B&D The Designer Series User manual

www.bnd.com.au
& P7 Industrial™
installation instructions PART NO: 0T2429
The Designer Series
These instructions are intended for professional garage door
installers.All references are taken from inside looking out.
DOC# 165005_01
PART NO# 0T2429
RELEASED: 29/05/19
Standard Designer Series
Installation
New ush mount
Installation

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 door panels 7
3.0 installation 8
3.1 installing vertical tracks 8
3.2 installing bottom panel 8
3.3 adding panels 9
3.4 installing horizontal tracks 10
3.5 install top panel 11
3.5 standard spring counterbalance system 12
3.6 install torsion bar 13
3.7 adding tension to spring 14
3.8 nal checks 15
4.0 troubleshooting 16
5.0 appendix 18
5.1 ush mount installation 18
5.1.1 Assemble the frame 18
5.1.2 Assemble the tracks 19
5.1.3 door panels 20
5.1.4 Install the tracks 20
5.1.5 install seal carrier 21
5.1.6 installing bottom panel 21
5.1.7 Assemble Horizontal track 21
5.1.8 installing top panel 22
5.1.9 spring counterbalance system 22
5.2 rear torsion systems 23
5.3 hinged tapers 25
5.4 two piece shafts for large doors 26
6.0 after installation care 27
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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 • 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
CHORIZONTAL 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
A
B
C
D
E
F
L
H
I
J
K
M
N
O
P
Q
R
S
T
U
G
V
1.3.1 pack contents
ITEM DESCRIPTION QTY
L SIDE BEARING BRACKETS 2
MWHEEL AXLES 8+
N LIFTING CABLE 2
O TEK SCREWS 20+
P HANGERS 9+
Q HINGED HANGERS 8+
R BOTTOM PANEL BRACKET 2
S AXLE PLATE HANGER 2
T BOTTOM HANGERS 2
U SNAP PINS 2+
V SHAFT COLLAR 1
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The Designer Series & P7 Industrial™installation instructions

mounting - The door is designed to be mounted behind the opening, however for ush mount doors, refer to the
Appendix for mounting instructions.
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.
headroom - depending on the cable drums used
a minimum of 340mm (390mm 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.
vertical track height - the track height should be the
door height minus the short top track angle measurement.
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) Calculate the vertical track length:
tip
door height
Fig: 1.4.1
(standard 127mm,
low headroom 275mm)
short top track angle
-=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
d) Calculate the track width:
tip
door height 3/4
x=horizontal track
brace postion
e) Calculate the horizontal track brace position:
tip
panel width 20mm
+=track width
(from the inside edge)
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The Designer Series & P7 Industrial™installation instructions

2.0 assembly
2.1 vertical tracks
a) Cut the Vertical Straight tracks Dto the calculated
length as listed in section 1.4.2.
b) Afx the small angle jamb brackets Gand short top
track angle Eto the straight track Dusing 6 x 5/16 at
head bolts and wiz nuts, noting the distance required
from the wall to the track as shown in Fig 2.1.1.
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 the “V”.
D
E
G
Fig: 2.1.1
left hand track shown
2.2 door panels
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.
b) Place the axles plate hanger Sonto the bottom
hanger Tand secure onto the bottom panel as
shown in Fig 2.2.1 using tek screws. Ensure to line up
the holes with the bottom panel bracket R.
NOTE: Refer to appendix if installing a taper or rear torsion system as this requires a different hanger.
N
T
tip
Do not unwind lifting cable until specified
to do so.
c) Secure the bottom panel bracket Rwith 2 tek
screws, then slide in wheel axle Mthrough the axle
plate hanger to the bottom panel bracket.
d) Push the end of each lifting cable N, onto the
bottom hanger, followed by a washer Hand secure
with a snap pin UFig 2.2.1.
Fig: 2.2.1
F
70mm
40mm
HU
R
S
M
M
NOTE: Refer to appendix for
ush mounting installations
P
Q
M
tip
Apply general purpose grease to all axles
before fitting them.
e) Attach the hanger Pto the top of the panel at every
door stile, using 2 tek screws, then place 2 hinged
hangers Qat either end of the panel and secure
with tek screws.
NOTE: The small angle jamb brackets and the short top track angle, provide adjustable slots to move the
track out from the wall. For larger doors one bracket is placed at the bottom and the second backet placed
approximately midway.
f) Insert the wheel axle M. NOTE: Once the panel is in place the hinged hangers
Qcan be adjusted if needed to ensure the panels are parallel to the opening.
g) Repeat steps e) and f) to assemble other middle panels.
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The Designer Series & P7 Industrial™installation instructions

3.0 installation
3.1 installing vertical tracks
10 mm
“V” section
a) Set the vertical tracks parallel on both sides of the door
at the vertical track width calculated in Section 1.4.2.
b) The tracks should be panel width + 20mm apart. Use
the level/datum marks to ensure the tracks are level with
each other and the same distance to the top of the track
or the door will not function correctly. Fig 3.1.1
c) Ensure to follow the measurements as shown in Fig 3.1.2
to set out the placement of the track and brackets.
d) 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
NOTE: Refer to appendix to install ush mount track system.
WARNING! All fixings must be fitted after the door
is fully adjusted and operating satisfactorily.
Equal Equal
3.2 installing bottom panel
10 mm
“V” section
TWO PERSON LIFT: depending on the size of the door, this process may
require two persons to lift into place.
a) Carefully lower the wheels of the bottom
panel into the tracks and lower so the panel
is sitting level in the door opening Fig 3.2.1.
b) Check that the wheels are stiting in the “V”
groove of the vertical track on each side
and there is sufcient clearance between
the panel and the track as per Fig 3.1.2.
CAUTION: After installation is complete all
plastic protective lm must be removed
from all panels.
Fig: 3.2.1
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The Designer Series & P7 Industrial™installation instructions

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, 1-2mm thick, at each panel joint
to give clearance between each panel in order to
decrease paint rub.
b) Insert the next panel into the guides and lower to
rest on top of the bottom panel. Fig 3.3.1 and 3.3.2.
c) Screw the hangers and hinged hangers to the
lowered panel.
NOTE: The hinged hangers are adjustable to ensure the
panels are parallel to the opening.
d) Repeat this procedure for all other panels with the
exception of the top panel which is positioned after
the horizontal track is installed Fig 3.3.3.
e) Once satised with the door placement, secure all
xing points on the vertical tracks.
Fig: 3.3.1
CAUTION: Ensure the warning label is placed on
the door in a clearly visible position.
Fig: 3.3.2
Fig: 3.3.3
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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
track
stop
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 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.
For doors higher than 2280mm and/or wider
than 4700mm two supports will be required.
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 wider than 4700mm 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 at 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 to install ush mount track system.
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The Designer Series & P7 Industrial™installation instructions

3.5 install top panel
fixed to
ceiling
fixed to
wall
cut corner
facing down cable drums
red* & black*
springs
red* &
black*
axle 2 x washers 2 x side
bearing
brackets
shaft collar
spring
anchor
bracket
NOTE: Refer to appendix if installing a rear torsion systems
as installation of top panel may be different.
a) Rest the top panel into position.
b) Thread the wheel axle Mdown the horizontal track and
slide the hinged hangers Qonto the wheel axle.
c) Secure hinged hangers with tek screws as shown in
top corner of panel and adjust hinge to wheel height
if necessary.
d) Repeat for other side of panel.
e) Attach top panel to panel below via the hangers and
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
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The Designer Series & P7 Industrial™installation instructions

3.5 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: 3.5.1
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. 3.5.1.
a) Place the torsion bar Bon the oor and slide the spring
anchor bracket Konto the torsion bar, positioning it
approximately half way along.
b) Locate the cable drum/s J, spring/s I, shaft collar V
and washers Hand assemble them as shown in Fig. 3.5.2.
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. 3.5.2 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
Fig: 3.5.2
K
J
I
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 doors containing two piece shafts and ush mount systems.
12
The Designer Series & P7 Industrial™installation instructions

3.6 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. 3.6.1.
Fig: 3.6.1
Fig: 3.6.2
Fig: 3.6.3
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 3.6.1.
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)
Fig 3.6.2.
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 3.6.3.
tip
It may be necessary to offset the anchor bracket
in order to clear room for the opener C-rail.
13
The Designer Series & P7 Industrial™installation instructions

3.7 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 3.7.1
a) Secure the torsion bar using 2 pipe wrenches,
tensioning bar or mechanical spring winder as
shown in Fig 3.7.2.
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 3.7.3.
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
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 3.7.4.
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.
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.
WARNING! Keep hands clear of the spring
and the spring winding plug at all times.
Fig: 3.7.1
Fig: 3.7. 2 Fig: 3.7.3
Fig: 3.7. 4
always have one hand firmly
holding bar while turning
grub screw 1
grub screw 2
maintain tension while
tightening both screws
14
The Designer Series & P7 Industrial™installation instructions

3.8 nal checks
pull cord
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 3.8.1.
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. TAL 5 or similar oil rich lubricant in a
pressure spray can is acceptable. Fig 3.8.2
Finally, the safety pull cord or handle must always be
tted to the door.
h) pass the cord through the white hinge pin on the
bottom panel. Fig 3.8.3.
i) Adjust the length and tie in a knot at each end.
j) Alternatively t a “D” handle.
Fig: 3.8.1
Fig: 3.8.2
Fig: 3.8.3
WARNING! The safety pull cord or handle
must always be fitted to the door
15
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 3.5.
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 3.7.
check the springs are on the correct side/s, refer to
section 3.5.
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 3.7. Ensure springs have been
lubricated.
check sping plug grub screws are tight, refer to section
3.7
check the springs are on the correct side/s, refer to
section 3.5.
16
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

B1
A
C
F
L
H
J
K
M
N
O
P
Q
R
S
T
U
G
D
E
I
B2
5.0 appendix
5.1 ush mount installation
a) Use the level/datum marks to determine whether there
is any height variation in the door opening, allowing for
spacers between the frame and opening.
b) Assemble the frame lengths B1 on the ground with
bolts, washers and nuts provided as per Fig 5.1.1.
Fig: 5.1.1
ITEM DESCRIPTION QTY
A PACK OF DOOR PANELS 1
B1 ALUMINIUM FRAME LENGTHS 3
B2 ALUMINIUM SEAL 1
C TORSION BAR 1
DHORIZONTAL CURVE TRACKS 2
EVERTICAL TRACKS 2
F FLAG BRACKET 2
G SMALL ANGLE JAMB BRACKETS 2+
H WASHERS 6+
I TENSION SPRING 1-4
J CABLE DRUMS 2
ITEM DESCRIPTION QTY
KSPRING ANCHOR BRACKET 2
L SIDE BEARING COMBO BRACKETS 2
MWHEEL AXLES 8+
N LIFTING CABLE 2
O TEK SCREWS 2
P HANGERS 9+
Q HINGED HANGERS 16
R AXLE PLATE HANGER 2
S BOTTOM HANGERS 2
T SNAP PINS 2
U SHAFT COLLAR 1
5.1.1 Assemble the frame
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The Designer Series & P7 Industrial™installation instructions

a) Cut the Vertical Straight tracks Eto the calculated
length.
b) Afx the small angle jamb brackets Gand
ag bracket Fto the vertical straight track
Eusing 6 x 5/16 at head bolts and wiz
nuts, noting the distance required from the
front of the frame to the track as shown in
Fig 5.1.5.
c) Lift the frame into position:
i) ensure the face of the frame
is aligned with the cladding
substrate ie. the frame will
protrude out of the door
jamb to the depth of the
cladding Fig 5.1.2.
ii) hold into place temporarily
with the use of clamps or
stands.
iii) place window spacers
between the frame and the
opening evenly on all sides
Fig 5.1.3.
d) Refer to the Fastener table
in section 1.2 to determine
the size of the drill holes and
fasteners required to t the
frame to the door jamb.
Fig: 5.1.4
Fig: 5.1.3
window spacers
Fig: 5.1.2
e) Start by drilling holes in the vertical frame, 200mm from the top and
200mm from the bottom. Then at intervals no greater than 600mm.
f) Use a long spirit level to ensure the frame remains level on both sides
as it is screwed into place.
g) Remove one of the boards on the packaging from the door panel crate
and mount it to the surface of the cladding substrate as shown in Fig
5.1.4. (Alternatively use a board t for purpose)
h) Repeat step g) for the other side of the garage. With boards in place it
will be easier to assemble panels and secure hinges.
Fig: 5.1.5
E
G
right hand track shown
F
5.1.2 Assemble the tracks
tip
door height 384mm
-=vertical track length
NOTE: The small angle jamb brackets and the ag
bracket, provide adjustable slots to move the track
out from the frame. For larger doors one bracket is
placed at the bottom and the second backet placed
approximately midway.
19
The Designer Series & P7 Industrial™installation instructions

5.1.3 door panels
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.
b) Place the bottom hanger Sonto the bottom panel
as shown in Fig 5.1.6 using tek screws O. Secure the
hinged hangers Qusing tek screws.
S
tip
Do not unwind lifting cable until specified
to do so.
c) Slide in wheel axle Mthrough the axle plate hanger
to the bottom panel bracket.
d) Push the end of each lifting cable N, onto the
bottom hanger, followed by a washer Hand secure
with a snap pin UFig 5.1.6
Fig: 5.1.6
H
U
Q
M M
P
Q
M
tip
Apply general purpose grease to all axles
before fitting them.
e) Attach the hanger Pto the top of the panel at every
door stile, using 2 tek screws, then place 2 hinged
hangers Qat either end of the panel and secure
with tek screws.
f) Insert the wheel axle M. NOTE: Once the panel is
in place the hinged hangers Qcan be adjusted
if needed to ensure the panels are parallel to the
opening.
g) Repeat steps e) and f) to assemble other middle
panels.
5.1.4 Install the tracks
Fig: 5.1.7
a) Set the vertical tracks parallel on both sides of the
ush mount frame.
b) The tracks should be panel width + 20mm apart. Use
the level/datum marks to ensure the tracks are level
with each other and the same distance to the top of
the track or the door will not function correctly.
c) Ensure to use the adjustable jamb brackets and set
the bottom of the vertical track 45mm from the front
of the frame. Fig 5.1.7.
d) 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.
N
O
45mm
tip
The thickness of the cladding to the exterior of
the garage determines whether to rotate the
axle carrier on the hinged hanger Fig 5.1.6.
< than 18mm
> than 18mm
rotate
cladding
thickness
20
The Designer Series & P7 Industrial™installation instructions