CGI Series 560 SGD Installation Instructions

CGI Series 560 SGD Installation Instructions Read these instructions completely before beginning to install. Become familiar with what type of installation will be required. This door can be installed in concrete or wood structures and using wood bucks (at the top and sides) or directly to the structure. The wood bucks can also be 1x or 2x and the installation screw types vary based on the installation. Additionally, read and familiarize yourself with the Miami Dade County NOA or State of Florida Product Approval documents. These show other limitations that may apply to your installation. If any questions, feel free to contact the dealer or CGI at 305-593-6590. Keep in mind that some installations may be done in stages while others are done all at once. For example, frame installation may occur well before the panels are installed in some instances, yet in other, the frame installation, frame sealing and panel installation will be performed all at once. Know what type of installation will be required. There are six common types of installation: Type I: Into concrete with 1x wood bucks on top and sides Type II: Into concrete with 2x wood bucks on top and sides Type III: Into wood structures with 1x wood bucks on top and sides Type IV: Into wood structures with 2x wood bucks on top and sides Type V: Into concrete without using wood bucks Type VI: Into wood structures without using wood bucks Refer to the back section of these instructions for illustrations on the different types of installations mentioned above for both 2 and 3 track frames. NOTE: Read instructions completely before attempting any installation. These instructions are provided as a general guide in the installation of our Series 560 products. Applicable approval documents (such as, but not limited to, Miami-Dade County NOA Product Approvals, State of Florida Approvals, TDI Approvals, etc.) should be used in conjunction with these instructions. Only experienced installers familiar with these or similar products should attempt to install these units. Incorrect installations could void the warranty. Technical support is available by contacting CGI at 305-593-6590 (local) or 1-800-442-904 www.cgiwindows.com ECN2012-05

Verify the opening is correctly built This part is written assuming installation is going into a concrete structure. If installation is being performed on a wood framed structure, then references to masonry or concrete will actually mean the primary wood structure. If pressure treated wood bucks are required (at top and sides only), make sure they are: o the correct size- 1 x 6 or 2 x 6 nominal or larger for the 2-track system OR custom 1x or 2x minimum 8 3/8 deep for the 3-track system. o wood for pocket door hook jamb varies, see pocket details P for further information o that they run continuous to ends o that they abut each other at the joints o that they are set in bed of sealant (sealant should spill out on sides) and are fully sealed to each other (at joint) and to the adjacent masonry structure. CGI always suggests that a recess (minimum ¾ ) be used at the sill (see illustration A below). The recess is usually located on the same plane as the inside face of the concrete blocks. Check that the opening is plumb and level. Use a large level (6 feet long if possible) Check the diagonal dimensions of the opening and make sure they are within ¼ of each other. Measure opening width at top, middle and bottom of opening. If installing with wood bucks, measure between bucks. If installing directly to concrete, measure concrete opening. Make sure size is correct, if not, the opening may need to be corrected. Measure opening height at three different points of the opening (at both end and at the center). If installing with wood bucks, measure between underside of wood at top and concrete at bottom. If installing directly to concrete, measure concrete opening. Make sure size is correct, if not, the opening may need to be corrected. Chip out any concrete that protrudes from the mounting surface and may interfere with the installation. This very often occurs at the corners. 2

3 Before attempting to build the frame, know what comes in a frame pack Extrusions: 1 header, 1 sill, 1 waterbar adaptor and 2 reversible jambs o 3 track frames also have 2 sill inserts and 2 jamb covers o Pocket doors replace the jamb for a pocket hook at each pocket Note: On certain very wide doors, the head and sill members may be split in 2 parts (12) #12 x 1 1/2 Hex head SMS Stainless Steel frame assembly screws (7) #10 x 1 ½ Pan head SMS Stainless Steel astragal attachment screws (4) #8 x 1 ½ flat head self drilling stainless (with plastic cover) fixed panel screws (4) 3 1/4" long adhesive backed pile pad (Part 586) to be field installed at bottom of each interlock (6) 2 1/4" long adhesive backed angled pile pad (Part 578) to be field installed at the top and end of any exposed panel edge (12) 1/2" x 1 adhesive backed pile pad (Part 597) to be field installed at the sill track below each interlock that is exposed to the exterior (50) Adhesive backed 30 PPI reticulating foam baffle (large quantities required for large 3 track configurations) (12) 3/8 hole plug for roller adjustment holes

4 These components are taped to one of the jamb extrusions. Note that all parts will not be used. These frame packs contain components for every SGD configuration. This is done to simplify the manufacturing process. Note that Handle Sets (back to back and single sided), keepers and door stops are shipped separately of panels or frames. Building the frame (on 2, 3, 4, and 6 panel doors) Open the frame pack and make sure the required contents are all there. Refer to the previous page of these instructions that clearly describes what each pack contains. The jambs on the CGI SGD are reversible and contain only one pocket to engage the panel. It is critical that the frame jamb pocket be correctly located. Refer to diagram B1, B2, B3 or B4 at the back of these instructions in order to make sure you assemble the frame jambs in the correct position. Note that when assembling a pocket door, the pocket hook does not attach to the head or sill. These instructions are based on a non-pocket door frame assembly. Clean the ends of jambs with IPA Alcohol, where the header and sill attach, so all grease and debris can be removed. Clean the cut ends of the header and sill member as well. Apply a generous amount of sealant (such as a low modulus 100% clear silicone rubber) to the end of a header or sill. Also apply sealant at cut edge of the jamb pocket legs that attach at this corner. Secure corner using supplied assembly screws (3 screws per corner). Repeat this step for the other three corners. IT IS CRITICAL THAT THE SILL BE SEALED CORRECTLY. If this is not accomplished on this step, the frame could leak and corrective work can become very difficult. Make sure that the sill is not rotated and is properly centered on the jamb, otherwise, the waterbar adaptor may not fit correctly and the sill may retain unnecessary water. Check the header member as well. It is recommended that after all four corners are sealed and attached, the sill member be resealed again from the bottom of the frame. Verify that the size of the assembled frame is correct. Installing the waterbar adaptor The waterbar adaptor can be installed on the frame, prior to installing the frame on the opening or at any time after the frame has been installed. Refer to illustration C below which shows how the waterbar is installed. Once installed on the frame, seal the ends of the waterbar where they meet the jambs (see End Seal note below). Remember the waterbar is secured using sealant alone (no mechanical fasteners are required). Allow time for the sealant to cure or secure with duct tape temporarily while the sealant cures.

5 Installing the frame (this does not apply to O single panel configuration) - For installations that require vertical mullions within an opening, refer to this section plus the mullion installation instructions that follow this section - For doors that are very wide, the head and sill members may be split in two. If this is the case, the installer will need to seal the joint between the parts in the field. Position the frame in the opening to make sure that it fits inside. Mark where the sill will be located on the bottom. If you intend on installing the waterbar after installing the frame, make sure you leave enough room on the backside between the frame and recess, to attach the waterbar. CGI suggest mounting the sill on a bed of high strength grout (refer to NOA s for grout specifications). This will provide a more solid sound when operating the door. Sweep the area where the sill will be mounted and place the grout material on the floor at this point. Insert the frame in the opening by positioning the sill on the grout first. Center on all sides using temporary shims at each corner. Make sure frame is plumb and straight. Level the sill at this point. Check diagonal dimension of frame. The diagonal dimension should not vary by more than 1/8. Note: Use a level that is at least 6 feet long if possible. Do not install with a 2 foot level. Secure the frame in the opening using the required installation screws. If installing a pocket door, install the pocket hook at this time. Note that the hook may need to be notched at the bottom to clear the recess (no notch required if no recess is present). Refer to detail P of the pocket condition. o The hook is notched at the ends to straddle the head and sill members. The notches are the same at both ends, so the part is symmetrical. o To insert the hook, the hook must be inserted at an angle, straddled over the head and sill and then positioned straight up and down.

6 o Make sure the hook is properly located with respect to horizontal dimensional placement; refer to diagrams B3 or B4 for dimension points. o Secure as needed with correct installation screws Seal the pocket hook to the sill and head member watertight. Seal all sill installation screws. It is suggested that you begin to insert the sill screw and stop when the screw is about 1/2" to 1 away from the frame. Apply clear silicone sealant to the hole and underside of screw and then tighten completely. This allows the screw to be set in a bed of sealant. Any excess silicone should be spread over the head of the screw making sure the edges are fully sealed. Make sure all screw heads are flat and not protruding away from the frame. Check the frame to ensure it is plumb and level as you secure the frame. Make sure the frame members are not bowed at any point. When frame installation is complete, recheck the diagonal dimension and make sure they are within 1/8. Clean off any excess grout or setting material used at sill. Tool the grout on the outside face to allow future application of perimeter caulking, once the grout dries. The grout should be recessed at least 1/8 in from the outer face of the sill. If waterbar has not been installed, make sure to clean off the grout on the backside to avoid interference with waterbar. If this door is extremely large or being installed into a very high windload required opening, it is possible that extra installation screws may be required. These would normally occur at the location of interlocks and astragals, mainly into wood bucks. If extra screws are required, they must be drilled in the field by the installer. Refer to the product approval documents to determine if any are needed. If they are, these can be drilled now, or before the frame is assembled and installed. On 2 track frames, you should cover the drain holes that are located on the top of interior track. These holes lead to an internal drain chamber of the sill that can become plugged with construction debris. On 3 track frames, the holes will be covered in the next section. CGI suggests protecting the frame, primarily the sill to avoid damage during construction. Cementious materials that fall on the track and dry up may cause problems in the future both for proper operation of panels and sealing. The frame can be protected with cardboard, wood, films, tapes or a combination of these. Installation of sill inserts and jamb covers on 3-Track Frame Systems ONLY Unlike the 2 track frame, the 3 track frame has 2 sill inserts and 2 jamb covers. They must be installed after the frame has been installed in the opening. Note: In order to clearly see the installation screws, installation of sill inserts and jamb covers may need to be delayed until job is inspected; consult your building inspector. Identify the exterior and interior sill inserts. The interior sill inserts will have additional drain holes with foam baffles adhered below drain holes.

7 Install the sill inserts in accordance with diagram M. You will need to use a piece of wood and hammer or mallet to snap the sill inserts. Cover the drain holes on the interior sill insert while construction is going on. These holes lead to an internal drain chamber of the sill that can become plugged with construction debris. Snap jamb covers into place as per diagram M. Installation of frames to mullions rather than walls Sometimes doors are installed to a mullion on one side (or to mullions on both sides), rather than the walls of a building. The installation process is the same, except the concrete screws should be replaced with ¼ diameter x 2 long Philips Flat Head S/S Sheet Metal Screws. CGI offers 2 x 6, 2 x 8 and 2 x 10 tube mullions, without the need for a mullion clip. It is often necessary to add installation screws at the head and sill of doors since mullion clips are not used. Refer to the Miami Dade County or Sate of Florida Product Approvals to see if you need to add additional screws. This information can be found on the mullion page. You will need to know the size of the panel that is adjacent to the mullion and the required windload (in PSF) of the opening. Sealing the frame at the perimeter to surrounding materials (Perimeter Caulking) The frame should be sealed before the stucco or stone trims are installed, but after the grout has dried. Sealing the frame directly to the stucco is strongly discouraged as this will eventually create leaks. Clean the area that will be sealed with a hard clean brush or small broom. Clean the frame area that will be sealed with IPA alcohol. Insert a sealant back-up material such as a backer rod, between the frame and wood bucks (or structure if wood bucks have not been used) at the head and jambs. The backer material should be set in about 3/16 to 1/4"from the face of the frame. This backer material will assure a proper perimeter seal thickness. Apply the perimeter sealant on all four sides. Seal the ends of the mullions if any have been used. If installing a pocket door, make sure to seal the pocket hook to the wall as well. Also seal the end of the sill track at the open end. When applying sealant between the sill frame member and concrete, make sure you have at least 1/8 worth of sealant thickness. The sealant should be continuous without any holes.

8 Tool the edge of the sealant with a plastic spoon to assure the sealant does not have any voids. Many installers also like to use the back edge of the tube that the sealant came in. Install miscellaneous frame components Install the keepers on any jambs that will contain a lockable panel. There are two sets of pre-drilled holes/markings on each jamb. Use the lower set of marks and install the keeper using the two slotted holes in the keeper. This will allow for vertical adjustments during final adjustment. The round hole in the keeper will be used after the panels are installed and the door is checked for proper locking and operation. If the door being installed is a 3 or 4 panel 2-track configuration or 6 panel 3-track configuration, the keeper will be secured to the astragal adaptor, not the jambs. Install the 3 1/4 long self adhesive pile pad (part 586) at the interlock location at the sill. The pad should be located at the exact same distance from the end as the anti-lift block that is located on the header (refer to illustration D). You can also drop a plumb line from the center of the anti-lift block and mark that point on the sill. The sill should be cleaned with alcohol before applying the pad. Installing the panels and Astragal Adaptor (Astragal on 3 or 4 panel 2-track doors and 6 panel 3-track doors only) Locate the panels that will be required for the opening mark you are installing. Each panel has a specific two letter panel mark type (such as A-L). The same type of panel may be used on more than one door type, so make sure you find the correct one. Refer to illustrations E1 or E2 at the back of these instructions for panel marks. Clean the frame of all debris and remove any remaining protective materials that were installed. Remove any protective covering on the panel.

9 Adjust the rollers on any moving panel to the uppermost retracted position. This will make the installation easier. Install the panels beginning with those that are used on the inner track first and then those that are on the outer track. Installation must be done from the outside. After all panels are in place adjust the height of the rollers. Refer to diagram F which illustrates the correct height of the panels with respect to the sill. Once panels are properly adjusted, install the 3/8 hole plug in the screw hole. If the door requires an astragal adaptor, it should be installed at this point. Refer to door configuration types in diagrams B1, B2, B3 or B4 for the location of astragal adaptors. The adaptor requires sealant to be applied along two surfaces (see diagram G ). Note that the astragal may face inside or outside based on the door configuration. The adaptor needs to be inserted at an angle on the frame and then straightened to its correct location. The height of the astragal is consistent with the height of the panel. Secure the astragal with the supplied #10 x 1 1/2" Philips Pan Head S/S SMS s. Install the keeper on any astragal adaptors that you may be using. Instructions on installing keepers are found in the Installation of Miscellaneous Frame Components section of these instructions. Make sure all the panels fit correctly and the interlocks engage correctly. When panels approach the jambs, the visible gap from the top to the bottom, between the panel and the jamb, should be consistent. The same applies when the interlocks are coming together. There should be a uniform gap top to bottom. If this is not happening, then either the rollers are not properly adjusted or the frame is not correctly installed. A level should be used to determine which is wrong. Secure the fixed panels to the jamb (refer to diagram H ). These panels do not have rollers. You may need to lift each panel in order to insert it into the jamb. Suction cups can be very helpful with larger panels. Note that the fixed panels should penetrate into the jamb pocket at least ¾. The panel should be secured with two #8 x 1 ½ Flat Head Self Drilling Stainless Steel screws mounted on a 2 part nylon cover cap. The installer needs to drill the jamb leg from the inside at the v groove that exists on the extrusion. One screw is required at the top and one at the bottom. The distance from the ends should be no more than 24. Adjust all keepers and make sure that all the panels operate and lock correctly. Hint on panel locking: The thumbturn should rotate completely approximately one full turn after locking. You will hear when the lock engages as this makes an obvious sound. If you feel that the thumbturn stops rotating when locking, then the keeper is probably too low and preventing the lock from fully engaging. Raise the keeper slightly and try again. Repeat this step until the condition improves. Once the keeper is set correctly, insert the third screw into the keeper s round hole. This third screw will prevent the keeper from moving up or down.

10 Hint on keeper attachment and security: For added security, any keeper that is attached to a jamb can have the supplied screws replaced with longer screws that will attach through the jamb into the building s structure. While this is not required, it is strongly suggested as it will provide added strength to the locking system. If installing a 3 track frame, install the adhesive backed pile pads 578 & 597 at this point. Refer to Illustration D2 for location of these pads. Install the handles on the panels. The primary operating panel uses back to back, double sided handles with escutcheon plates. The secondary operating panel may use a single sided handle and escutcheon plate with threaded bushings on the opposite side. Refer to diagram J for an illustration of these different handles. Make sure to tighten the set screws on the interior handles when completing the handle installation. Note: On door stiles with reinforcing, the reinforcing inside the secondary operable panel needs to be drilled through in the field in order to install the single sided handle. Install the door stop with the supplied screw. The location of the doors stops is based on the configuration of the door (2- track, 3-track, pocket, etc.). When locating the door stop, make sure that when the panel is opened, the door stop prevents the panels from opening too much and pinching your fingers against the stationary panel or the pocket hook. Check from both the inside and outside. Door stop may be placed on the frame head or panel face. Some configurations require a combination of both. See diagrams S1, S2 and S3 for recommended location based on the configuration being used. These are suggested locations of door stops. Other location of door stops may also be possible. Illustration D2 - Pads 578 & 597 at 3 track frames ONLY

Installation of O panels An O panel is basically a fixed window utilizing a single door panel and a 2 track frame. Unlike a normal sliding glass door where the frame is installed and then the panels are installed into the frame, the O panel requires that the frame be assembled around the panel and then the whole assembly be lifted into place and installed as a single unit. If glass damage were to occur, these panels require that the glass be replaced on site, since the panel cannot be removed without removing the frame. This is the same as would occur with any direct set type fixed window. Following is the sequence in which the O panel and frame is installed. Note that many of these steps are better described in the regular installation instructions herein, so become familiar with those before reading this section. The jambs on single O panels must be attached to the walls using an exposed fastener, not the normal installation fastener location used on a typical frame. This fastener requires a support clip on the backside of the jamb (refer to diagram K ) which is installed at CGI. Verify that these clips are on the backside of the jambs you are using before building the frame. Build three sides of the frame by attaching one end of the head and sill member to one jamb. Seal these members as described in Building the frame (on 2, 3, 4 and 6 panel doors) section of these instructions. Refer to Step 1 of illustration L. Place the O panel on a work bench and insert the three sided frame from one end of the panel into the outer track area (refer to Step 2 of illustration L ). Make sure you insert the panel on the outer track. You may want to install a 5/8 high temporary shim at each end of the head of the O panel or frame head (see note on step 3). This will prevent the panel from moving excessively inside the frame while the assembly is being built and transported to the opening. Attach the missing jamb and seal the ends as shown in step 3 of illustration L. Place the assembled frame and panel in the opening. Remember that the panel must be sitting on the outer track; otherwise you will not be able to access the installation holes of the head and sill. Secure the frame to the wall. When installing the jamb installation screws, you should use the included plastic cap to cover the screw heads. Since these screws are exposed, it is suggested to use the 1/4" diameter installation screws option whenever possible. Make sure the panel is properly sitting on its track. Center the panel left to right on the frame, measure the diagonal dimensions to make sure it is correct and secure the panel at each jamb as you would any other fixed panel. Secure the panel to the jamb with the #8 x 1 ½ screws as shown on diagram K. Install the waterbar and seal the frame at the perimeter as described previously in these installation instructions. Suggested Installation Screws 2-Track Configurations: 11

12 Type: 5/16 Diameter Flat Head UltraCon Masonry Fasteners by ELCO Length if installing using 1x or 2x wood bucks into concrete: 4" long at Head and Jambs 3 1/4" long at Sills Length if installing using 1x or 2x wood bucks into wood structure: 3 1/4" long on all four sides Length if installing directly into concrete or wood: 3 1/4" long on all four sides Note: These fasteners are available in Silver, White and Bronze Stalgard corrosion resistant finish. The NOA s also allow the use of 1/4" diameter Hilti Kwik-Con II fasteners in lieu of the 5/16 UltraCon mentioned above. Note that the 1/4" Hilti fasteners are not as strong as the 5/16 and have reduced capacities in some instances. This information is shown on the NOA. 3-Track Configurations: Type: 1/4 Diameter Flat Head UltraCon Masonry Fasteners by ELCO Length if installing using 1x or 2x wood bucks into concrete: 4" long at Head and Jambs 3 1/4" long at Sills Length if installing using 1x or 2x wood bucks into wood structure: 3 1/4" long on all four sides Length if installing directly into concrete or wood: 3 1/4" long on all four sides Note: These fasteners are available in Silver, White and Bronze Stalgard corrosion resistant finish. The NOA s also allow the use of 1/4" diameter Hilti Kwik-Con II fasteners in lieu of the UltraCon mentioned above. Note that the different fastener types affect the capacities in some instances. This information is shown on the NOA. See following pages for additional diagrams and illustrations

Optional Sliding Glass Door Screens Screens are supplied assembled from CGI. The screens have concealed nylon guides at the top and nylon rollers on stainless steel housings at the bottom. The rollers are adjusted from the ends of the panel. The screen panels are manufactured non-specific to a particular door type. There are a few items that need to be installed or customized in the field to suit the specific application. They are as follows: 1. Install the interior black screen handle (refer to picture and item 1 below) with the two supplied #8 x 3/4" Oval Head screws. The screen frame will need to be drilled to accept the screws. The height of the handle is up to the consumer, but most handles are installed centered within the tubular door handles installed on the panels. 2. Notch the black bug flap (item 2 below) at the top and bottom so that flap clears frame head and sill. On two panel doors ONLY, trim the bug flap to a shorter length on the side that meets the frame jamb. There are ridges on the flap to simplify trimming. 3. On OXXO doors that have a pair of screens, a black rubber astragal (item 3 below) needs to be inserted on one of the screen edges that meet. This astragal is shipped loose for field installation. The bug flaps (item 2) can be removed on OXXO doors since they will serve no purpose. 4. The optional thin screen will require an additional handle to the exterior (item 4 below). This will be installed with the two supplied #8 x 1/2 Pan Head screws. Handle should line up centered with the interior screen handle (item 1). 5. When an optional Pet Screen Lock is required (see photo), install according to the desired location as shown in the Mounting Option Diagrams below. There are numerous locations where the lock can be located. Screen Handle and Lock Installed Screen Components (Items 1 through 4)

Mounting Option Diagram of Screen Lock Mounting Option Diagram of Screen Lock (Thin Profile Screen)