B&D The Designer Series User manual

www.bnd.com.au
& P7 Industrial™
installation instructions
The Designer Series
These instructions are intended for professional garage door
installers.All references are taken from inside looking out.
DOC# 165005_08
RELEASED: 28/09/23

contents
1.0 before you begin 3
1.1 installation safety warnings 3
1.2 fastener recommendations for tting garage doors 4
1.3 parts checklist 5
1.4 requirements before installation 6
1.4.1 measurements 6
1.4.2 initial calculations 6
1.5 tools 6
2.0 assembly 7
2.1 vertical tracks 7
2.2 bottom panel 7
2.3 middle panel 8
3.0 installation 9
3.1 installing vertical tracks 9
3.2 installing bottom panel 9
3.3 adding panels 10
3.4 installing horizontal tracks 11
3.5 install top panel 12
3.6 standard spring counterbalance system 13
3.7 install torsion bar 14
3.8 adding tension to spring 15
3.9 nal checks 16
4.0 troubleshooting 17
common spring problems 18
5.0 appendix 19
5.1 BTRK parts and install 19
5.2 two piece shafts for large doors 20
5.3 hinged tapers 21
6.0 after installation care 22
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The Designer Series & P7 Industrial™installation instructions

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.
• Follow the installation instructions.
Tension Springs • FRAME ONLY DOORS require spring tensioning AFTER the cladding is installed.
DO NOT operate the door without tensioning the springs.
• Ensure correctly tting 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.
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.
• Ensure you check the substrate for electrical wiring prior to penetration.
• 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 panel doors, as the unrolled cut out edges presents a very sharp
edge.
CAUTION:
Muscular strain • Practice correct lifting techniques when required.
• Use mechanical aids such as lifting devices, forklift and cranes where
possible.
• Avoid twisting.
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: • Depending on the size of the door, this product may requires a two person
lift. Use proper techniques and equipment to lift the door from the trailer
and into position.
This B&D 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.
1.0 before you begin
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The Designer Series & P7 Industrial™installation instructions

WARNING!
The installer must select and use fasteners appropriate to the material into which they are being fixed.
1.2 fastener recommendations for tting garage doors
substrate type fastener required washer
required
plug
required
drilled
hole ø
(mm)
min hole depth
(mm)
B&D fastner
pack
Unlined Plaster
Lined 100pk 500pk
solid brick
(>10 MPa)
screw, coach
5/16 - 9tpi x 50 washer at M8 plug, nylon 5/16 x 50 10 60 90 FK0 011 FK0012
three hole brick
(> 30 MPa)
screw anka M8 x 75
ange hex head washer 3/8”n/a 875 75 FK0024 FK0023
(50PK)
ten hole brick
(>15 MPa)
screw anka M8 x 75
ange hex head washer 3/8”n/a 875 75 FK0024 FK0023
(50PK)
concrete block
(> 8 MPa)
screw anka M8 x 75
ange hex head washer 3/8”n/a 875 75 FK0024 FK0023
(50PK)
concrete
(> 15 MPa)
screw, coach
5/16 - 9tpi x 80 washer at M8 plug, nylon 5/16 x 80 10 60 90 FK0013 FK0014
timber screw, coach
5/16 - 9tpi x 50 washer at M8 n/a 560 90 F K0 011 FK0012
steel section
(0.9-2mm thick)
screw tek
14g - 20tpi x 25
ange hex head ZP
washer at M8 n/a n/a n/a n/a FK0019 FK0020
important notes
1. For installation to substrate materials not covered in the above chart, the installer should seek expert advice.
2. Substitute fasteners are not recommend unless approved.
3. The above chart species the fasteners for new substrate materials only. Seek specialist advice regarding
pre-existing substrate materials.
4. It is important that correct washer and plug is used and the correct pilot hole drilled where specied.
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The Designer Series & P7 Industrial™installation instructions

1.3 parts checklist
ITEM DESCRIPTION QTY
A DOOR PANELS PACKAGE 1
B TORSION BAR 1
C* HORIZONTAL TRACKS* 2
DVERTICAL TRACKS 2
ESHORT TOP TRACK ANGLE 2
F HORIZONTAL BRACKETS 2
G SMALL ANGLE JAMB BRACKETS 2+
H WASHERS 6+
I TENSION SPRING 1-4
J CABLE DRUMS 2
KSPRING ANCHOR BRACKET 2
HD ANCHOR BRACKET + 2” ROLLER BEARING 2
L SIDE BEARING BRACKETS 2
A
B
C
D
E
F
L
H
I
J
K
M
N
O
R
S
T
G
U
V
P
Q
or
or
W
X
ITEM DESCRIPTION QTY
MWHEEL AXLES 8+
N LIFTING CABLE 2
O TEK SCREWS 20+
P HINGES 9+
Q END HINGES 8+
R AXLE PLATE HANGER 2
SBOTTOM HANGERS 2
HD BOTTOM HANGER 2
T SNAP PINS 2+
U SHAFT COLLAR 1
V SAFETY STOP 2
W AXLE SPACER 2
X BOTTOM PANEL BRACKET** 2
* Refer to appendix for BTRK drawing ** Supplied only with certain doors
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The Designer Series & P7 Industrial™installation instructions

mounting - The door is designed to be mounted behind the opening.
obstructions - Ensure that the surface where the door will be tted is 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 requirements before installation
HEIGHT
WIDTH
SIDEROOM
BACKROOM
HEADROOM
LEVEL DATUM
1.4.1 measurements
(refer to appendix for rear torsion allowances)
opening width - As the door overlaps each side by
30mm or more, the door should be 60mm wider than the
opening. A wider door can be tted as long as additional
sideroom and xing is available. See Fig 1.4.1.
opening height - The door will t any opening height
up to the marked door size.
sideroom - A minimum of 120mm of sideroom is required
over and above door width and should extend above
the head to allow for bracket xing. Rear torsion requires
150mm.
headroom - depending on the cable drums used,
a minimum of 390mm (440mm for larger doors) of
headroom is required.
backroom - as the door extends into the garage when
opening a minimum of the door height + 300mm for tracks
is required (+ 1000mm if opener tted).
level datum - use a water or lazer level to mark a datum
line on both sides approx. 1.5m from the oor. Use this line
to compare the distance on each side to the opening
height to determine if the opening is level.
1.4.2 initial calculations
a) Open the package of door panels and locate the label on the end of the door panel.
b) The label lists the Sales No: XXXXXX, then underneath DH: X,XXXmm (door height).
c) All the vertical track lengths are precut in the factory. However to calculate the vertical track length:
tip
door height
Fig: 1.4.1
(standard 127mm, low headroom 275mm)
(BTRK 242mm)
-=vertical track length
It is recommended that this door is installed by a professional door installer using a professional and specialised
tool kit.
1.5 tools
tip
d) Calculate the horizontal track brace position:
Refer to substrate detail information on the B&D website for recommended brace
positions.
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The Designer Series & P7 Industrial™installation instructions

2.0 assembly
2.1 vertical tracks
a) All the Vertical Straight tracks Dare cut to length in factory.
Conrm the measurement matches calculation in 1.4.2.
b) Afx the small angle jamb brackets Gand short top track
angle Eto the straight track Dusing 6 x 1/4at head bolts
and wiz nuts, noting the distance required from the wall to
the track as shown in Fig 2.1.1. Further adjustment may be
required, depending on type of structure.
c) Connect the horizontal bracket Fto the short top track angle
Eusing a 1/4 domed head bolts and wiz nut in top corner of
t h e “ V ”.
NOTE: The small angle jamb brackets and the short top track
D
E
G
Fig: 2.1.1
left hand track shown
2.2 bottom panel
a) Open up the pack of door panels, making sure the bottom panel (weather strip seal on the bottom of the panel
and bottom hinge hole) is on top of the pack. Start with the bottom panel.
NOTE: Refer to appendix if installing a taper or rear torsion system as this requires a different hanger.
N
S
tip
Do not unwind lifting cable until specified
to do so.
b) For single end stile doors; Place the axles plate
hanger Ronto the bottom hanger Sand
secure onto the bottom panel as shown in Fig
2.2.1a using six (6) tek screws. NOTE: Bottom
panel bracket Yneeded only on some doors.
For double end stile large doors: Place the bottom
HD hanger Sand secure onto the bottom panel as
shown in Fig 2.2.1 using nine (9) tek screws.
Fig: 2.2.1
F
70mm
40mm
H
T
R
M
M
P
Q
tip
Apply general purpose grease to all axles
before fitting them.
c) Slide the wheel axle Mthrough the axle plate
hanger RFig 2.2.1a or bottom HD hanger S
Fig 2.2.1.
angle, provide adjustable slots to move the track out from the wall. For larger doors over 2400mm high
one bracket is placed at the bottom and the second backet placed approximately midway.
d) For single end stile doors; Push the end of each lifting
cable N, onto the bottom hanger, followed by a
washer Hand secure with a snap pin TFig 2.2.1a.
For double end stile large doors: Push the end of
each lifting cable N, onto the panel side pin of the
bottom hanger and secure with a snap pin Tto the
outside of the pin in Fig 2.2.1.
e) To attach hinge Pto the top of the panel, align the
edges of the hinge with the vertical grooves in every
door stile. Position the hinge as shown and afx with
(2) tek screws (Fig 2.2.1b). Fig: 2.2.1a
Fig: 2.2.1b
Fig: 2.2.1c
Fig: 2.2.1d
S
N
T
oil hole to
the top
Ensuring the hinges are horizontally aligned across the panel will
provide a smoother door operation.
ii
W
M
f) Before placing 2 end hinges Qat either end of the panel, remove the 2 axle plates ii and screws from each hinge. Slide
in wheel axle Mthrough the axle spacer Wand onto the axle plates ii for each end and put aside for later (Fig 2.2.1c).
g) The xings must align with the vertical grooves in the stile then, secure both end hinges Qwith eight (8) tek screws as
shown in Fig 2.2.1d. NOTE: Once the panel is in place the hinged hangers Qcan be adjusted if needed to ensure the
panels are parallel to the opening.
Y
tip
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The Designer Series & P7 Industrial™installation instructions

2.3 middle panel
Fig: 2.3.1
M
P
Q
Fig: 2.3.1a
Fig: 2.3.1b
Fig: 2.2.1c
ii
oil hole to
the top
a) To attach hinge Pto the top of the panel, align the
edges of the hinge with the vertical grooves in every
door stile, position the hinge as shown and afx with
2 tek screws (Fig 2.3.1a).
b) Before placing 2 end hinges Qat either end of the
panel, remove the 2 axle plates ii , screws and nuts
from each hinge (Fig 2.3.1b).
tip
Apply general purpose grease to all axles
before fitting them.
c) Slide in wheel axle Monto the axle plates ii for
each end and put aside for later (Fig 2.4.1b).
d) The xings must align with the vertical grooves in
the end stile then, measure down 15mm from the
top of the panel to mark the centre screw position
of each of the end hinges Qto ensure horizontal
alignment. Secure with eight (8) tek screws as
shown in Fig 2.4.1c.
tip
Ensuring the hinges Pand Qare
horizontally aligned across the panel
will provide a smoother door operation
(Fig 2.3.2d).
NOTE: Once the panel is in place the hinged
hangers Qcan be adjusted if needed to ensure
the panels are parallel to the opening.
e) Repeat steps to assemble other middle panels.
P
Q
Fig: 2.3.2d
Q
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The Designer Series & P7 Industrial™installation instructions

3.0 installation
3.1 installing vertical tracks
50mm
90mm Recommended
30mm
a) Set the vertical tracks parallel on both sides of the door
Use the level/datum marks to ensure the tops of the tracks
are level with each other and the same distance to the
top of the track or the door will not function correctly.
See Fig 3.1.1
b) Ensure to follow the measurements as shown in Fig 3.1.2
to set out the placement of the track and brackets.
Measurements are from the edge of the opening to the
edge of the track, including the recommended 30mm
overlap on each side for the panel.
c) Once satised temporarily x in position with at least
two (2) xings to the top bracket and one to each of the
lower track brackets. These will hold the tracks in position
and allow for minor adjustments. Fig: 3.1.1
Fig: 3.1.2
WARNING! All fixings must be fitted after the door
is fully adjusted and operating satisfactorily.
Equal Equal
3.2 installing bottom panel
TWO PERSON LIFT: depending on the size of the door, this process may
require two persons to lift into place.
a) Carefully move the bottom panel into
position between the tracks and rest onto
tressle tables as per Fig 3.2.1.
CAUTION: After installation is complete all
plastic protective lm must be removed
from all panels.
Fig: 3.2.1
M
tip
Apply general purpose grease to
all axles before fitting them.
b) Slide in wheel axle Mthrough 2 axle plates
(that were removed in step 2.2f) and t the
wheel into the vertical track, before lowering
down onto end hinges. (Fig 3.2.1) Secure
axle plates with the 4 screws and nuts as
shown, ensuring there is sufcient clearance
between the panel and the track as per Fig
3.1.2.
c) Repeat step b) for other side of panel.
d) Adjust position of bottom hangers ensuring
the face of panel lines up with cladding.
e) Tighten bottom hanger bolts before lowering
to the ground.
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The Designer Series & P7 Industrial™installation instructions

WARNING
DO NOT REMOVE, PAINT OVER OR CONCEAL THIS LABEL
P/N MS0300
When manually operating this door,
DO NOT place your fingers between the
door panels.
Components of this door are under extreme
spring tension and can cause serious injury if
interfered with by an inexperienced person.
Adjustment and repairs must be made by an
experienced garage door technician, using
proper tools.
3.3 adding panels
TWO PERSON LIFT: depending on the size of
the door, this process may require two persons
to lift into place.
a) Before adding the next panel into the tracks t
a temporary spacer to the inside lip of the panel,
1-2mm thick, at each panel joint to give clearance
between each panel in order to decrease paint rub.
b) Carefully move the second panel into position
between the tracks as per Fig 3.3.1.
Fig: 3.3.1
CAUTION: Ensure the warning label is placed on
the door in a clearly visible position.
Fig: 3.3.2
M
tip
Apply general purpose grease to all axles
before fitting them.
c) Slide in wheel axle Mthrough 2 axle plates (that
were removed in step 2.2f) and t the wheel into
the vertical track, before lowering down onto end
hinges. (Fig 3.2.1) Secure axle plates with 4 screws
and nuts as shown, ensuring there is sufcient
clearance between the panel and the track as per
Fig 3.1.2.
d) Repeat step c) for other side of panel.
e) Screw the hangers and hinged hangers to the
lowered panel, before removing the temporary
spacer.
NOTE: The end hinges Qare adjustable for the axle
plate to ensure the panels are parallel to the opening.
f) Repeat steps a) - e) for all other panels with the
exception of the top panel which is positioned after
the horizontal track is installed.
g) Once satised with the door placement, secure all
xing points on the vertical tracks.
Q
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The Designer Series & P7 Industrial™installation instructions

EQUAL
EQUAL
Assemble the track as shown in Figure 3.4.1. The
curve must align and butt up against the vertical
track snugly.
3.4 installing horizontal tracks
¾ track length
equal equal
¾ track length
Fig: 3.4.1
Before bracing the horizontal tracks, ensure that
they are square to the opening and level. To
check whether your diagonals are equal:
a) Measure from the top of the vertical track to
the end of the opposite horizontal track.
b) Check both sides.
c) Adjust if necessary.
The track support must be located along the
horizontal track approximately at 3/4door height.
d) Calculate the horizontal track brace position as per
section 1.4.2.
e) Measure along the horizontal track to the desired
position and nd a structurally sound location to x
your support to the ceiling or side wall. Fig 3.4.2 or
Fig 3.4.3.
f) Each installation must be assessed individually for
ceiling xing requirements.
WARNING! Failure to position supports
approximately 3/4door height along the
track can result in the tracks twisting out.
Fig: 3.4.2
WARNING! For all doors higher than 2280mm
and/or wider than 4700mm, or heavier than
110kg, two (2) ceiling supports must be fitted
per horizontal track.
single support
double support
The safety stop must always be tted to prevent the
panels from accidently exiting the track
g) Install the safety stop Wat the end of the horizontal
track as shown in Fig 3.4.4.
Fig: 3.4.4
WARNING! The safety stop must be installed.
Failure to do so may cause serious personal
injury or damage to property.
tip
Check that the clearance in the vertical
tracks as per Fig 3.1.2 is also in the
horizontal tracks.
Fig: 3.4.3
NOTE: Refer to appendix if installing a BTRK for
different cladded doors as they require different
horizontal tracks.
W
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The Designer Series & P7 Industrial™installation instructions

3.5 install top panel
NOTE: Refer to appendix if installing a rear torsion systems as
installation of top panel may be different.
a) Before adding the top panel t a temporary spacer on
top of last panel, 1-2mm thick, at each panel joint to give
clearance between each panel in order to decrease
paint rub. Rest the top panel into position.
b) Thread the wheel axle Mdown the horizontal track
and slide the end hinges Qonto the wheel axle
(g 3.5.1a standard, 3.5.1b for BTRK).
c) Secure end hinges, using installation tool with tek screws
as shown in both top corners of the panel and adjust
hinge to wheel height if necessary.
d) Attach top panel to panel below via the hinges on
previous panel.
TWO PERSON LIFT: depending on the size of the
door, this process may require two persons to lift
into place.
Q
M
Q
Fig: 3.5.1a
Fig: 3.5.1b
Q
M
Q
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The Designer Series & P7 Industrial™installation instructions

3.6 standard spring counterbalance system
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 SIDE
Fig: 3.6.1
The springs and drums for the counterbalance system are now colour coded to
easily identify which side of the centre bracket the spring is placed. Fig. 3.6.1.
a) Place the torsion bar Bon the oor and slide the spring anchor bracket K
onto the torsion bar, positioning it approximately half way along.
b) Locate the cable drum/s J, spring/s I, shaft collar Vand washers Hand
assemble them as shown in Fig. 3.6.2.
NOTE: Shaft Collar not required in double spring mountings.
c) Ensure the shaft collar is butted up against the anchor bracket as shown in Fig.
3.6.2 and xed to axle on spring side of anchor bracket.
cable drum marked
with red paint
cable drum marked
with black paint
bolt 3/8”
nut 3/8”
washer 3/8”
black plug
red plug
shaft collar
HD anchor bracket
Fig: 3.6.2
K
J
B
CAUTION: DO NOT tighten
bolts in cable drums yet
J
H
double spring shown
Only for
single spring
installations
V
H
NOTE: Refer to appendix for large / heavy doors containing two piece shafts and heavy duty brackets.
I
13
The Designer Series & P7 Industrial™installation instructions

3.7 install torsion bar
Before lifting the torsion bar into position, check there
is a solid foundation of either brickwork, timber studs,
head or ceiling that will support the lifting system
correctly.
CAUTION: Be careful not to
over tighten the set-screws
a) Lift the torsion bar assembly into position, resting both ends
over the top of the horizontal tracks. Fig. 3.7.1.
Fi g: 3.7.1
Fi g: 3.7.2
Fi g: 3.7.3
J
L
K
NOTE: Refer to appendix if installing a rear torsion systems.
b) Ensure that the side bearing brackets Land cable drums
Jare situated on the inside of the horizontal tracks.
c) Line up the spring anchor bracket Kwith the middle of the
door, so that the cut corner is facing down.
d) Slide the torsion bar assembly towards the wall so the
spring anchor bracket can touch the wall (the axle must be
parallel with the opening).
tip
Unwind the lifting cable from the
bottom panel.
CAUTION: For larger doors refer to 5.4 appendix as a
stronger system may be required.
e) Secure the spring anchor bracket to the wall/ceiling and
the side bearing brackets to the tracks as shown in Fig 3.71.
tip
For wide doors, place a temporary support in
the center of the torsion assembly to prevent sag
and possible collapse.
f) Attach the lifting cable to the cable drum by slipping
the cable into the slot on the outside groove. (the
ferrule will prevent the cable from coming out)
F i g 3 .7. 2 .
g) Wind the cable by hand by turning the cable drum away
from the door.
h) Once the cable is taut, slide the cable drum against the
side bearing bracket and tighten the screws to the torsion
bar. Fig 3.7.3.
tip
It may be necessary to offset the anchor bracket
in order to clear room for the opener C-rail.
tip
If an opener is being tted, consider where
the C-Rail wall bracket is to be placed
before xing the spring anchor bracket K
tip
tip
There must be no more than ONE turn of cable around the cable drum.
Too much cable will affect the spring tension.
14
The Designer Series & P7 Industrial™installation instructions

3.8 adding tension to spring
Line Item: 30
Turns: 9.62
Quantity: 2
Ref No: XXX
KSPR: KIT SPRING SECTIONAL OVERHEAD DOOR
DH 2,650 mm X DW 5,300 mm
Diameter: 50.8 X 2 X 9.4
Wire Diameter: 6.17 mm
Delivery No: 82059200
Wgt: 12.9 kg
123456
78
WARNING! Torsion springs can cause serious
injury. DO NOT underestimate the tension in
the spring.
The number of turns required for each spring is shown
on a paper tag attached to the springs. Fig 3.8.1
a) Secure the torsion bar using 2 pipe wrenches, as
shown in Fig 3.8.2.
tip
The label lists how many full turns.
Alternatively, a line is painted along every
spring. If the spring is turned 8 times, 8 lines
can be seen along the spring
b) Turn the spring by inserting winding bars into the
plug holes of the spring and wind up in the direction
towards the opening. Fig 3.8.3.
WARNING! Always have one winding bar
engaged and firmly held while turning and
tightening screws.
CAUTION: Be careful not to
over tighten the grub screws.
c) Once you have completed the turns required,
remove one winding bar. If spring snaking occurs,
tap the remaining bar back towards the spring
anchor bracket.
d) Maintain rm tension on the winding bar, while
using a spanner to tighten the two (2) grub screws.
Fig 3.8.4.
WARNING! Keep hands clear of the spring
and the spring winding plug at all times.
Fig: 3.8.1
Fig: 3.8.2
Fig: 3.8.3
Fig: 3.8.4
always have one hand firmly
holding bar while turning
grub screw 1
grub screw 2
maintain tension while
tightening both screws
e) Repeat this procedure if there is more than one
spring, remembering to always wind the spring,
whether left or right hand, in an up direction
towards the opening.
f) Check that all screws are properly tightened before
removing the wrenches on the torsion bar.
tip
Doors with total weight over 200kg require
850mm+long winding bars. These can be
purchased from B&D (p/n 0T05480-1).
850mm long winding bars are
needed to safely tension springs
on heavy doors.
WARNING! FRAME ONLY DOORS must be
tensioned after the cladding is installed for
springs to adjust to the new weight.
15
The Designer Series & P7 Industrial™installation instructions

3.9 nal checks
For optimal performance the door needs to operate
efciently.
a) Manually move the door up and down, the door
should move freely without binding or sticking.
b) The maximum force required to move the door
should not exceed 20kg.
c) Lift the door to about halfway. When released, the
door should stay in place. Fig 3.9.1.
d) Check that the clearances in the vertical tracks as
per Fig 3.1.2 is also in the horizontal tracks.
e) If you nd that the door is binding, open out the
horizontal tracks slightly to create the correct
tolerance.
f) Once satised that the operation of the door is as
near perfect as possible, check that all nuts and
bolts are tight.
g) Oil the springs full length to prevent noise and
reduce friction. INOX MX5 or similar oil rich lubricant
in a pressure spray can is acceptable. Fig 3.9.2 Fig: 3.9.1
Fig: 3.9.2
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The Designer Series & P7 Industrial™installation instructions

4.0 troubleshooting
Symptom Possible cause Remedy
lifting cables loose
when door is
opened
cable drums have slipped
diagonals out of square
lifting cables not wound till taut
check the screws on the cable drums
check the horizontal tracks are square
loosen screws on cable drums and wind cables till
taut, then tighten screws.
torsion bar moving cable drums not adjusted correctly
springs not adjusted correctly
shaft collar not tted (single spring)
end bearing brackets are not straight
check and adjust
check spring tension
t shaft collar, see section 3.6.
check end bearing brackets are square and vertical
door will not
hold up in open
position
spring tension not tight enough
incorrect placement of springs
check the correct number of turns has been made to
spring/s. refer to section 3.8.
check the springs are on the correct side/s, refer to
section 3.6.
door not level water level marks incorrect
lifting cable not equally taut
check the water level marks are correct
loosen screws on cable drums and wind cables till
taut, then tighten screws.
door moving to
one side
clearances incorrect
cable drums not close to end
bearing brackets
check the clearance/overlap of the door is equal on
each side.
loosen screws on cable drums and ensure they are
hard up against the end bearing bracket and tighten
screws.
door panels
jamming /
rubbing on tracks
incorrect clearance between wheel
and vertical track
door not level
cable drum not lined up correctly
vertical tracks not parallel
lifting cables slipping
Check that the clearances per Fig 3.1.2 are the same in
both vertical and horizontal tracks.
check water level marks are correct.
loosen screws on cable drums and ensure they are
hard up against the end bearing bracket and tighten
screws.
Check that the clearances per Fig 3.1.2 are the same
on both vertical tracks.
loosen screws on cable drums and wind cables till
taut, then tighten screws.
door hard to lift spring tension
spring may have slipped on set
screws
wrong spring
check the correct number of turns has been made to
spring/s. refer to section 3.8. Ensure springs have been
lubricated.
check sping plug grub screws are tight, refer to section
3.8
check the springs are on the correct side/s, refer to
section 3.6.
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The Designer Series & P7 Industrial™installation instructions

common spring problems
symptom possible cause rememdy
door raises from
the oor and
hangs down in
opening
cable length too long with cable not
on high portion of drum
shorten cable length until the cable rolls onto the
at portion of the drum when the door starts into the
horizontal position
springs may be too strong (too short) replace spring
wrong cable drums for springs (too
small)
replace cable drums
door lifts from the
oor and runs
away at the top
door is over tensioned. too many turns
on spring or wrong spring
ensure that the correct spring is supplied (if not
replace) and that it has the correct number of turns
applied
wrong cable drums for spring, (too
small)
replace cable drums
door falls to the
oor and hangs
down in the
opening
door is under tensioned too few turns
on spring or wrong springs
ensure that the correct spring is supplied (if not
replace) and that it has the correct number of turns
have been applied
wrong cable drums for springs (too
large)
replace cable drums
door falls to the
oor and runs
away at the top
lifting cable may be too short for high
lift cable drum or vertical lift drum and
is sitting too high on the spiral portion
of the drum
increase the cable length to bring the cable down
lower on the spiral
torsion springs too long shorten springs
door balances at
the oor but runs
up or down in
between
cables in wrong position on spiral of
the drums
adjust cable length
poor balance
throughout
winding spring in wrong direction wind in correct direction
door weight incorrect supply correct springs
springs binding t torsion bar collar
lubricate springs
door not level cable lengths are equal
equal turns on both springs
level door during installation
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The Designer Series & P7 Industrial™installation instructions

5.0 appendix
The BTRK is a double track with top curve C
that opens up to t the top panel tted with thick
cladding on the face Figure 5.1.1.
Cut vertical tracks to match dimensions for
low headroom or BTRK as shown in 1.4.2 initial
calculations on page 6. Assemble the track as
shown in Figure 5.1.2. The curve Cmust align
and butt up against the vertical track Bsnugly
and the top curve track needs to be close to the
lintel.
Before bracing the horizontal tracks, ensure that
they are square to the opening and level. To
check whether your diagonals are equal:
a) Measure from the top of the vertical track to
the end of the horizontal track.
b) Check both sides.
c) Adjust if necessary.
Refer back to 3.4 c) to nish installing horizontal
tracks.
Fig: 5.1.2
5.1 BTRK parts and install
Fig: 5.1.1
C
B
C
Panel Cladding
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The Designer Series & P7 Industrial™installation instructions

black plug
torsion shaft
couple
bolt 3/8”
washer 3/8”
cable drum marked
with red paint
red plug
cable drum marked
with black paint
bolt 3/8”
washer 3/8”
roller bearing
slide
slide
roller bearing
5.2 two piece shafts for large doors
The springs and drums for the counterbalance system are now colour coded to easily identify which
side of the centre bracket the spring is placed. Fig. 5.2.1.
a) Place the 2 x torsion bars Bon the oor and slide the 2 x
HD spring anchor bracket Kand roller bearings onto the
torsion bar, positioning them towards the middle.
b) Slide on the springs I, ensuring the roller bearing
is butted up against the spring anchor bracket K
and spring I.
c) Connect each assembly together using 2 x 3/8”
washers and bolts.
d) Place the cable drums Jon each end.
e) Mount the remaining 2 x spring
anchor brackets to the wall
above the horizontal track.
CAUTION: DO NOT tighten
bolts in cable drums yet
TWO PERSON LIFT: For large doors, this process may require two persons to lift into place and
a ladder or scissor lift to support while xing into place.
TWO PERSON LIFT: Next step may require two persons to lift into
place and a ladder or scissor lift to support while xing into place.
insert key then x into
place with grub screw
torsion
shaft key
torsion
shaft key
torsion
shaft key
Fig: 5.2.1
Fig: 5.2.2
a) Attach the lifting cable to the cable drum by slipping the cable into the slot
on the outside groove. (the ferrule will prevent the cable from coming out) .
b) Wind the cable by hand by turning the cable drum away from the door.
tip
Unwind the lifting cable from the
bottom panel.
CAUTION: Be careful not to
over tighten the set-screws
Fig: 5.2.3
K
J
B
J
I
tip
The smaller end of the roller
bearing is to face the spring.
f) Lift and thread the right hand side of the assembly through the mounted spring
anchor bracket and x the loose spring anchor bracket securely to the wall.
g) Assemble the torsion shaft couple, without tightening the bolts and slide onto
the end of the torsion bar, ready to connect to the other torsion bar.
h) Repeat step f) for the left hand side assembly.
i) Position the torsion shaft couple in the middle as shown in Fig 5.2.1, the axles
should be ush with each couple allowing free rotation to occur.
j) Cut torsion shaft key in half and insert into torsion bar at the torsion shaft
couple, and x into place by tightening the grub screws on the shaft couple
Fig 5.2.2.
K
I
B
c) Once the cable is taut, slide the cable drum against the side bearing bracket
and tighten the screws to the torsion bar. Fig 5.2.3.
d) Proceed to section 3.8 to tension the springs.
tip
There must be no more than ONE turn of cable around the cable
drum. Too much cable will affect the spring tension.
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The Designer Series & P7 Industrial™installation instructions