Assa Abloy Corbin Russwin ED7800 Series User manual

Installation Instructions
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or
in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
FM466 04/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
WARNING
This product can expose you to lead
which is known to the state of California
to cause cancer and birth defects or other
reproductive harm. For more information
go to www.P65warnings.ca.gov.
ED7800 Series
Concealed Vertical Rod
Exit Devices

2
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
TOC Table of Contents
1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Prepare Door and Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4 Insert Rods and Secure Top Latches and Bottom Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5 Pin Top Rod and Bottom Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
6 Install Active Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
7 Test Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
8 Install inactive Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
9 Install Crossbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
10 Install Outside Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
11 Install Stakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
12 Adjust Plunger Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
13 Test Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or
in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
1 Components
Bottom Strike
Mounting
Bracket
Bottom Bolt
Tension Spring
Bottom Bolt
Operating Tube
Screw
Tenon
Dogging Key
Felt Deadener
Dogging Hole
Cotter Pin Hole
Lifting Flange
for Active Case
Active Case
Outside
Operator
Lifting Flange
for Outside
Operator
Top Rod
Top Latch
Mounting
Bracket
Top Strike
Screws Furnished
Screw Thread Tap Drill Placement
10-32
8-32
1/4-20
1/4-20 & Anchor
No. 21
No. 29
No. 7
Bottom and Top Mounting Brackets
(Concealed Bracket Mounting)
Top Latch and Bottom Bolt Cases
(Exposed Screw Mounting)
Top Strike
Active and Inactive Cases
Bottom Strike
10-24 Self-
Tapping
Tap
Drill
18
11/64
17
16
%
Thread
75%
70%
65%
55%
Outside Operator
Figure 1
Figure 2

4
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
2 Pre-Installation
Important
4061, 4062, 4063, 4068, CH641, CH642, CH643, CH648 “U” indicates UL Listed and “MR” indicates
Master Ring Cylinder.
Flush
LHRB
RHRB
Flush
Cover A Active
Case
Plate
Inactive
Case Cover B
Active
Case and
Cover B
Inactive
Case and
Cover A
Lift
Figure 3
3 Prepare Door and Frame
If not already fully prepared, follow template furnished and drawings shown for exposed screw or hidden
(bracket) mounting. See Figure 6 on page 5.
Figure 4
Figure 5
Before installing, check position of parts
for hand of door and reverse hand of
fixture if necessary.
1. To change to opposite hand,
hammer pin to opposite side of
flange.
(Figure 3)
2. Remove case covers by removing
top and bottom screw at back of
each case.
3. Switch case covers and
reassemble.
a. Place cover from present active
case (A) on inactive case,
engaging lifting finger with
bottom of slide.
(Figure 4)
b. Place cover from inactive case
(B) on active case, engaging
lifting finger with bottom of
slide. Be sure that nylon button
on back of cover fits into hole
in plate. (Figure 5)
NOTE: Be sure that plate with
hole in it is positioned in active
case with rounded end down.

5
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or
in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Note: See exposed screw or hidden (bracket) mounting illlustrations. See Figure 6.
Before inserting, check for proper positioning of all parts.
1. If using CONCEALED (bracket) MOUNTING, attach mounting brackets to cases of top latch and
bottom bolt NOW.
2. Slide bottom tube into bottom of stile. Secure with screws indicated in chart. (Figure 2 on page 3)
3. Retract top latch by holding case and pushing up on rod. Insert top latch rod into top of stile and
into bottom tube. Secure with screws indicated in chart. (Figure 2 on page 3)
4 Insert Rods and Secure Top Latches and Bottom Bolt
Inside of Door
LHRB
Hinge
Stile
of Door
Hinge
Stile
of Door
Long side of roll pin
points toward
hinge stile of door.
Roll pin side
of lifting flange
faces inside of door.
Mounting Bracket
Screw Holes
(Face Hinge Stile of Door)
Poll pin must
be parallel to
face of door.
Inside of Door
LHRB
Hinge
Stile
of Door
Long side of roll pin
points toward
hinge stile of door.
Roll pin side
of lifting flange
faces inside of door.
Hinge
Stile
of Door
If necessary to reposition
case, remove roll pin, turn
case so screw holes are
facing inside of door and
replace roll pin through slot
in case into rod, parallel
to face of door.
Mounting Bracket
Screw Holes
(Face Inside of Door)
Figure 6
LHRB Shown - RHRB
Opposite
Exposed Screw Mounting Concealed Screw (Bracket) Mounting

6
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
1. Push down on active case lever to
be sure top latch and bottom bolt
retract completely and remain
retracted when lever is released.
2. If bottom bolt does not retract flush
with bottom of door, check “Pin Top
Rod and Bottom Tube” procedure.
7 Test Operation
1. Place case in position. Be sure cases
are level at same height. (Figure 9)
2. Drill and tap for No. 1/4-20 screws.
3. Mount cases.
8 Install Inactive Case
Figure 7
1. Undog cases. Using key furnished,
back out screw and remove tenon
from active case lever. (Figure 1 on
page 3)
2. Mount active case, engaging hook
under lifting flange. Secure with
screws furnished. (Figure 8)
6 Install Active Case
Figure 8
1. Using access hole, raise lifting flange
for active case so that bottom bolt
is fully retracted. DO NOT PRESS
BOTTOM BOLT FROM BOTTOM OF
DOOR. Be sure that top latch is
retracted.
2. Drill 1/8" diameter hole through rod
and tube using pre-drilled hole in
bottom tube as guide. (Figure 7)
3. Insert hammer-lock cotter pin
through hole and secure with punch
and hammer. Flatten pin head
completely. (Figure 7) Hang door.
5 Pin Top Rod and Bottom Tube
Drill Thru
Guide Hole
Insert cotter pin
and flatten head
completely.
Inserted Flattened
Hook Lifting Flange
Figure 9

7
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or
in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
1. Measure distance between levers
near hole where top of lever enters
case.
• Add 3/16" to this dimension
and cut crossbar to this
measurement. (Figure 10)
• Remove burrs on inside and
outside of bar.
2. Place tenon removed from active case
into end of crossbar so it is just flush
with end of bar. (Figure 11)
3. Place open end of crossbar over
tenon secured to inactive case lever.
(Figure 12)
NOTE: If crossbar will not slide over
tenon, loosen screw slightly and tap
head of screw with mallet.
4. Set other end of crossbar into recess
in active case lever.
5. Thread screw into tenon and finger
tighten.
6. Seat bar in lever by pushing down
easily on right lever while pulling up
on left. Alternate procedure. This
rocking will assure lineup of two (2)
tenon pins in holes in lever.
(Figure 13)
7. Tightly secure screws using
screwdriver through bow of furnished
dogging key. (Figure 14)
NOTE: If tenon pins are not seated
in lever holes, bar will be loose and
twist. Repeat rocking procedure.
NOTE: If after completion of installation,
crossbar does not work freely, check
installation of binding of levers
due to improper bar length or case
misalignment.
9 Install Crossbar
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Add 3/16"
Alternately push down on one lever
while pushing up on other.

8
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
1. Apply top strike on header with
screws furnished. (Figure 18)
2. Install bottom strike. (Figure 19)
• If not using threshold, mortise
bottom strike into floor, lining up
carefully with bolt centerline.
• With metal threshold, drill 7/8"
hole in threshold in line with
centerline of bottom bolt.
11 Install Strikes
Top Strike
Door
C
L
of Bottom Bolt
(Backset)
Figure 15
1. Following template furnished, mark
bolt backset on outside of door.
2. Press in top latch plunger screw to
project top latch and bottom bolt.
3. Put operator in locked position.
4. Center operator on backset line
so top side of lifting lever contacts
underside of auxiliary lifting flange.
(Figure 15)
5. Spot door through hole at top of
operator and drill starting hole with
No. 18 drill for self-tapping screw.
6. Mount operator with screws
furnished.
7. Unlock operator and swing operator
lever to side retracting latch and bolt.
(Figure 16)
8. Spot and drill hole with No. 18 drill
for self-tapping screw.
9. Secure.
NOTE: If door offers too much resistance
to self-tapping screw, use next larger drill.
(See chart, marked Figure 17)
10 Install Outside Operator
Figure 16
Self Tapping
Screws
Size % Thread
No. 18 75%
11/64" 70%
No. 17 65%
No. 16 55%
Figure 17
Figure 18 Figure 19

9
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or
in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
From Outside: When door is opened by turning operator latch, top latch and bottom bolt should
retract and stay retracted until plunger screw is pushed in.
From Inside: When door is opened by depressing crossbar, top latch and bottom bolts should retract,
and stay retracted until plunger screw is pushed in.
Lock crossbar in dogged down position. Latch and bolt should be fully retracted.
NOTE: No dogging feature on “U” series.
13 Test Operation
When door is closed against top strike,
plunger screw releases top latch and
bottom bolt. Adjust so that when door is
shut tight, screw head just touches strike.
(Figure 20)
12 Adjust Plunger Screw
Just Touch
Figure 20

10
ED7800 Series
Installation Instructions
Concealed Vertical Rod Exit Devices
FM466 04/20
Copyright © 2018, 2020, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]