AlluGuard 77 User manual

1MK3001RP April 2023 R1
AlluGuard 77
Installation Instructions
This equipment must be installed and used in accordance with
these instructions. Failure to follow these instructions could result
in damage to the integrity of the safety circuits.
Two persons are required to install this product to ensure safe
handling procedures.
CAUTION
Do not wear rings, watches or loose clothing while installing or
servicing the unit and ensure correct PPE is worn.
To avoid serious personal injury from entanglement, remove any
loose objects from the equipment prior to operating door.
DANGER
Installation and wiring must be in accordance with your local
building and electrical regulations.
Any electrical work must be carried out by a suitably qualified
person, if in doubt consult a qualified electrician.
Use only the mains lead supplied with the Remote Control Unit as
failure to do so will invalidate the warranty.
Connect the mains lead to an adjacent 13 amp 3 pin switched
socket. The plug must be fitted with a 13 amp fuse.
Note: For optimum electrical safety this unit should be connected
to circuit protected by a R.C.D. (max 30 mA trip rating).
This unit should not be installed in a damp or wet space or on a
damp or single skinned wall without sufficient spacers.
DANGER
Disconnect electric power to the control unit before making repairs
or removing covers.
Install the Control Box and/or Switch Control in a location where
the garage door is visible, but out of the reach of children. The
door must be in direct sight of the control and must not be
operated via security or doorbell cameras. Do not allow children to
operate push button(s) or remote control(s). Serious personal injury
from a closing garage door may result from misuse of the operator.
CAUTION
Activate unit only when the door is in full view, free of obstructions
and operator is properly adjusted. No one should enter or leave the
garage while the door is in motion. Do not allow children to play
near the door.
Please read these instructions carefully prior to commencing the installation of the door.
IMPORTANT SAFETY RULES
Always check on delivery that the order details are correct and the
door is undamaged, especially before removing any existing doors.
Sequence of Installation & Contents
01. Pre-Installation and Component Check
02. Installation Options
03. Prepare the Guide Rails
04. Installation of Box Supports
05. Fix Guide Rails
06. Install the Axle Assembly
07. Fit Emergency Overrides
08. Install the Curtain in the Guides (incl curtain adjustment)
09. Attach the Curtain
10. Set-up the Control Unit (where supplied)
11. Set the Motor Limits
12. Commissioning
13. Technical Assistance
14. Notes
77
AlluGuard
01. PRE-INSTALLATION AND COMPONENT CHECK

2MK3001RP April 2023 R1
Check:
i. Delivery note
ii. Order sheet
iii. Door dimensions / colour
iv. Opening dimensions / clearances
v. Components
vi. Check for any damage to the guide rails
or the outside roll of the curtain
Do not proceed further with the
installation unless you are sure that
the door is the correct size, and all
components are present.
WIDTHS
Manufacturing Width = Over Guide Width
Drive Through Width = Over Guide Width less
150mm for 75mm guides
HEIGHTS
Manufacturing Height = Guide Height
Total Height = Guide Height + End Plate
Headroom/End Plate up to 2.5m Guide Height =
300mm
Drive Through Height = Guide Height less 100mm
Before removing the old door check that the door size and colour
correspond with that which was ordered.
Structural condition of opening.
i. Ensure the area around the opening is strong enough to
support the weight of the door.
ii. The surface where the door is to be fitted must be flush and
reasonably smooth. Small irregularities in the brickwork will be
acceptable.
iii. No obstacles in fitting footprint eg. no sharp objects, pipes,
cables, bumps etc. sticking out from the pillars, lintel or header
to twist the guides, distort the fascia or catch on the curtain.
iv. The lintel must not protrude backwards or forwards from the
brick piers. Should the lintel protrude backwards or forwards
from the brick piers this will require special instructions, please
consult your supplier.
v. The floor must be flat/level. If necessary install a sub-frame to
ensure secure, flush and level fixing (recommended minimum
70 X 70 PAR). The lintel must not protrude backwards or
forwards from the brick piers. Should the lintel protrude
backwards or forwards from the brick piers this will require
special instructions, please consult your installer.
Fitting Notes
vi. It is recommended that 2 people are available for fitting all
door sizes.
vii. The door must be fitted square and level, irrespective
of the shape of the opening; on no account should any
compensation be made to suit an irregular opening.
viii. Ensure all necessary tools are to hand before starting.
ix. The door package and its contents should be checked for
obvious damage before removal of the wrapping.
IF THERE IS ANY DAMAGE YOUR SUPPLIER SHOULD BE
CONTACTED IMMEDIATELY.
x. Ensure there is a suitable 13amp 3 pin switched socket
adjacent to where the Remote Control Box is to be fitted.
xi. Ensure all tools and door components are gathered together
inside the garage prior to starting the installation.
Recommended Tools for Assembly:
• 2 stepladders
• Spirit/laser level
• Tape measure
• Power drill
• 10mm A/F spanner
• Slot screwdriver
• Pozidrive screwdriver
• 3.5mm drill bit
• 7.0mm drill bit
• 11.0mm drill bit
• 3mm A/F Allen key
• 4mm A/F Allen key
• Hacksaw
• Suitable wall plugs (not supplied)
• Suitable fixings (not supplied)
Note: In case of power failure a manual override system is fitted as standard but this can only be operated from inside the garage. If
the garage has no service entrance door then an exterior release kit must be fitted to allow manual operation of the garage door from
outside.
01. PRE-INSTALLATION AND COMPONENT CHECK (CONTINUED)
PRE-INSTALLATION CHECK

3MK3001RP April 2023 R1
01. Control Unit (where supplied) *
02. Motor (fitted into axle)
03. 70mm Octagonal Axle
04. 2 to 6 Pairs of Rings for Auto Lock Collars (fitted on axle)
05. Safety Brake
06. R/H End Plate
07. 2 to 6 Autolock Straps (3 elements) *
08. 2 to 6 No.8 x 1/2” Pozi Pan Screws *
09. L/H End Plate
10. Guide Rails (UPH 75) 75mm or (UPH 250) 90mm
fitted with Brush Insert
11. Curtain
12. End Locks (fitted to curtain)
13. Bottom Slat (fitted to curtain)
14. Rubber Seal (fitted to bottom slat)
15. Override Eye *
16. 6 No. M8 X 21mm Penny Washers *
17. 10 No. 4mm X 8mm Rivets * (for securing endlocks)
18. Crank Handle Clip *
19. Crank Handle *
20. Optional Half Box
21. Optional Full Box Cover
22. Optional Box Supports
*Supplied in Accessory Box
Recommended Fixings (not supplied)
12 x 1” Self Tapping Screws for Steel
12 x 2 1⁄2” Countersunk Screws for
Masonry and Wood
Guides, axle assembly and the crank handle will be
wrapped together in one bubble wrapped parcel
and strapped together. The curtain is individually
packed. A separate accessories box is packed with
the installation and end user instructions, the
attachment/locking arms, the accessory pack and
a box containing the electrical items.
A A
B B
C C
D D
E E
F F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
1
2
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4
4
4
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7
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8
8
8
9
10
10
11
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13
12
14
Internal Face Fit Reveal Fit
Combination of Face and Reveal Fit
Fitted to existing or New Timber Frame
Undersize Face Fit
Set Back Face Fit
19
15
18
16
17
COMPONENT CHECK
02. INSTALLATION OPTIONS
20
21
22

4MK3001RP April 2023 R1
If the guides require cutting down refer to the ‘Widths and
Heights’ information on page 2. If face fixing where possible set
the guide height at least 110mm above the structural opening
height to maximise drive through height.
If you need to reduce the length of the guide rails you must cut
from the bottom of the guide rails.
i. Position guides
ii. Drill a minimum of 4 guide fixing holes, with a 7mm pilot hole
and 13mm outer hole. Position the first hole position 250mm
from the top of the guide and the second hole 250mm from
the bottom of the guide. Equally space out the remaining
holes with a maximum gap of 500mm between each fixing.
Avoid mortar joints and edges of bricks etc.
REVEAL
DRILL
OR FACE DRILL
GUIDE/ DOOR
HEIGHT
BOTTOM SLAT HANG
DOW N 110 mm
DRIVE THROUGH
HEIGHT Note: Guides are handed. Please take note of the orientation of
the guides. If cutting guides cut excess length from bottom of
guide.
REVEAL FIX
INTERNAL SIDE
13mm 7mm
FACE FIX
INTERNAL SIDE 13mm
7mm
Where supplied, the box supports need to be riveted to the fascia to hold them in place.
03. PREPARE THE GUIDE RAILS
04. INSTALLATION OF BOX SUPPORTS – OPTIONAL EXTRA FOR HALF BOX OR FULL BOX
i. First fix the fascia in place then position the box supports
within the fascia with equal distances between each support
(see Drawing A).
ii. Drill a hole with a 4.2mm drill bit through each box support
and the fascia.
iii. Fasten the box support to the fascia using a 4 x 8 rivet.
Note: Ensure that both ends of each box support are positioned
within the lip of the fascia (see Drawing B).
A A
B B
C C
D D
E E
F F
8
8
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7
6
6
5
5
4
4
3
3
2
2
1
1
A
A A
B B
C C
D D
E E
F F
8
8
7
7
6
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5
5
4
4
3
3
2
2
1
1
B
Correct box support
positioning

5MK3001RP April 2023 R1
Note: Before positioning check that there are no sharp objects or
bumps sticking out from the pillars, lintel or header to twist the
guides or that will catch the door during operation.
If in doubt pack the guides and end plates out by at least 10mm.
i. Slot end plate lugs into guides (see Drawing A) remembering
the guides are handed
ii. Position guides and end plates against opening
iii. Hold or prop securely the assembly in position
iv. Drill fixing holes (min 4 in guides and 2 in each end plate) -
see 4.ii
v. Fix guides/end plates with minimum No. 12 x 21⁄2”
countersunk screws (and plugs) to masonry/timber or 12 x 1”
self tapping screws to steel.
Note: If end plates are fitted within the reveal, the side of the end
plates must be fitted to the structure with at least 2 fixing points.
Ensure that fixing heads are clear of the curtain operation to
prevent damage when the door is in use.
Note: Extreme care should be taken while manoeuvring the
door into place to avoid the possibility of snapping the end
plate lugs. It is imperative that fixings are put through the end
plates into the wall as the aluminium lugs are not designed to
carry the weight of the door.
A
Lug
Note: Axle assembly
must be level
Check:
• Back faces of guides and end plates are flush and untwisted
(see Drawing B)
• Guides are vertical/parallel/same height
B
Dummy End
i. For doors supplied with a dummy end only, fix the bracket
(A) to the end plate using the screws provided in the
accessories kit.
Ensure that the open end of the bracket cup is facing
towards the top of the end plate (B).
ii. Locate the dummy end in to the bracket fitted to the end
plate (B).
If the dummy end appears to be too short, loosen the grub
screw and extend the dummy end to the required length,
then tighten the grub screw.
iii. Fold the top tabs on the bracket round the bearing to secure
the bearing.
Dummy End Bracket
A
B
05. FIX GUIDE RAILS
06. INSTALL THE AXLE ASSEMBLY