Pro Series - PFB Installation Instructions PART NO: MS0116 These instructions are intended for professional garage door installers. All references are taken from inside looking out.
2 Contents 1.0 Before You Start 3 1.1 Safety Checklist 3 1.2 Checking Measurements 4 1.3 Fastener Recommendations 4 1.4 Tools 5 1.5 Parts Checklist 5 1.6 Check & Mark Out the Opening 6 2.0 Installation 7 2.1 Assembling & Installing Standard Vertical Tracks 7 2.2 Assembling Bottom & Middle Panels 8 2.3 Installing Panels 9 2.4 Installing Horizontal Tracks 10 2.5 Assembling Top Panel 11 2.6 Fitting Reinforcing 11 2.7 Counterbalance System Assembly & Placing in Position 12 2.8 Adding Tension to Spring 15 3.0 After Installation Care 16
3 1.0 Before You Start 1.1 Safety Checklist The following hazards and hazard controls have been identified for installers during the installation of this door. hazard Housekeeping - risk of slip trip or fall Housekeeping - risk of injury to other people or animals in the installers work area Manual handling when moving the door from the Trailer or Ute to the installation area - risk of musculoskeletal injury Manual handling when installing Doors & Openers particularly above head height - risk of musculoskeletal injury or twisting Manual handling when installing tracks and torsion bars - risk of musculoskeletal injury Working at heights and working with ladders, scissor lifts, scaffold - risk of fall from height sharp edges on door, tracks or related jewellery - risk of laceration Pinch points - risk of cut, puncture or crush injury use of hand tools - risk of eye injury, laceration, cut, stab or puncture injuries (Tools checklist) use of Electric/ Battery or pneumatic tools - noise hazard use of cutting tools creating sparks - risk of fire Tension spring - risk of release of stored energy (striking installer on the head or body) control Tidy up site prior to start work as a minimum area should be at least the area of the installation back into the garage and 2 metres in front If the site housekeeping is deemed to be unsafe do not install the door Keep all people well clear of installers work area with appropriate signage and discussion with owner Pack sizes use of 2 person lifts use of mechanical aids Avoid twisting (practice correct lifting techniques) correct use of ladders while installing tracks ladder check ladder placement Do not work off the top rung Wear appropriate PPE (Dyneema cut off gloves) Follow instruction explicitly particularly for the installation of windows in some panel doors as the unrolled cut out edges presents a very sharp edge Wear appropriate PPE and keep hands well clear of pinch points Ensure hands well clear of the panels Wear appropriate PPE and utilise operators manual use appropriate noise/hearing protection in the form of ear plugs or ear muffs Ensure appropriate fire protection available and housekeeping to ensure that flammable liquids or materials are removed from the area of work Ensure correctly fitting winding bar is used Ensure the correct length winding bar is utilised Ensure winding bar is placed appropriately in the torsion socket plug Ensure correct bolts are tightened or loosened (or clamp pliers) to ensure there is no release or controlled release of energy from the spring either through the torsion bar or the winding bar Keep hands clear of the torsion plug at all times Keep head clear of the tensioning bar at all times
4 1.2 Checking Measurements Headroom Standard 300mm including opener Low 200mm including opener (will only work with an opener) headroom 10mm Sideroom (with 25mm door overlap) Standard Limited reverse fix (not recommended) Backroom Recommended door height plus Minimum with opener door height plus 120mm 85mm 350mm 600mm sideroom 25mm opening width opening height 25mm door height 1.3 Fastener Recommendations door width Unlined Garage substrate type solid brick (>10 mpa) three hole brick (> 30 mpa) ten hole brick (>15 mpa) concrete block (> 8 mpa) concrete (> 15 mpa) timber steel section (0.9-2mm thick) fastener required screw, coach 5/16-9tpix50 screw anka m8x75 flange hex head screw anka m8x75 flange hex head screw anka m8x75 flange hex head screw, coach 5/16-9tpix50 screw, coach 5/16-9tpix50 screw tek 14g-20tpix25 flange hex head zp washer required washer flat m8 plug required plug, nylon 5/16x50 drilled hole ø (mm) min hole depth (mm) 10 60 washer 3/8 n/a 8 75 washer 3/8 n/a 8 75 washer 3/8 n/a 8 75 washer flat m8 plug, nylon 5/16x50 10 60 washer flat m8 n/a 5 60 washer flat m8 n/a n/a n/a Lined Garage (up to 13mm thick plasterboard) substrate type solid brick (>10 mpa) three hole brick (> 30 mpa) ten hole brick (>15 mpa) concrete block (> 8 mpa) concrete (> 15 mpa) timber steel section (0.9-2mm thick) fastener required screw, coach 5/16-9tpix80 screw anka m8x75 flange hex head screw anka m8x75 flange hex head screw anka m8x75 flange hex head screw, coach 5/16-9tpix80 screw, coach 5/16-9tpix50 screw tek 14g-20tpix25 flange hex head zp washer required washer flat m8 plug required plug, nylon 5/16x80 drilled hole ø (mm) min hole depth (mm) 10 90 washer 3/8 n/a 8 75 washer 3/8 n/a 8 75 washer 3/8 n/a 8 75 washer flat m8 plug, nylon 5/16x80 10 90 washer flat m8 n/a 5 90 washer flat m8 n/a n/a n/a
5 Available Standard Fastener Packs fastener screw, coach 5/16-9TPIx50 screw, coach 5/16-9TPIx80 plug, nylon 5/16x50 plug, nylon 5/16x80 screw tek 14G-20TPIx25 flange hex head ZP screw tek 14G-20TPIx35 flange hex head ZP screw masonary M8x75 flange hex head standard fastener pack part no. FK0011 FK0012 FK0013 FK0014 FK0015 FK0016 FK0017 FK0018 FK0019 FK0020 FK0021 FK0022 FK0023 FK0024 standard fastener pack description kit, screw, coach 5/16-9TPIX50 100pk kit, screw, coach 5/16-9TPIX50 500pk kit, screw, coach 5/16-9TPIx80 100pk kit, screw, coach 5/16-9TPIx80 500pk kit, plug, nylon 5/16x50 100pk kit, plug, nylon 5/16x50 500pk kit, plug, nylon 5/16x80 100pk kit, plug, nylon 5/16x80 500pk kit, screw tek 14-20x25 100pk kit, screw tek 14-20x25 500pk kit, screw tek 14-20x35 100pk kit, screw tek 14-20x35 500pk kit, screw anka M8x75 flange hex head 50pk kit, screw anka M8x75 flange hex head 100pk screw, coach M10x90 FK0037 kit, screw coach M10x90 100pk plug nylon 14x70 M10 FK0038 kit, plug nylon 14x70 M10 100pk screw masonary M10x75 FK0028 kit, screw masonary M10x75 100pk bolt & nut 1/4"1/2"UNC FK0040 kit, bolt & nut 1/4x1/2 UNC 100pk bolt & nut 5/16"7/8"UNC FK0041 kit, bolt & nut 5/16x7/8 UNC 100pk Important Notes 1. The above chart specifies the fasteners for new substrate materials only. Seek specialist advice regarding pre-existing substrate materials. 2. It is important that correct washer and plug is used and the correct pilot hole drilled where specified. Important Information on Fasteners The installer must select and use fasteners appropriate to the material into which they are being fixed. 1.4 Tools It is recommended that this door is installed by a professional door installer using a professional and specialised tool kit. 1.5 Parts Checklist When taking delivery of your sectional overhead door you will be supplied with the following: 1 package with door panels 2 pairs of tracks straight tracks for vertical and curved tracks for horizonal 1 torsion bar (tube) 1 or 2 springs depending on door size panel reinforcing (refer to chart) 1 parts box 1 bag of polypropylene hinge links, pins and screws Reo Assignment All Doors panel count width ranges (from - to, mm) 2200-3000 4500-4900 4905-5300 4/5 0 1 2 1 reo = top panel 2 reo = top panel + bottom panel
6 1.6 Check & Mark Out the Opening 1. using a lazer or water level mark datum as below. 2. Mark top track bracket based on detail 1.6.1 B or C measurement. datum line B or C measurement mark equal overlap on each side from datum line to the floor based on the panel size Figure 1.6.1 Wheel-Axle E/F E/F A C A C B Standard Sideroom Limited Sideroom Figure 1.6.2 detail A at bottom axle standard sideroom 5mm 95mm 50mm limited sideroom 5mm n/a 50mm NOTE: These measurements allow for final adjustment. B C E/F (ref pg 7) 5-8mm without BAL seals 5-8mm without BAL seals
7 2.0 Installation 2.1 Assembling & Installing Standard Vertical Tracks Parts Needed 2 straight tracks 2 long angle brackets 2 top bearing brackets 4 small angle brackets 4 x 5/16 bolts and nuts 6 x 1/4 bolts and nuts Note: For low headroom an additional kit is required. 20 Standard Headroom Low Headroom Assemble the top angle bracket and horizontal bearing bracket with the flanges facing out away from the door. The initial position for the horizontal bracket is forward and upward in the slots, this may need to be adjusted later. Before cutting the vertical tracks measure from the horizontal datum line to the floor on each side to determine if floor is level. Add any difference to the vertical track cut height which is door height minus 220mm for standard headroom and minus 345mm for low headroom. Note: For low headroom an additional kit is required - Part No: SD0368 Ensure they are cut left and right as a pair. E/F Assemble left and right tracks and small brackets. The bottom bracket should be approximately 150mm from the floor and the second half way between it and the top of the track. Take note of the E&F measurement as a guide, Figures 1.6.1 and 1.6.2. Attach the top bracket assembly to the structure using the previously marked horizontal datum marks with the top of the vertical angle bracket for standard headroom 250mm and low headroom 125mm above the datum mark and spaced correctly using detail from Figure 1.6.1 and 1.6.2. Datum NOTE: There must be at least 3 fixings with washers to each top bracket, other fixings are to have washers fitted. Now attach the vertical tracks to the bottom slot of the top angle bracket and secure in place to the structure. Note: The fixing flange can be placed in either the standard or limited sideroom position. For the low headroom quick closer system additional L shaped bearing brackets are fitted in addition to the standard bearing brackets (see detail). brackets turned in for limited sideroom
8 2.2 Assembling Bottom & Middle Panels Before opening the panel pack make sure the bottom panel with weather strip and gray plastic blocks is on top. As the panels are assembled carefully place to one side or install directly into the vertical tracks (Section 2.3). Bottom panel: Locate both bottom hangers and cables. Insert cable through the holes of the bottom hanger as shown in Figure 2.2.2A. Remove existing screws in the two bottom corners of the panel near the weather strip and discard, see Figure 2.2.2B. Attach the bottom hangers to the lower end of the door using 6 TEK screws in each as shown in Figure 2.2.2C. Insert the polyethylene hinge links into the recesses of the top of the panel and fix into place using the white pins. Insert four wheels and axles into the top of the panel (white pins) and the bottom of the panel (grey block), Figure 2.2.2C. Ensure the axles are lightly lubricated with lithium or general purpose grease before inserting. Middle panels: Repeat the process for fitting links, pins and wheels and axles to the top of each middle panel. Lightly grease each axle and insert as shown in Figure 2.2.3. The top panel will be assembled after the horizontal tracks are fitted. Parts Used Figure 2.2.1 other panels bottom panels hinge pin hinge links wheel axles weather strip bottom hangers (left hand- right hand) 2 lifting cable (variable) standard bottom black hinge bottom grey hinge with offset Figure 2.2.2 NOTE: The cable will be held in place when the assembly is fitted to the panel. DO NOT hold cable in place by squeezing the bracket around it as this will cause the cable to fracture and break. secure hanger using 6 tek screws to each A B C Figure 2.2.3 Assemble links & pins onto the panel
CSI Classic Pro Series PFB Sectional Garage Door Installation Instructions 2.3 Installing Panels Figure 2.3.2 Carefully lower the wheels of the bottom panel into the tracks. The bottom door panel is to sit level in the door opening, Figure 2.3.2. The wheels are to sit in the V groove of the vertical tracks and there should be clearance between the shouldered axle and the grey block, if not correct adjust tracks to suit, Figure 1.6.1. Before fitting the next panel fold all the hinge links down. Insert panel into the guide engaging the wheels into the vertical tracks, Figure 2.3.2 and Figure 2.3.3. Starting at the centre, lift the panel enough to insert the link, repeat this one at a time for the remaining links. Repeat this procedure for all other panels with the exception of the top panel which is assembled differently later. Figure 2.3.1 Label Figure 2.3.3 Note: Ensure warning label is clearly visible. Figure 2.3.4 9
10 2.4 Installing Horizontal Tracks Fit the top curved tracks as shown in Figure 2.4.1, ensure that the bearing brackets are level and the curve is aligned and butts up against the vertical track snugly. The horizontal tracks should be at least door height + 350mm and have the safety stops fitted. Figure 2.4.1 Assembling Horizontal Track Figure 2.4.2 Bracing Bracing must be fitted approximately 1.6>2m from the lintel (about 2/3rds of the door height) fix to ceiling angle horizontal track Figure 2.4.3 Single Brace Before bracing the horizontal tracks, ensure that they are square to the opening, parallel with each other and level. To check whether your diagonals are equal, measure from the top of the vertical track to the end of the horizontal track on both sides. Adjust ceiling brackets as required (Figure 2.4.2) make sure that the structural fixing is sound. Installing the Safety Pull Cord Installing the Safety Stop pull cord track stop The safety pull cord must always be fitted to the door. Pass the cord through the white hinge pin, adjust length and tie in a knot at each end.
11 2.5 Assembling Top Panel The top panel can be easily identified by always having a centre stile for use with an opener and no hinge link cut outs in the curved top edge. Figure 2.5.2 Ensure all screws indicated are fitted after adjusting. Lightly lubricated the axles with lithium or general purpose grease before inserting into the top hangers as shown in Figure 2.5.1. Then assemble top hangers to top corners of the panel as shown in Figure 2.5.2 using the vertical slots only. The additional two fixings will be fitted to the left and right side after the panel is lowered into the tracks and adjusted up or down until the panel is vertical. Figure 2.5.1 Installing Top Panel top hanger 2.6 Fitting Reinforcing Doors wider than 3505mm require panel reinforcing, the number and positioning of the reinforcing is shown on page 5. The top panel reinforcing must be fitted as high as possible as shown at Figure 2.6.1 and the bottom panel reinforcing at the centre of the panel, Figure 2.2.3. It is important to secure all reinforcing with 2 tek screws per stile. Figure 2.6.2 Low headroom quick closer installed to the top panel Figure 2.6.1 Reinforcing installed on the top panel of the door
12 2.7 Counterbalance System Assembly & Placing in Position Fix the spring anchor bracket to the lintel with the longer section at the top. It should be centrally mounted between the left and right bearing brackets with the center of the bearing slot in line with the end bearings or fit to this assembly as shown and secure to lintel later. With single spring doors, slide a shaft collar against the spring anchor bracket. The bearing flange in the spring anchor bracket must face the spring. It may need to be reversed depending on whether a left or right hand spring is supplied, see Figure 2.7.1. The shaft collar is tightened against the bearing flange. Slide the spring onto the torsion bar and over the shaft collar. The winding plugs should face away from the spring anchor bracket, see Figure 2.7.2. Fit the red and black cable drum, Figure 2.7.2/2.7.5, to the shaft but do not tighten, fit 5 large washers to each end. This is to provide correct cable clearance. Refer to page 15 when adding spring tension. Parts Needed - Single Springs cable drums red* & black* spring axle centre bracket 10 large washers shaft collar Figure 2.7.1 black cable drum Figure 2.7.2 spring plug colour refer to Figure 2.7.5 red cable drum
13 With two springs no shaft collar is necessary. Slide the two springs onto the shaft taking note of the plug colours and spring direction, Figure 2.7.3 & 2.7.5. Fit the red and black cable drum, Figure 2.7.2/2.7.5, to the shaft but do not tighten and place 5 large washers to each end this is to provide correct cable clearance. Refer to page 15 when adding spring tension. Parts Needed - Double Springs cable drums red* & black* springs red* & black* axle 10 large washers centre bracket Figure 2.7.3 Axle Assembly black cable drum Lift the complete assembly and insert one end of the axle into the end bearing bracket, slide to one side and insert into the opposite bearing, ensure it is correctly positioned into the centre spring anchor bracket. spring plug colour refer to Figure 2.7.5 red cable drum Figure 2.7.4 Ensure the axle is level and the bracket is securely attached to the structure before fitting the springs to the bracket, if not already fitted, Figure 2.7.3. Thread one cable from the bottom hangar up to the top cable drum and secure into the slot, tighten the two grub screws firmly to the axle and turn the drum and shaft back towards you until the cable is taught, clamp the axle (Figure 2.7.4), repeat the procedure to the other side.
14 Figure 2.7.5 ATTENTION INSTALLERS! New colour coding standard for sectional door springs LEFT HAND SIDE These springs are right hand wound and can be identified by the direction of the curled fingers of the right hand when the thumb is pointing left, matching the same direction of the spring end and pointing to the red cable drum. The plugs in these springs are painted black and go on the left hand side of the door. NOTE: Red cable drum mounted on the left side (standard headroom). RIGHT HAND SIDE These springs are left hand wound and can be identified by the direction of the curled fingers of the left hand when the thumb is pointing right, matching the same direction of the spring end and pointing to the black cable drum. The plugs in these springs are painted red and go on the right hand side of the door. NOTE: Black cable drum mounted on the right side (standard headroom). red cable drum black plug red plug black cable drum INSIDE GARAGE LOOKING OUT Springs & drums are now colour coded based on winding direction to match international standards.
15 2.8 Adding Tension to Spring Secure the torsion bar to prevent any rotation, as shown in Figure 2.8.1. WARNING: TORSION SPRINGS CAN CAUSE SERIOUS INJURY! IF YOU ARE NOT SURE, STOP NOW! ASK TRAINED PERSONNEL. The number of turns required for each spring is shown on a paper tag attached to the springs Figure 2.8.2. If the spring is required to have 7.5 turns for example, these are full turns and are equivalent to 30 quarter turns. Some springs will have a straight painted line along them alternatively draw a straight chalk line along the spring. If the spring is turned for example 8 times, then 8 lines can be counted along the spring, See Figure 2.8.3. WARNING: ONLY USE AUTHORISED WINDING BARS AS LISTED ON PAGE 4. Turn the spring by inserting winding bars into the winding plug holes and wind up in an up and over direction towards the ceiling, Figure 2.8.4. Once you have completed the amount of turns required, remove one winding bar then tap the remaining bar back towards the spring anchor bracket if spring snaking occurs. Now you can tighten the two set screws with an open ended spanner, Figure 2.8.5. Again be careful not to over-tighten the set screws. Repeat this procedure if there is more than one spring but remember, always wind the springs, whether left or right hand, in an up and over direction towards the opening. WARNING: KEEP HANDS CLEAR OF THE SPRING AND THE SPRING WINDING PLUG AT ALL TIMES. Double check that the set screws are properly tightened, before removing the restraints on the torsion bar. Test the balance of the door. Put the door into the open position and view along the horizontal tracks. Check that the clearance in the vertical tracks (5-10mm) is also in the horizontal tracks. If you find that the door is binding, open out the horizontal tracks slightly to create the correct tolerance. Once satisfied that the operation of the door is as near perfect as possible, check that all nuts and bolts are tight and oil the springs full length to prevent noise and reduce friction, TAL 5 or similar oil rich lubricant in a pressure spray can is acceptable, Figure 2.8.6. Figure 2.8.1 Securing Torsion Bar Figure 2.8.4 Adding Tension always have one winding bar engaged and firmly held while turning tension the springs by winding in the up direction Figure 2.8.2 Spring Label Figure 2.8.6 Lubricating Springs Figure 2.8.5 Tightening Grub Screws grub screw 2 Figure 2.8.3 Counting the Turns 8 7 6 5 4 3 2 1 use a spanner to tighten grub screw grub screw 1 maintain tension while tightening both screws, these must be very firmly tightened but not to the point of deforming the axle
16 3.0 After Installation Care General Care of your Panelift PFB Builder Door Cleaning COLORBOND & COLOURED STEEL FINISH Your CSI CLASSIC Pro Series door has been pre-painted with one of the best paint films commercially available today. However, all exposed surfaces require some attention to guard against the premature onset of corrosion and any other harmful atmospheric effects. In our atmosphere there are harmful deposits that gather on the door surface and if not removed regularly, will seriously affect the appearance and life of the door. Washing of the door with clean water and a cloth every 14 days is recommended particular care should be taken to clean areas of the door not normally washed by rain. Hinges & Hangers Plastic hinges: No lubrication is generally required, however silicon spray or lithium grease may be used if necessary. Cables Check the cables regularly for corrosion, fraying or tangling, if any of these are evident call your service provider. Regular Maintenance Required It is recomended that you check the operation of your CSI CLASSIC Pro Series door at least every six months (more regularly in extreme environments or frequent use). The effort required to manually open and to manually close the door should be about the same (if door has an automatic opener, put into manual mode before testing door). If the door is difficult to operate in either direction (up or down) then check that the inside surfaces of the guides are clean and free of obstructions. If the door is still difficult to operate, then your door will need a service to adjust the spring tension and possibly other operational parts of the door. This service should only be carried out by an experienced door technician, using the correct tools. If you have an automatic opener fitted to your door, it is particularly important that you ensure the optimum operation of the door, otherwise you may reduce the effective life of the opener. To keep your door running well, it is recommended that your door be serviced, by an experienced door technician, every 12 months (more regularly in extreme environments or frequent use), or earlier if required. Spring Tension It is natural for springs to lose tension over time. When spring tension is adjusted or when your door is first installed it is usual to apply a little more tension than is required for balanced operation, to allow for the normal settling in of the springs. Lightly lubricate to prevent friction between the coils. Warranty Warranty conditional on proper care as recommended above. Full details of the warranty are available from csiclassicgd.com.au Pro Series - PFB Installation Instructions PART NO: MS0116