OVER 14'
DRUM
WHEEL
HAND
CHAIN (53)
22
56
25
52
DIAGRAM 11
51
provide adequate backing for bracket location.
Step #2 - install support brackets
a.mark the horizontal (A1) & (A2) of the support brackets
(32-33). (See Diagram 9)
b.mark the vertical location of the support brackets
by using the "y" dimension. check the height of each
bracket to verify that the door will be parallel to the
floor. the door must be level.
NOTE
verify the minimum headroom requirement,
dimension "x." if insufficient, lower the brackets
and guides until "x" is obtained.
C.drill holes and fasten the brackets with the fasteners
provided or as required to obtain a solid mounting.
use through bolts on soft brick or block.
D.DOORS LARGER THAN 12' WIDE AND/OR 12' HIGH COME
WITH HEAVY DUTY SUPPORT BRACKETS (34-35).
Step #3 - DRIVE INSTALLATION
a.POCKET WHEEL REDUCTION GEAR
1.install drive sprocket on preferred side using 3/8" X
1.1/2" hex boltS (56), 3/8" NUTS (44) AND 3/8" LOCK WASHERS (41).
2.slide pocket wheel assembly onto door axle
and align sprockets parallel to each other.
3.connect drive chain around both sprockets using the
master link provided.
4.after door tension has been adjusted (step 6), tighten
set screws on pocket wheel assembly.
NOTE
if further adjustment is needed, set screws must
be loosened for adjustment and retightened
after adjustment. (see diagram 10)
22
56
25
52
Step #4 - POSITION DOOR ASSEMBLY
a.PLACE THE AXLE CLAMP (36) ONTO DOOR SUPPORT BRACKET.
LIFT THE DOOR ASSEMBLY UP ONTO THE SUPPORT BRACKET
(SEE DIAGRAM 12).
NOTE
POSITION THE DOOR AS CLOSE TO THE HEADER AS
POSSIBLE. ALLOW ROOM TO SPIN THE DOOR. DO NOT
ALLOW THE DOOR CURTAIN TO SCRAPE THE HEADER.
DO NOT USE FORKLIFTS OR GENIE LIFTS WITH
UNPROTECTED ARMS/FORKS. THIS CAN CAUSE
IRREPARABLE DAMAGE TO DOOR CURTAIN.
DIAGRAM 12
Step #5 - AXLE HARDWARE
DIAGRAM 15
a.POCKET WHEEL REDUCTION DRIVE CHAIN HOIST (DRIVE SIDE)
1.PLACE THE AXLE CLAMP (36) AND THE STANDARD KEEPER
PLATE (37) OVER THE DOOR AXLE AS SHOWN.
2.fasten together using 3/8" x 3.1/2" hex bolt (38),
3/8" lock washer (41), 3/8" flat washers (40), and
3/8"- 24 nuts (fine thread) (39) - tighten securely.
(see diagram 13)
B.NON-DRIVE SIDE (POCKET WHEEL REDUCTION DRIVES
AND E.O. KITS):
1.PLACE THE TWO AXLE CLAMPS (36) AND EXTENDED KEEPER
PLATE (42) ON TOP OF THE DOOR AXLE AS SHOWN.
2.fasten AXLE CLAMPS (36) AND EXTENDED KEEPER PLATE
(42) and u-bolt (43) TOGETHER USING 3/8" x 3.1/2" hex
bolt (38), 3/8" lock washer (41), 3/8" flat washers (40),
3/8" - 24 nuts (fine thread) (39) FOR HEX BOLTS AND
3/8" - 16 NUTS (44) FOR U-BOLT. tighten securely.
(see diagram 13)
C.if you're unable to rotate door to pre-tension, use a
pipe wrench to rotate axle in opposite direction. with
one person on each side of door, each person should
firmly place a large pipe wrench on the door axle
(see diagram 16). pull down to apply tension
incrementally until you achieve two (2) full rotations
of the door axle. then tighten the axle hardware.
d.repeat step c if adjustment is necessary.
DIAGRAM 16
DIAGRAM 13
DRIVE SIDE
Step #7 - cut the bands
NON-DRIVE SIDE
WARNING
37
38
39
42
43
40
36
44
41
THE DOOR IS NOW UNDER TENSION. BEFORE CUTTING
THE BANDS, TAKE HOLD OF THE DOOR ROLL BY THE
BOTTOM ANGLE.
a.CUT THE BANDS AND BRING THE CURTAIN DOWN NO FURTHER
THAN THE 1/4 THE HEIGHT OF THE DOOR OPENING.
SECURE CHAIN OVER THE CHAIN RETAINER OR WEDGE A WOOD
PROP BETWEEN THE BOTTOM ANGLE AND THE DOOR ROLL TO
PREVENT UPWARD TRAVEL.
Step #8 - INSTALL DOOR STOPS (LIFT CLIPS)
AND SLIDE BOLT LOCKS
FOR DOORS 20' WIDE OR WIDER
C.SAME PROCEDURE AS "A" FOR TWO BRACKETS ON
THE DRIVE AND NON-DRIVE SIDE (SEE DIAGRAM 14).
a.INSTALL THE DOOR STOPS (45) AND THE SLIDE BOLT LOCKS (46)
USING 1/4" X 1.1/4" TRUSS HEAD BOLT (47), 1/4" FLAT WASHERS (50),
5/16" NUT (45), AND 1/4" SELF LOCKING NUT (48) PER SIDE.
B.ELECTRONICALLY OPERATED DOORS STILL REQUIRE
DOOR STOPS (LIFT CLIPS) TO BE INSTALLED.
DIAGRAM 14
DIAGRAM 17
47
50
46
45
48
45
NOTE
REQUIRES A MINIMUM OF 40 LBS. TORQUE TO PROPERLY
SECURE HARDWARE.
Step #6 - pre-tension springs
a.install chain clip approximately 4'0" above floor on
chain operated doors. installation must be secure.
b.apply pre-tension to the springs by rotating the door
two (2) turns in a forward direction (see diagram 15).
the bottom angle is to be in a 6 o'clock position.
NOTE
when installing slide bolt locks, the threads
from the truss head bolt protruding from the
self locking nut should be removed to a flush
position with the self locking nut to prevent
door from hanging up on the head stops. clamp
a pair of vice grips onto the thread and break off.
Step #9 - install door guides
a.the head stops on the guides should be no more
Than 1" higher (to bottom of stops) than the door
header. if not, cut the bottom of the guides to match
your opening height and relocate slide bolt notch
at bottom of guide.
b.raise the door curtain so the bottom angle is
approximately 3" below the header. slide the guide
over the door curtain and position against the door
opening allowing 3/8" clearance from edge of curtain
to inside the guide.
install the top fasteners, lower curtain into guides
slowly, maintaining proper clearance and stop at 6"
above the floor. install bottom fasteners. check
if the guides are plumb using a level. the fasteners
should be located approximately every 24" starting 6"
from the finished floor. install balance of fasteners
and bend the lead-in at the top of the guide to a
45-degree angle (see diagrams 3 through 8 and 18).
DIAGRAM 18
LEAD-IN
HEADSTOP
C.for windlock models: use same procedure as above,
allowing 1/4" clearance between curtain and the
windlock spur. lower the curtain into the guides
slowly. be sure there is sufficient clearance for
the windlock clips to enter the guides (see diagrams
7 and 8).
d. for "windload certified doors" refer to drawing for
fastner/anchor type and frequency.
e. spray silicone lubricant in guides for ease of operation.
NOTE
doors ordered for concrete/masonry applications
will include 1/4" x 2.1/2" tapcons for guide
installation. block clips welded to back of guide
for concrete/masonry application are optional
UNLESS THEY ARE 3-PC STRUCTURAL STEEL ANGLE GUIDES.
Step #10 - check and adjust balance
if door lowers easily and raises hard, more tension is
required. if the door lowers hard and raises easily, less
tension is required (see diagram 19).
CAUTION: for all door drives: before adjusting
the springs, pull the doors into the up position.
secure the door by the following methods:
1. tie a rope around the door roll
2. place a clamp at the top of the guide channel
to secure the curtain in the guides.
a.reduction drive doors only
WARNING: when the axle clamps are loosened,
the chain leads will be under tension. use
extreme care when handling the chain leads.
secure both leads of the cHAIN TO THE CHAIN RETAINER.
SCORE A HORIZONTAL LINE ON THE AXLE. LOOSEN AXLE
HARDWARE TO ALLOW AXLE TO SPIN FREELY. GRIP BOTH LEADS OF
THE CHAIN SECURELY. NOTE DIRECTION AXLE MUST TURN TO ADD
OR REDUCE TENSION (SEE DIAGRAM 19). ROTATE AXLE AS REQUIRED.
SECURE BOTH CHAIN LEADS TO CHAIN RETAINER. TIGHTEN ALL AXLE
HARDWARE. REPEAT THIS OPERATION IF MORE OR LESS TENSION IS
REQUIRED.
B. ALL OTHER DOORS
WARNING: when the axle clamps are loosened, THE
SPRINGS WILL BE VERY STRONG. YOU WILL NEED TWO
PEOPLE TO SAFELY ADJUST THE DOOR TENSION.
1. EACH PERSON SHOULD FIRMLY PLACE A LARGE PIPE WRENCH
ON THE AXLE (SEE DIAGRAM 16). LOOSEN THE AXLE CLAMPS AND
PULL DOWN FOR MORE TENSION AND UP FOR LESS TENSION. FOR
POCKET WHEEL REDUCTION DRIVE DOORS, REMEMBER TO LOOSEN
SET SCREWS PRIOR TO ADJUSTEMENT AND RETIGHTEN SECURELY
AFTER ADJUSTMENT.
2. RETIGHTEN THE AXLE CLAMP HARDWARE
3. IF FURTHER ADJUSTEMENT IS NECESSARY, REPEAT ABOVE STEPS
BEGINNING WITH STEP 6B (PRE-TENSION SPRINGS).
SERVICE AND MAINTENANCE HINTS
USE THE FOLLOWING HINTS FOR TROUBLESHOOTING:
1. DOOR CURTAIN DRAGS IN GUIDES OR
DOOR OPERATES HARD IN ONE DIRECTION:
A. CHECK THAT DOOR SUPPORT BRACKETS ARE PLUMB.
B. ADJUST LOCATION OF GUIDES FOR 3/8" - 1/4" SIDE CLEARANCE,
TOP AND BOTTOM.
C. DOOR DRUM ASSEMBLY MAY BE SET TOO CLOSE OR TOO FAR
FROM WALL. NOTE SLOTTED BRACKETS FOR ADJUSTMENT.
D. CHECK GUIDES FOR FOREIGN MATTER SUCH AS DIRT, ETC.
E. CHECK FOR DAMAGED GUIDES
F. A
DJUST LEAD-IN BEND AT TOP INSIDE OF GUIDES (DIAGRAM 18).
G. LUBRICATE GUIDES
H. RE-CHECK STEP NO. 10 (CHECK AND ADJUST BALANCE).
2. CHAIN JUMPS OFF CHAIN GEAR
A. ON ELECTRIC OPERATOR DOORS OR POCKET WHEEL
REDUCTION GEAR DOORS, CHECK FOR SPROCKET ALIGNMENT
AND PROPER CHAIN TENSION. ALSO CHECK THAT SET SCREWS
ON POCKET WHEEL ASSEMBLY ARE SECURELY FASTENED.
3. DOOR DOES NOT CONTACT FLOOR LEVEL
A. USE SPIRIT LEVEL TO CHECK WHETHER DOOR OR FLOOR IS
OFF LEVEL. IF DOOR IS OUT OF LEVEL, PORCEED TO CHECK THE
FOLLOWING POINTS:
- CHECK IF "SUPPORT BRACKETS" AND GUIDES ARE LEVEL.
- IF "A" AND "B" CHECK OUT, ROLL DOOR ALL THE WAY UP AND
SEE IF CURTAIN ROLLS UP STRAIGHT ONTO DRUMS. END OF
DOOR SHOULD BE SQUARE. IF CONE SHAPED, GO TO SEC. 4.
4. DOOR DOES NOT ROLL UP STRAIGHT
A. C
HECK ALL POINTS IN SEC. 1
B. ROLL DOOR UP TO STOPS. ROLL DOOR DOWN SLOWLY TO
CHECK SLAT ALIGNMENT ON CURTAIN. THERE IS A SMALL GAP
BETWEEN THE ENDLOCK AND END OF SLAT THAT COULD ALLOW
SLAT(S) TO SHIFT SLIGHTLY DURING TRANSIT. PRY OR TAP SLAT
BACK INTO ALIGNMENT AS NEEDED.
C. AN ALTERNATIVE SOLUTION TO CORRECT THE CONING DOOR
IS TO RAISE THE CURTAIN UP TO THE STOPS AND DETERMINE
WHICH SIDE OF THE BOTTOM ANGLE TOUCHES THE STOPS
FIRST.
D. S
ECURE HAND CHAIN, REMOVE GUIDES, LOWER CURTAIN DOWN
TO FLOOR LEVEL. INSTALL A DRUM WEDGE ON SIDE OF THE
DOOR FROM WHICH THE BOTTOM ANGLE TOUCHES FIRST.
E. PROCEED TO STEP 9 TO REINSTALL THE DOOR GUIDES.
F. IF PROBLEM PERSISTS, CONSULT FACTORY.
REVISION DATE: 08-01-11