Assa Abloy Corbin Russwin FE5400S Series User manual

®
ASSA ABLOY
In U.S.:
Corbin Russwin, Inc.
225 Episcopal Road
Berlin, CT 06037 USA
www.corbinrusswin.com
In Canada:
ASSA ABLOY Door Security Solutions Canada
160 Four Valley Drive
Vaughan, Ontario, Canada L4K4T9
www.assaabloy.ca
Technical Product Support: Phone: [phone]
Installation Instructions
FE5400S(A) Series
3 Point Exit Devices
1 of 14
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.
FM329 (11/18)
Front Cover
Strike
Top
Chassis
Top Latch
Outside Trim
Device is packed ready for
any compatible trim.
Bottom Chassis
Bottom Strike
Dogging
Key
Dogging
Feature to hold bolts retracted and
touchpad depressed, for push-pull door
operation.
To Dog Device
1. Insert dogging key.
2. Hold touchbar depressed.
3. Turn key 1/4 turn clockwise.
(Not a feature of fire labeled devices.)
Top Chassis Cover
Upper Rod
Rod Guide
Bottom Chassis
Cover
Lower Rod
Rod Guide
End Cap
Bottom Rail
Maintenance
1. Periodically remove covers and
coat mechanisms with a silicone
base lubricant. This is particularly
required in corrosive environments
for proper product function.
2. Check mounting fasteners
periodically. Retighten if found
loose. Apply screw locking
compound (available at automotive
part stores).
3. Periodic checks (and adjustments)
of strikes are required to
compensate for changes in the
opening (e.g. door sagging,
binding, etc...).
NOTE: To meet the certification
requirements, use fasteners and hardware
provided with this product. Factory
supplied fasteners & hardware must be
used to maintain product certification.
Touch Bar
End Cover
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.
08/2018

®
ASSA ABLOY
General Information
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.
FM329 (11/18)
This device is intended to be part of an integrated door, frame and hardware assembly UL-
approved for both FEMA 361 and ICC 500 guidelines for out swing doors. This instruction
sheet will take you through the necessary steps to install this device.
Step 1: Check Before Starting
Check to assure that the Top and Bottom latch openings in the frame align with the vertical centerline location for the
top and bottom chassis centerline location (refer to page 3 "Mark Door", and Appendix B).
Step 2: Tools Required
Measuring Tape - Power Drill – Level – Square – Center Punch or Center Drill - Hacksaw or any power cutter (to cut
rail if necessary) – Screwdrivers (Phillips #2 and #3), Allen Head Hex Wrenches (5/32", 1/8"), Drills (3/8", 1/4", 5/16",
7/16"), Drills and Taps (13/64" or #7 Drill and 1/4"-20 Tap), (11/64" or #16 Drill and #12-24 Tap), (5/32" or #25 Drill
and #10-24 Tap).
Step #
1
2
3
4
5
6
7
8
9
10
11
12
Table of Contents
Check Before Starting
Tools Required
Mark Door
Size Device
Install Device
Install Device Strike
Prepare Top Rod
Install Top Chassis
Install Bottom Chassis
Install Top Latch
Install Bottom Strike
Install Covers
Appendix A Door Template
Appendix B Top Frame Template
Appendix C Plastic Door Template
Page
2
2
3
3
4
5-6
7
8
9
10
10
11
12
13
14
Door Must Not Sag Door Must Not Bind
Door Must Not Be Warped Door Must Swing Freely
2 of 14

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ASSA ABLOY
Step 3: Mark Door
FM329 (11/18)
Door Bevel Centerline (at Centerline of door thickness).
Centerline of Rods, Latches & Strikes
2-7/16" (62)
Centerline of Door
Thickness
LHR DOOR
INSIDE FACE
Centerline of Device
Finished Floor
5/8"
(16)
LOCATE AND MARK CENTERLINES AS SHOWN
11/16"(17) from the cen erline of the 11/16" (17)
Diameter Hole for the Device Cam Hub
t
39-15/16" (1014)
from Finished Floor
Step 4: Size Device (If necessary)
Align the mounting holes in the device with the
vertical centerline of the rods, latches and strikes.
Mark cutoff line
and cut square
on line.
Align the device with the level horizontal line
created while marking the door.
LHR DOOR OPEN 90° INSIDE FACE
Slide the End Cover on and verify no
gaps exist between the Touch Bar
End Cover and End Cover prior to
making cutoff.
Centerline of Dogging Hole
or Fire Plug
MINIMUM
1-3/8
(35) 2-3/8
(60)
Hinge
edge of
door.
Touch Bar
End Cover
3 of 14
The accuracy of marking the vertical and horizontal centerlines will aid in the installation and operation of the device.
A plastic template and block strike are provided to aid in marking these centerlines. See Appendix C page 14.
(Touch Bar)
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

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ASSA ABLOY
When preparing to install device, be prepared to prop the door open during
the installation process.
Refer to Appendix A to assure all the holes are in the correct location.
Insert two sexnuts into the door from the outside. Align the interlock bracket
and device as shown and hand tighten top and bottom 1/4 -20 by 1-1/4"
long pan head screws. Hand tighten two 1/4 - 20 by 1" flat head screws into
the door. This will require moving the slide to allow the screws to be
inserted into the holes with the countersinks. These screws should not be
tightened at this time since the interlock bracket will require finer adjustment
in step 6.
Step 5: Install Device
FASTENERS:
With the latchhead loosely in place, level the device and mark
the position of the 3 holes for the hinge end of the device.
Prepare the door per the template (Appendix A).
Insert 3 sexnuts into the door from the outside, place the end
clamp into the space between the rail and carrier, align the
end clamp shim and the end clamp of the device then insert
and hand tighten the 3 pan head screws to hold the end
clamp and shim of the device to the door.
FM329 (11/18)
1.556 1"
#1/4-20 Flat Head Machine - Socket
#1/4-20 Sexnut
7/16" dia.
#1/4-20 Pan Head Machine - Phillips
1-1/4"
4 of 14
End Clamp
NOTE: If the device has been sized
in the field, a 1/4" (6) diameter thru
hole will need to be drilled so that the
center sexnut and fastener can be used to
secure the end of the device to the door.
If device is furnished with the trim,
the two sexnuts for the latchhead will
not be used. The outside trim studs
will be used to thru bolt the device to
the trim. If trim is furnished, it will be
supplied with two more 1/4 -20 by 1-
1/4" oval head screws that will be
required for thru bolting the trim.
These will be used in the two slots of
the interlock bracket that are not
under the latchhead. Refer to the
trim template for hole placement for
the 2 additional holes required.
A
A
NOTE : Measure from device seat
(door face or shim surface).
*
Device is bolted
to trim using
holes "A" (closest
to door lock edge).
(2) Screws and
washers bolt trim
to door using
holes "B".
Tailpiece (T)
engages with
cross hole of
cam slot.
Cut per Fig. 2. *Hold
Cut Line
B
B
T
Device Mounting
Surface
(See Note)
5/16
(8)
Trim must be un-locked.
(Tailpiece fully extended)
If furnished
with trim,
assure that
the spindle
from the trim
is engaged
with the hub
on the
latchhead.
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.
C
L
Ø 1/4"
(6)
1/2"
(12.7)
Thru

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ASSA ABLOY
Step 6: Install Device Strike
To install the device strike (Fig. A), check to
assure the device is level.
Position the strike so that it is centered in
relation to the SecureBolt.
Add spacers so that you will achieve the
clearance shown in (Fig. B) on the next
page, as well as allow the 3 interlock bracket
tabs to engage the strike.
12-24 x 1-1/4", 5/32 socket head
flat head screw
(1-5/8" long for single door application)
Fig A
12-24 x 1", 1/8 socket head
flat head screw
(1-5/8" long for single door application)
Locking Strike
Locking Spacer
Strike Spacers
Add strike block for single
door application only.
FASTENERS:
1-1/8"
#12-24 Flat Head Machine - Socket
1-5/8"
#12-24 Flat Head Machine - Socket
#12-24 Allen Head Machine - Socket
1-5/8"
#12-24 Allen Head Machine - Socket
1-1/4"
FM329 (11/18) 5 of 14
Single Door Double Door With Mullion
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

®
ASSA ABLOY
Step 6: Install Device Strike (continued)
Latch Head
Interlock Bracket
Top of Strike
Shim Strike
as required.
Fig B
Fig C
3/16 ± 1/32
(4.0 - 5.6)
The interlock bracket does have some side to side
adjustability that will allow a final adjustment after clearance
between the strike and latch head is achieved. This
adjustability will require the 4 latch head fasteners to be
loosened allowing the interlock bracket to slide into the proper
engagement with the strike. Mark the door frame to establish
the vertical position of the strike. Its centerline should be on
the same centerline as the device.
With the door in the closed position, adjust the strike's
position so that when the door is closed, the SecureBolt will
be just touching the roller of the strike. This will allow the
Securebolt to retract freely when the door is closed. Using the
top and bottom slots of the strike (Fig C) center your punch in
the middle of the slot and mark the two locations for the 12-24
x 1" Flat Head screws for the strike. Drill and tap these two
locations. DO NOT DRILL AND TAP the other two screw
locations at this time. Recheck the alignment to the centerline
of the device.
Reassemble the strike assembly and finger tighten the flat
head screws using a 1/8" allen wrench so that final
adjustments can be made. Check to assure you have the
proper clearance between the strike and the latch head, the
interlock bracket is engaged with the strike and the
SecureBolt is not pressing against the roller of the strike.
When you have made all these adjustments you may tighten
the mounting screws so that the device is securely fastened
to the door. Retract the SecureBolt, open the door. Using the
strike as a drill guide drill thru the Locking spacer and let your
drill mark the two locations for the 12-24 x 1-1/4" 5/32 Socket
Head Cap Screws. Remove the strike assembly and drill and
tap these two locations. Reassemble the strike assembly and
secure it to the frame. Recheck the clearances to assure no
further adjustments need to be made.
Check the operation of the device to assure that the strike is
aligned properly with the device.
FM329 (11/18)
6 of 14
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

®
ASSA ABLOY
Step 7: Prepare Top Rod
Product comes with the top rod for a 7 foot (84") high opening. If your opening is less, the
top rod will need to be shortened. If your opening is more, than an extension will be
required and adjustment may or may not be necessary.
To Lengthen Rods
• Use Rod Extension(s) to extend Rod to length needed or
longer (2", 6", or 12" Rod Extensions available).
• Cut excess length from the end of the top rod with the
rollpin hole.
To Cut Top Rods
• Cut from end with pin hole. NEVER CUT THREADED END.
• Press Jig until it bottoms over Rod.
• Drill 1/8" dia. hole thru, 3/8" (10) from the end of the
shortened top rod. Use jug provided to assure accurate
distance.
Top Rod
1/8 x 1/2 Rollpin
Flat Face
(2 Sides)
37-13/16"
(960)
Top Rod Connector
PRESS FLUSH
Example of opening less than 84" (using 80" as example):
Subtract your opening from 84" and cut off the necessary amount.
84" minus 80" = 4" (shorten rod by 4")
Example of opening more than 84" (actual opening 88"):
Subtract 84" from the size of your opening.
88" minus 84" = 4" (you need a rod that is 4" longer)
In this case you will need a 6" rod extension, and you will need
to cut 2" off the bottom of the top rod (the end with the hole for
the roll pin). Rod extensions are always added to the top of
the rod where it meets the top chassis.
Rod
(Typical Pin End)
3/8
(10)
Jig
1/8" Dia. Thru
Rod Extension Options
2" (51mm) PN: 655F15
6" (152mm) PN: 655F16
12" (305mm) PN: 655F17
(Specify Device Finish)
FM329 (11/18) 7 of 14
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

®
ASSA ABLOY
Step 8: Install Top Chassis
Prepare the top of the door per the door template Appendix A. Check alignment
of the top latch location in the frame to assure it lines up with the Top Chassis
pusher.
Insert two 3/8" dia. sexnut into the holes on the outside of the door.
Screw the upper rod (approximately 1/2 of the way) onto the top chassis.
Position the shim and Top Chassis so that the mounting holes line up with the
holes in the door. Insert and finger tighten the 4 mounting screws provided. Note
that the two flat head security screws are for the lower positions.
Depress the touchbar and slide the top rod connector into the slot on the latch
head slide. With the touchbar depressed the top slide pusher should be flush with
the top reinforcement. If adjustment is necessary the rod can be rotated
clockwise to shorten it and counterclockwise to lengthen it.
Install the rod guide for the upper rod per the template in Appendix A.
Flush
FASTENERS:
1.550
#12-24 Allen Head Machine - Socket
1-1/4"
#12-24 Sexnut
3/8" Dia.
1"
1"
#10-24 Button Head Machine - Socket
FM329 (11/18)
8 of 14
Pusher
1-1/8"
#12-24 Flat Head Machine - Socket
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

®
ASSA ABLOY
Step 9: Install Bottom Chassis
Prepare the BOTTOM of the door per the door template Appendix A. Check
alignment of the bottom strike location in the frame to assure it lines up with the
Bottom Chassis.
Insert two 3/8" dia. sexnuts into the holes on the outside of the door.
Screw the bottom rod (approximately 1/2 of the way) onto the bottom chassis.
Position the shim and Bottom Chassis so that the mounting holes line up with the
holes in the door. Insert and finger tighten the 4 mounting screws provided. Note
that the two flat head security screws are for the top two positions.
Depress the touchbar and insert the bottom rod connector
into the slot on the latch head slide. The bottom bolt should
be retracted so that it only projects 1/16" below the bottom
of the door in the latch hold back mode. If adjustment is
necessary the rod can be rotated clockwise to shorten it
and counterclockwise to lengthen it.
Install the rod guide for the bottom rod per the template in Appendix A.
Approx.
1/16"
(1.6)
Max.
FM329 (11/18) 9 of 14
FASTENERS:
1.550
#12-24 Allen Head Machine - Socket
1-1/4"
#12-24 Sexnut
3/8" Dia.
1"
1"
#10-24 Button Head Machine - Socket
1-1/8"
#12-24 Flat Head Machine - Socket
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.

®
ASSA ABLOY
Step 10: Install Top Latch
Check the alignment of the top latch location on the frame to
assure it will line up properly with Top Chassis on door. The
pusher in the top chassis is designed to push the top latch up
when the touchbar is depressed.
Install the top latch to the frame using the 4, 1/4-20 by 1" Flat
Head (5/32" Hex Key) Cap Screws provided.
The 5/32 hex key has been provided with the device.
If the frame has not been prepared for installation refer to
Appendix B page 13 for preparing the frame.
Allen Socket Head
FASTENERS:
Step 11: Install Bottom Strike
Mount the bottom strike as illustrated in the template (Appendix B). The two
tabs on the bottom of the strike must come in contact with the inside face of
the door for proper engagement.
FASTENERS:
2"
#1/4-20 Flat Head Machine - Socket
1"
#1/4-20 Flat Head Machine - Allen Socket Head
FM329 (11/18)
10 of 14
5/8"
(16)
Finished Floor
Copyright © 2012 Corbin Russwin Inc., an ASSA ABLOY Group company.
All rights reserved. Reproduction in whole or in part without the express written
permission of Corbin Russwin, Inc. is prohibited.