Pro Series - PFBcsiclassicgd.com.au/.../CSI_ProSeriesPFB_Rev3NOV17.pdf · CSI® Classic Pro Series...

These instructions are intended for professional garage door installers. All references are taken from inside looking out.

Pro Series - PFBInsTAllATIon InsTrucTIonsPART NO: MS0116

PART NO. MS0116 > Revision 3 > NOVEMBER 2017


Contents1.0 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

2CSI® Classic Pro Series PFB Sectional Garage Door Installation Instructions


hazard control

• Housekeeping - risk of slip trip or fall

• Housekeeping - risk of injury to other people or animals in the installers work area

• 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

• 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

• Pack sizes

• use of 2 person lifts

• use of mechanical aids

• Avoid twisting (practice correct lifting techniques)

• correct use of ladders while installing tracks

• Working at heights and working with ladders, scissor lifts, scaffold - risk of fall from height

• ladder check

• ladder placement

• Do not work off the top rung

• sharp edges on door, tracks or related jewellery - risk of laceration

• 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

• Pinch points - risk of cut, puncture or crush injury • Wear appropriate PPE and keep hands well clear of pinch points

• Ensure hands well clear of the panels

• 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

• 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

• Tension spring - risk of release of stored energy (striking installer on the head or body)

• 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

The following hazards and hazard controls have been identified for installers during the installation of this door.

1.0 Before You Start1.1 Safety Checklist



1.2 Checking Measurements

Headroom standard 300mm including openerlow 200mm including opener (will only work with an opener)

Sideroom (with 25mm door overlap) standard 120mmlimited reverse fix (not recommended) 85mm

Backroomrecommended door height plus 350mmMinimum with opener door height plus 600mm

headroom

side

room

open

ing

heig

ht

door

hei

ght

opening width

door width

25mm 25mm

10mm

1.3 Fastener Recommendations

Unlined Garage

substrate type fastener requiredwasher

requiredplug required

drilled hole ø (mm)

min hole depth (mm)

solid brick (>10 MPa)

screw, coach 5/16-9tpix50

washer flat M8plug, nylon

5/16x5010 60

three hole brick (> 30 MPa)

screw anka m8x75 flange hex head

washer 3/8” n/a 8 75

ten hole brick (>15 MPa)



concrete block (> 8 MPa)



concrete (> 15 MPa)

screw, coach 5/16-9tpix50


5/16x5010 60

timberscrew, coach 5/16-9tpix50

washer flat M8 n/a 5 60

steel section (0.9-2mm thick)

screw tek 14g-20tpix25

flange hex head zPwasher flat M8 n/a n/a n/a

Lined Garage (up to 13mm thick plasterboard)

substrate type fastener requiredwasher

requiredplug required

drilled hole ø (mm)

min hole depth (mm)

solid brick (>10 MPa)

screw, coach 5/16-9TPIx80


5/16x8010 90

three hole brick (> 30 MPa)

screw anka M8x75 flange hex head


ten hole brick (>15 MPa)



concrete block (> 8 MPa)



concrete (> 15 MPa)

screw, coach 5/16-9TPIx80


5/16x8010 90

timberscrew, coach 5/16-9TPIx50

washer flat M8 n/a 5 90

steel section (0.9-2mm thick)

screw tek 14g-20TPIx25

flange hex head zPwasher flat M8 n/a n/a n/a



It is recommended that this door is installed by a professional door installer using a professional and specialised tool kit.

1.4 Tools

Available Standard Fastener Packs

fastenerstandard fastener

pack part no.standard fastener pack description

screw, coach 5/16-9TPIx50FK0011 kit, screw, coach 5/16-9TPIX50 100pk

FK0012 kit, screw, coach 5/16-9TPIX50 500pk

screw, coach 5/16-9TPIx80FK0013 kit, screw, coach 5/16-9TPIx80 100pk

FK0014 kit, screw, coach 5/16-9TPIx80 500pk

plug, nylon 5/16x50FK0015 kit, plug, nylon 5/16x50 100pk

FK0016 kit, plug, nylon 5/16x50 500pk

plug, nylon 5/16x80FK0017 kit, plug, nylon 5/16x80 100pk

FK0018 kit, plug, nylon 5/16x80 500pk

screw tek 14G-20TPIx25 flange hex head zP

FK0019 kit, screw tek 14-20x25 100pk


screw tek 14G-20TPIx35 flange hex head zP



screw masonary M8x75 flange hex head

FK0023 kit, screw anka M8x75 flange hex head 50pk

FK0024 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 Information on FastenersThe installer must select and use fasteners appropriate to the material into which they are being fixed.

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

1.5 Parts Checklist

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 panel2 reo = top panel + bottom panel

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.



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.

detailA

at bottom axleB C

E/F (ref pg 7)

standard sideroom 5mm 95mm 50mm5-8mm without

BAl seals

limited sideroom 5mm n/a 50mm5-8mm without

BAl seals

NOTE: These measurements allow for final adjustment.

Figure 1.6.2

Figure 1.6.1 Wheel-Axle

Standard Sideroom Limited Sideroom

A

B

C

E/F

A

CE/

F

B or c measurement

datum line

mark equal overlap on each side from datum line to the floor based on the

panel size



2.0 Installation2.1 Assembling & Installing Standard Vertical Tracks

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.

Ensure they are cut left and right as a pair.

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.

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).

20FOR STDHEAD ROOM

7

• 2straighttracks• 2longanglebrackets

• 2topbearingbrackets• 4smallanglebrackets

• 4x5/16boltsandnuts• 6x1/4boltsandnuts

NOTE: For low headroom an additional kit is required.

Parts Needed

20

E/F

Standard Headroom

Low Headroom

NOTE: For low headroom an additional kit is required - Part no: sD0368

brackets turned in for limited sideroom

Datum



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.

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

2.2 Assembling Bottom & Middle Panels

Parts Used Figure 2.2.1

hinge pin hinge links

bottom hangers (left hand- right hand)

2 lifting cable (variable)

wheel axles

standard bottom

black hinge

other panels

bottom grey hinge with offset

bottom panels

weather strip

Figure 2.2.3 Assemble links & pins onto the panel



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

2.3 Installing Panels

NOTE: Ensure warning label is clearly visible.

Figure 2.3.2

Figure 2.3.4

Figure 2.3.3



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.

2.4 Installing Horizontal Tracks

Figure 2.4.1 Assembling Horizontal Track Figure 2.4.2 Bracing

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.

Figure 2.4.3 Single Brace

fix toceiling

horizontal track

angle

Installing the Safety Stop

trackstop

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.

Installing the Safety Pull Cord

pull cord

Bracing must be fitted approximately 1.6>2m from the lintel (about 2/3rds of the door height)



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 2.6.1 Reinforcing installed on the top panel of the door

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.

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 2.5.2

Ensure all screws indicated are fitted after adjusting.

Figure 2.5.1 Installing Top Panel

top hanger

Figure 2.6.2 Low headroom quick closer installed to the top panel



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.

Figure 2.7.1

2.7 Counterbalance System Assembly & Placing in Position

Parts Needed - Single Springs

Figure 2.7.2

spring plug colour refer to Figure 2.7.5

black cable drum

red cable drum

cable drums red* & black*

spring axleshaftcollar

10 largewashers

centrebracket



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

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.

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.

Figure 2.7.3 Axle Assemblyblack cable drum

red cable drum

spring plug colour refer to Figure 2.7.5

cable drums red* & black*

springsred* & black* axle

10 largewashers

centrebracket

Figure 2.7.4



Figure 2.7.5

springs & drums are now colour coded based on winding direction to match

international standards.

INSIDE GARAGE LOOKING OUT

red cable drum black cable drumblack plug red plug

LEFT HAND SIDE RIGHT HAND SIDEThese 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).

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).

ATTENTION INSTALLERS!New colour coding standard for sectional door springs



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 2.8.2 Spring Label

Figure 2.8.4 Adding Tension

Figure 2.8.5 Tightening Grub Screws

Figure 2.8.3 Counting the Turns

2.8 Adding Tension to Spring

Figure 2.8.6 Lubricating Springs

12345678

tension the springs by winding in the up direction

always have onewinding bar engaged

and firmly held while turning

grub screw 2

grub screw 1

use a spanner to tighten grubscrew

maintain tensionwhile tightening bothscrews, these must bevery firmly tightenedbut not to the point ofdeforming the axle



Pro Series - PFBInsTAllATIon InsTrucTIonsPART NO: MS0116

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

3.0 After Installation Care

Pro Series - PFBcsiclassicgd.com.au/.../CSI_ProSeriesPFB_Rev3NOV17.pdf · CSI® Classic Pro Series...

Documents

Transcript of Pro Series - PFBcsiclassicgd.com.au/.../CSI_ProSeriesPFB_Rev3NOV17.pdf · CSI® Classic Pro Series...