B&D Roll-A-Door 2 Series User manual

www.bnd.com.au
Series 2
installation instructions
These instructions are intended for professional garage door
installers.All references are taken from inside looking out.
DOC# 165007_09
RELEASED: 03/05/22

Contents
1.0 before you start 3
1.1 installation safety warnings 3
1.2 substrate fastener recommendations 4
1.3 preparation 5
1.4 before installation 5
1.4.1 requirements 5
1.4.2 measurements 5
1.5 parts checklist 7
1.6 initial calculations 7
2.0 installation 8
2.1 install rst bracket 8
2.2 install second bracket 8
2.3 place door on brackets 9
2.4 install guides 10
2.5 tension the springs 11
2.5.1 tensioning and adjustments 11
2.5.2 creating proper guide lead-in 11
2.6 locking 12
2.6.1 centre lift lock (only with R2W & R2F) 12
2.6.2 internal waist high slide bolt (R2I) 12
2.6.3 high wind centre lift lock (only with R2W & R2F) 13
2.7 troubleshooting 14
2.8 centralise the axle when door is mounted 14
2.9 adjusting spring tension 15
3.0 appendix 16
3.1 after installation care 16
2Roll-A-Door®Series 2 installation instructions

1.0 before you start
1.1 installation safety warnings
WARNING!
Crush injury from
unsecured door
• Place a 2 metre exclusion zone around area under the garage opening
while installing door. If sufcient area is not available DO NOT install door.
• Do not move under a door while it is on the door support (or lifting device).
• Follow the installation instructions.
• Fit door support (or lifting device) snugly under door before lifting.
• Ensure door support (or lifting device) is on at ground.
• Ensure the door is immediately fastened to the bracket with the "U" Bolt.
• Ensure no-one walks under a door sitting on brackets.
Tension Springs • Ensure door is correctly secured at all times when making adjustments.
• Ensure the correct length pipe wrench is utilised.
• Ensure that pipe wrench is tted correctly to the axle and if it is gripped onto
the axle do not underestimate the tension in the spring when undoing the
clamps.
• Ensure correct bolts are tightened or loosened to ensure there is no release
or controlled release of energy from the spring through the pipe wrench.
• Keep head clear of the pipe wrench at all times.
ELECTROCUTION! • Check risk assessment for any highlighted electrical power concerns.
• Ensure power source is isolated prior to commencement of job.
• Turn off electricity to site when necessary.
• Wear rubber soled footwear.
LACERATION: • Wear appropriate PPE (Dyneema cut off gloves) and keep hands well clear
of pinch points.
• Follow instructions explicitly, particularly for the installation of some parts
of the doors, as the unrolled cut out edges presents a very sharp edge.
CAUTION:
Muscular strain • Practice correct lifting techniques when required to lift the door.
• Use mechanical aids such as lifting devices, forklift and cranes where
possible.
• Avoid twisting.
• Use correct technique of knotted rope installation aids.
Fall from ladder • Ensure ladder is the correct type for job.
• Ensure ladder is on at rm ground that will take the weight without the legs
sinking.
• Ensure user has 3 points of contact while on ladder.
Hand Tools • Wear appropriate PPE and utilise operators manual of all tools.
• Use appropriate noise/hearing protection in the form of ear plugs or ear
muffs.
• Ensure appropriate re protection available and housekeeping to ensure
that ammable liquids or materials are removed from the area of work.
Entanglement • Keep hands and loose clothing clear of moving door and guides at all
times.
TWO PERSON LIFT: • When a mechanical aid is not used this product requires a two person lift
to raise onto the brackets. Use proper techniques and equipment to lift the
door from the trailer and up onto brackets.
This B&D Roll-A-Door is designed and tested to provide security, attractive appearance and smooth ,
low effort operation provided it is installed and operated in strict accordance with the following safety
warnings. Failure to comply with the following instructions may result in death, serious personal injury
or property damage.
NOTE: No guarantee will be given or responsibility accepted by the manufacturers if the door is not
installed as instructed.
3Roll-A-Door®Series 2 installation instructions

1.2 substrate fastener recommendations
long bolts
steel plate
right hand
bracket
BRICK
CONSTRUCTION
left hand
bracket
masonry
anchors
(minimum
bolt size
12mm x
55mm)
coach
screws
into
masonry
plugs
SECURE GUIDE
weld
right
hand
bracket
bolt
guides
to steel
work
STEEL CONSTRUCTION
MASONRY BLOCK
CONSTRUCTION
Fig: 2.1.1
WARNING! Masonry blockwork should be properly lled and reinforced if
brackets are to be mounted directly to blockwork with masonry anchors.
Where the blockwork is not solidly lled but structurally sound, long bolts
should be passed through the blockwork using suitable steel plates
under bolt heads.
Special consideration should be given to brick type and construction
of wall, to ensure satisfactory xing e.g. welding detail if xed to steel.
WARNING! The installer
must select and use
fasteners appropriate to
the material into which
they are being fixed.
important notes
a) For installation to materials
not covered in the chart,
the installer should seek
expert advice from a
qualied builder.
b) Minimum length of fastener
does not exclude use of
longer lengths. Decision
must be made by tter to
ensure adequate strength.
c) Recommendations for old
materials or materials not
in good condition are not
included. If in doubt about
the strength of the material
seek specialist advice.
d) Fasteners for brackets in
masonry should be at least
8mm x 75mm long or metric
equivalent.
e) Use the washers supplied in
the parts bag to all xings.
material fastener type(s) diameter
or type
length of
fastener
(see note)
BKT GUIDE
New Solid Brick
Coach Bolts (Hex Lag Screw) and
washers - combined with wall plugs
5/16” x50mm •
5/16” x80mm • •
Macplugs (wall plugs) to suit above 5/16” x50mm •
5/16” x80mm • •
HLC Sleeve Anchors (Dyna Bolts)
with washers 12mm x55mm •
New Hollow Brick Screw Masonry Flange Hex Head
(M8 x75) 8mm x75mm • •
New Solid Concrete
Coach Bolts (Hex Lag Screw) and
washers - combined with wall plugs
5/16” x50mm •
5/16” x80mm • •
Macplugs (wall plugs) to suit above 5/16” x50mm •
5/16” x80mm • •
HLC Sleeve Anchors (Dyna Bolts)
with washers 12mm x55mm •
Steel Framing
e.g. BHP Framing
(with rear access)
Hex Head Bolt Zinc Plated,
Hexagon Nuts Zinc Plated,
Washers Zinc Plated
5/16” x1” •
3/8” x1” • •
10mm x25mm • •
12mm x25mm •
Heavy Gauge Steel Hex Head Tek and washers 14-20 x22mm • •
Light Steel Framing
e.g. BHP House
Framing
(no rear access)
Heavy Duty Kap Toggle 10mm x100mm • •
12mm x100mm •
Hex Head Tek and washers 6-10 x20mm •
New Timber
Coach Bolts (Hex Lag Screw) and
washers
5/16” x50mm •
5/16” x80mm • •
Hex Head Tek and washers 14-10 x50mm • •
WARNING! Coach bolts/
screws are NOT suitable
for windrated doors. Refer
to High Wind drawings on
the B&D Website.
4Roll-A-Door®Series 2 installation instructions

1.4.1 requirements
mounting - The door is designed to be mounted behind the opening.
obstructions - Ensure that the surface where the door will be tted
is ush and smooth, and the area behind the opening is free from any
protrusions.
structural suitability - Ensure the opening is strong enough to
support the door. If unsure, consult a builder.
level and plumb - The door must be installed in an absolutely
level position, if opening is not level and square, appearance and/
or sideroom requirements will be affected. The oor should be level or
recessed across the opening to avoid gaps.
1.4 before installation
LINTEL HEIGHT
OPENING
WIDTH
SIDEROOM
BACKROOM
H
E
A
DRO
OM
SIDEROOM
1.4.2 measurements
opening width - As the standard door overlaps each side by 50mm
or more, the door should be 100mm wider than the opening. A wider
door can be tted as long as additional sideroom and xing is available.
(Fig 1.4.1a) Wind-Locked doors require additional overlap dependent on
the substrate, consult the B&D High Wind Certication Drawings for more
detail.
opening height - The door opening height (or drive through
clearance) indicates the distance between the ground and rubber
seal at the bottom of the door, with door fully open. Max drive through
heights for each door height are listed in Fig 1.4.1b.
headroom - A minimum headroom is required for all doors. Refer to
Fig 1.4.2 - 1.4.5 for measurements. If the door is installed lower into the
opening than shown in Fig 1.4.2, additional loss of door opening height
will result.
backroom - A minimum of 460mm of backroom is required for
R2L doors up to 2400mm. For other doors, refer to Fig 1.4.2 - 1.4.5 for
measurements.
Fig: 1.4.1a
DO NOT CUT THE
PACKAGING THAT HOLDS
THE DOOR IN A ROLL
At a later stage during
the installation you will
be told just when to cut
the packaging. Remove
brackets, guides and bag
of small parts from each
end of the door roll.
1.3 preparation
Description Name Low Prole Traditional Industrial Light Industrial
Type Series 2 Series 2 Series 2 Series 2
Model code R2L R2W R2I R2F
Door & Max Drive Through
Heights (mm)
(non-Wind-Lock Doors)
Door Height Max Drive
Height Door Height Max Drive Height Door Height Max Drive Height Door Height Max Drive Height
- - 1400 1350 - - - -
- - 2100 2000 2100 2000 2100 2000
2400 2300 2400 2300 2400 2300 2400 2300
3000 (WA) 3000 3000 2985 3000 3000 3000 3000
3300 (WA) 3300 - - 3300 3300 3300 3300
- - - - 3600 3600 3600 3600
- - - - 4200 4200 4200 4200
- - - - 5100 5100 5100 5100
Max Door Width (including
overlap) 5500mm 5500mm 5500mm 5100mm
Fig: 1.4.1b
WARNING! If you need to remove an old door prior to installing a B&D door ensure to:
• Roll the door up and place a secure tie around the middle
• Place door support on at ground
• Fit door support snugly under door before loosening the brackets or locating U bolts.
• Slowly undo bolts to release the spring tension and the door from the brackets.
• Slowly lift the door from the brackets keeping it balanced as it is lowered to the ground.
5Roll-A-Door®Series 2 installation instructions

dimension panel
installation height
(mm)
width
(mm)
AB C DE F G H operation
A1*/ A10* A2 D1 D2*
Recommended
up to 2400
up to 5500
145/245
135 135 590 540 580 285 305 0 0 hand operated
2401-3300
195
135 620 570 610 300 320 035 planetary gearing
3301-4200 135 660 610 650 320 340 035 planetary gearing
4201-5100 135 680 630 670 330 350 035 planetary gearing
Restricted
up to 2400
up to 5500
135 135 530 540 580 285 245 60 0hand operated
2401-3300
195
135 560 570 610 300 260 60 35 planetary gearing
3301-4200 135 600 610 650 320 280 60 35 planetary gearing
4201-5100 135 640 630 670 330 310 40 35 planetary gearing
R2L Only
up to 2400 up to 5500
145/245
135 135 515 435 535 225 290 0 0 hand operated*
90 425 435 535 225 200 90 0hand operated*
2401-3300 up to 5500 195 135 540 475 585 250 290 035 planetary gearing*
90 480 475 585 250 230 60 35 planetary gearing*
Windlocked up to 2400 up to 5500 195/295 195** 175 590 540 580 285 305 0 0 hand operated
2401-3000 620 570 610 300 320 035 planetary gearing
*A1 Based on a Controll-A-Door PowerDrive and GDO-12 Hiro.
*A10 Based on a GDO-10 Toro (Right Hand Side install).
If an opener is installed there is no H measurement required.
D1 & D2* are the minimum measurements and optimum backroom clearance required for installation.
**NOTE: Wind-Locked doors may need between 55 - 68mm curtain overlap on both sides, depending on the substrate used.
R2F has a maximum width of 5100mm.
*R2L Only, above 2400mm only available in WA.
C
D2
D1
E
F
G
A1 / A10 B
50 50
A2 B
50
50
H
OPENER SIDEROOM (A1 / A10) PLANETARY GEARING SIDEROOM (A2)
Fig: 1.4.2
Fig: 1.4.3 Fig: 1.4.4
Fig: 1.4.5
1.4.2 measurements continued...
6Roll-A-Door®Series 2 installation instructions

1.5 parts checklist
1.6 initial calculations
a) Measure the opening width of garage.
b) Measure the door curtain width.
c) Calculate over lap for each side: door width - opening width : 2 = over lap
d) Mark the line for the edge of door curtain (over lap) on each side of the opening.
A
B
C
D
E
J
K
L
N
M
G
F
I
H
or
Fig: 1.5.1
SERIES 2 ROLL-A-DOOR R2F & R2I R2L & R2W HW
ITEM DESCRIPTION QTY QTY QTY
A ROLLED PLASTIC WRAPPED DOOR 1 1 1
B BRACKETS, LEFT AND RIGHT HANDED 2 2 2
C DOORS GUIDES LEFT AND RIGHT HANDED 2 2 2
D STEEL LOCKING BARS - 2 2
SMALL PARTS BAG CONTAINING
E BOTTOM RAIL STOPS AND SCREWS 2 2 2
FFACEPLATE AND LOCK ASSEMBLY - 1 1
G MUSHROOM HEAD SCREWS FOR LOCKING BAR - 2 2
H LOCKING BAR COVERS - 2 2
I LOCKING BAR RETAINER - 2 2
J "U" BOLTS 2 2 2
K AXLE / BRACKET SADDLES 2 2 2
L NUTS FOR "U" BOLTS 4 4 4
M SMALL WASHERS (DOOR SIZE DEPENDENT) 8-12 8-12 8-12
NLARGE WASHERS 4 4 4
tip
• Standard Series 2 doors
= 50mm (minimum) overlap each side
• Windlock (HW) Series 2 doors
= 55+mm (minimum) overlap each side
7Roll-A-Door®Series 2 installation instructions

2.0 installation
2.1 install rst bracket
2.2 install second bracket
EQUAL
WATER LEVEL
HOSE
EQUAL
a) Using a water level mark the position for
the second bracket (Fig 2.2.1)
b) Re-check levels then drill and x as with
rst bracket.
E
A OR B
F
C
CAUTION: The brackets must be
perfectly level for the door to operate.
Fig: 2.1.1
Fig: 2.2.1
dimension panel
Recommend
height
(mm)
width
(mm)
AB C E F
A1*/A10* A2
up to 2400
up to 5500
145/245
135 135 590 285 305
2401-3300
195
135 620 300 320
3301-4200 135 660 320 340
4201-5100 135 680 330 350
Restricted
up to 2400
up to 5500
135 135 530 285 245
2401-3300
195
135 560 300 260
3301-4200 135 600 320 280
4201-5100 135 640 330 310
R2L Only
up to 2400
up to 5500 145/245
135 135 515 225 290
90 425 225 200
2401-3300 195 135 540 250 290
90 480 250 230
Wind
up to 2400 up to 5500 195/295 195** 175 590 285 305
2401-3300 620 300 320
*A1 Based on a Controll-A-Door PowerDrive, GDO-6 EasyRoller and GDO-12 Hiro.
*A10 Based on a GDO-10 Toro (Right Hand Side install).
A2 is the minimum measurements without an opener.
R2F has a maximum width of 5100mm.
*R2L Only, above 2400mm only available in WA
Fig: 2.1.2
B
a) Use above diagrams Fig 2.1.1 and 2.1.2 for head and sideroom clearances.
b) Mark three hole positions using slots of the bracket B.
c) Drill holes, then attach bracket using six 10mm (3/8”) bolt size masonry anchors; (dynabolts or similar).
WARNING! The structure substrate must conform to the DTCM requirements. Refer to bac.nt.gov.au for
the DTCM Manual or High Wind drawings on the B&D Website.
tip
Take note of drive through clearance heights in fig 1.4.2b as the bottom rail will hang into
the opening on some doors, therefore reducing the opening.
8Roll-A-Door®Series 2 installation instructions

WARNING! practice correct
lifting techniques and use
suitable equipment
position bottom rail here
“U” bolt axle clamp
WARNING! Axle must be securely clamped
otherwise door will lose spring tension.
doors up to 5100mm* high
* R2L only available in WA
up to 3300mm
2.3 place door on brackets
a) Check the axle length and cut if sideroom is limited. Before
cutting, make sure the oating axle is free and centred
(Fig 2.3.1). Centre will be found by rotating the axle a quarter turn
in either direction then releasing . With centre found, make a clear
mark on the axle against the hub for later reference.
b) With the door the correct way round (the curtain rolls down the rear
of the opening) carefully lift door onto the brackets using block
and tackles attached to the door axles, or other suitable lifting
equipment – to avoid curtain damage.
c) Loosely t “U” bolt Jand/or saddle K,or double saddle and
position the door so that it overlaps the opening evenly both sides
so that the axle is positioned on the bracket arm slots as far forward
as possible (Fig 2.3.2) Fitting the saddles eliminates the door falling
from the brackets.
d) Centre the door with the opening, while ensuring the oating axle is
also centred with the door.
Do this by lining up previous marks with the hub, then lift both the
axle and the door together until it is centred with the opening.
Rotate both the door and the axle so that the bottom rail is level with
the arm of the bracket.
e) Now tighten the“U” bolts saddle K,or double saddle (door size
dependent), using washers under nuts L, to a torque of 40 newton
metres or 30 ft.lb.
centering axle
axle “oats” in
either direction
TWO PERSON LIFT: this product requires a two person lift to raise onto the brackets. Use proper techniques
and equipment to lift the door from the trailer and up onto brackets.
J
K
L
CAUTION: DO NOT CUT THE PLASTIC WRAP OR PACKAGING YET
Fig: 2.3.1
Fig: 2.3.2
saddle U-bolt
doors up to 3000mm* high
* R2L only available in WA
above 2400mm
saddles
10mm bolts
K
L
9Roll-A-Door®Series 2 installation instructions

2.4 install guides
guide clip
cushion head stop
bracket arm
G
CAUTION: Restricted headroom installation is not
recommended for automated doors unless the door is
installed lower into the opening. NOTE: This will reduce
the drive through height.
2.4.1 positioning guides
Fig: 2.4.1
a) Check that curtain overlaps equally on both sides.
b) Check that guides Care the correct length, that is, starts level with
the brackets (or as per table above at position G). (Fig 2.4.1) If guides
need to be shortened cut from bottom of guide.
dimension panel
Recommended
height (mm) width (mm) G
up to 2400 up to 5500 0
2401-3300 up to 5500 0
3301-4200 up to 5500 0
4201-5100 up to 5500 0
Restricted
up to 2400 up to 5500 60
2401-3300 up to 5500 60
3301-4200 up to 5500 60
4201-5100 up to 5500 40
R2L
up to 2400 up to 5500 90*
2401-3300 up to 5500 60*
Wind
up to 2400 up to 5500 0
2401-3300 up to 5500 0
R2F has a maximum width of 5100mm.
*R2L Only, above 2400mm only available in WA
WARNING! Do not grease the guides. Grease will
damage the Nylofelt®running strips and make doors
heavier to operate.
WARNING! All High Wind installations must adhere to fixing types and centres as referenced in the DTCM
Drawings and B&D High Wind Drawings.
tip
If securing to uneven brickwork, packers may be required behind clips, to prevent them twisting out
of square; also ensure that clips are positioned on secure bricks.
Fig: 2.4.2
Recommended
Sideroom
Restricted
Sideroom
B
C
B
C
c) For Series 2 Doors:
(i) Now position one guide over the edge of the door
curtain. Mark and drill the top xed guide clip and
secure using correct xing and washers as per table
in Section 1.2, allowing 3-4mm clearance between
the door and the inside of the guide.
(ii) Ensuring guide is plumb,using spirit level,then drill and
x remaining clips and head stop.
For Series 2 Windlock Doors:
(i) If there is limited sideroom available the guide may
need to have the side cut out to accommodate. See
Fig 2.4.2 for recommended and restricted sideroom
with a clearance of 2-5mm to the bottom rail roller.
(ii) Now position one guide over the edge of the door
curtain. Mark and drill at top guide hole and secure
guide using xing types as per High Wind Certification
Drawings, taking note of the specic spacing
requirements.
(iii) Ensuring guide is plumb, drill and x remaining holes in
guide as per spacing details listed.
d) With the top of the 2nd guide level with the rst, repeat (c)
for the specic door type.
NOTE: Welding of guides to steelwork is usually not
recommended
10Roll-A-Door®Series 2 installation instructions