Cornell Steel Weave Grille User manual

ECO# 1711 REVISION# 000 ES 10-451 DATE 05/15/2019
Steel Weave Grille
Installation Manual

ECO# 1711 REVISION# 000 ES 10-451 DATE 05/15/2019

Section 1 – Table of Contents
1
Section – 2 List of Figures and Tables 2
Section – 3 Safety Check List 3
Section – 4 Freight Receiving 4
Section – 5 Pre-Installation 5
Section – 6 Torque Specifications 6
Section – 7 Installation 7
Installation Overview 7
Guide Installation - Face of Wall (FOW) Units 10
Wall Bracket Installation 12
Guide Installation - Between Jamb (BJ) Units 14
Preparation of the Barrel, Curtain, and Brackets 22
Securing Brackets to Wall Brackets 25
Outer guide installation (Stainless Steel) 29
Attaching Additional Bracing (if required) 32
Applying Spring Turns 33
Curtain Alignment 34
Lock Strike Adjustment 36
Guide Mounted Interlocks (GMI) 37
Cable Management (Stainless) 39
Hood Support Installation 40
Hood and Fascia Installation 41
Cover installation 45

Section 2 – List of Figures and Tables
2
Section – 2 List of Figures and Tables
List of Figures
Figure 5.1 – Opening Dimensions and Designations 5
Figure 7.1 – Face of Wall (FOW) 8
Figure 7.2 – Between Jambs (BJ) 9
Figure 7.3 – Fascia Side Guide installation (Stainless Steel) 10
Figure 7.4 – Aluminum Guide installation (FOW) 11
Figure 7.5 – Wall Brackets 12
Figure 7.6 – Wall Bracket Installation (Stainless Steel) 12
Figure 7.7 – Wall Brackets Installation (Aluminum) 13
Figure 7.8 – Tube Saddle 16
Figure 7.9 – Slip Joint – Between Floor and Ceiling Mounting Assembly 17
Figure 7.10 – Slip Joint – Floor to Wall with Plate Mounting Assembly 18
Figure 7.11 – Slip Joint – Floor to Wall with Angle Mounting Assembly 19
Figure 7.12 – BJ Coil Side Guide Installation (Stainless Steel) 20
Figure 7.13 – BJ Guide installation (Aluminum) 21
Figure 7.14 – Bracket and Barrel Prior to Installation 22
Figure 7.15 – Barrel Spacer Installation 23
Figure 7.16 – Removing Curtain Assembly from Pallet 23
Figure 7.17 – Assembly Marking 23
Figure 7.18 – Curtain Spacing 24
Figure 7.19 – Removable Bellmouth Aluminum Guides 26
Figure 7.20 – Curtain/Barrel Installation (FOW) 27
Figure 7.21 – Curtain/Barrel Installation (BJ) 28
Figure 7.22 – Coil Side Guide installation (FOW) 29
Figure 7.23 – Coil Guide installation (BJ) 30
Figure 7.24 – Reinstall Removable Bellmouth (Aluminum) 31
Figure 7.25 – Curtain Alignment (Aluminum) 34
Figure 7.26 – Lock Strike (Stainless) 36
Figure 7.27 – Lock Strike (Aluminum) 36
Figure 7.28 – GMI (Stainless) 37
Figure 7.29 – GMI (Aluminum) 37
Figure 7.30 – GMI Switch Plate 38
Figure 7.31 – Cable Management (Stainless) 39
Figure 7.32 – Hood Supports 40
Figure 7.33 – Fascia Hood Installation (FOW) 41
Figure 7.34 – Fascia Hood Installation (BJ) 42
Figure 7.35 – Coil Side Hood Installation 42
Figure 7.36 – Low Clearance Hood Fasteners 43
Figure 7.37 – End Cap Installation 44
Figure 7.38 – Motor Cover Installation (Front of Coil) 45
Figure 7.39 – Non-drive side End Cap installation 45
Figure 7.40 – Drive side End Cap installation 46
Figure 7.41 – Chain Access Panel Installation 46
List of Tables
Table 3.1 – Potential Hazards and Preventative Measures 3
Table 6.1 – Torque Recommendations for Guide Assembly and Wall Fasteners 6
Table 6.2 – Torque Recommendations for Solid Masonry Wall Anchors 6

Section 3 – Introduction
3
Section – 3 Safety Check List
Rolling doors are large, movable objects. They move with the help of electric motors or manual operators
(chain, crank, push up, etc), and most have springs under high tension. These items and their
components can cause injury. In order to avoid injury to yourself and others, please follow the instructions
in this manual.
Review the potential hazards and preventative measures listed below:
Table 3.1 – Potential Hazards and Preventative Measures
Potential Hazard
Preventative Measure
Pinned or crushed
by closing door.
•Keep yourself and others clear of opening while door is in
motion.
•Do not allow children to play near or operate door.
•Do not operate if door becomes jammed or broken.
Struck by adjusting
wheel bar while
applying spring
turns.
•Be sure bar is adequate in strength and long enough to allow
installer to apply the necessary torque.
•Make sure bar is fully seated into the adjusting wheel slot
before applying pressure.
•
Use two bars while applying turns to the adjusting wheel.
Electrical shock.
•Make sure electrical operator is properly grounded.
•Turn off source power completely prior to servicing the motor.
•Make sure wires are clear of any moving or potentially moving
parts.
•Avoid pinching wires when installing the motor cover.
Pinched by moving
components.
•Make sure the motor is turned off and unplugged before
working with moving parts such as roller chain and sprockets,
drop-out mechanisms, adjusting wheels, etc.
•Locate the possible pinch-points of the unit (Drive chain, coil
area, bottom bar, etc.) Do not operate the door while
someone is near these areas.
Check the following during installation and before leaving the job site:
1. If the unit has tension springs, be sure the proper amount of tension is applied to the torsion
springs, in order to properly counterbalance the weight of the curtain.
2. Securely fasten the tension adjusting wheel in place with the appropriate hardware provided.
3. Check that the keys and/or cotter pins have been set in place and fit properly at all sprockets or
gears.
4. Check that the setscrews in each sprocket or gear (one over the key and one offset from the key)
have been tightened properly.
5. Check all fasteners holding the unit to the building structures.
6. Check all fasteners used to assemble the components of the unit together.
7. Instruct owner or representative in the proper method of operating the door.

Section 4 –Freight Receiving
4
Section – 4 Freight Receiving
Upon delivery, check condition of components for damage.
If damage occurred in transit, the installation should not proceed without authorization.
If the installation proceeds, neither the carrier nor the manufacturer will assume responsibility for
replacing the damaged material.
If the installation is stopped due to damage, do the following:
1. Take pictures of the damage.
2. Do not move material from point of delivery to other premises once the damaged components are
discovered.
3. Do not unpack, if the damage is visible prior to removing packaging, until an inspection is made.
4. If the damage is found while removing contents from packaging, the packaging material must be
saved until inspection is made.
5. Container and packaging should be retained by consignee until inspection is made.
6. Have components inspected by carrier’s representative within 15 days from date of delivery.
7. Consignee must obtain a copy of the Inspection Report.
Returning damaged components:
1. Obtain permission from carrier to return.
2. Route the return shipment via the identical carrier(s) involved in the original shipment.
3. Notify the manufacturer when shipment is returned to manufacture plant.
Verify that all components have arrived. Look for the following:
1. Job construction drawings featuring different views (elevation, section, plan, etc.)
2. (2) Guide assemblies
3. Curtain and Barrel assembly
4. Bracket assemblies
5. Operator; if not attached to bracket
6. Operator cover; may not be included in order
7. Adjusting wheel; if the barrel assembly contains springs
8. Hood and hood supports; may not be included in order
9. Hardware
10. Misc. items (Reelite, lintel seal, hood baffle, etc.)
11. Verify material/finish/color of components matches what is listed on the job construction drawings
and/or what was ordered.
If the delivery is incomplete:
1. Make note on delivery receipt.
2. Note should be verified by driver’s signature.
3. Notify carrier and manufacturer.

Section 5 – Pre-Installation
5
Section – 5 Pre-Installation
Read entire instruction manual thoroughly. The manufacturer will not be held responsible for any
charges incurred due to improperly installed components.
a. Only trained door systems technicians should perform installation, maintenance, etc.
b. Each unit comes with an individual item number. If the job contains multiple units, be sure to
locate all the components for each item and separate each.
Do not interchange parts from one door to another.
c. Find the job construction drawings for the unit being installed and check the dimensions of the
opening against those on the drawings. See Figure 5.1 below.
d. If the opening dimensions differ from those on the drawings, do not proceed, check with
distributor/manufacturer to be sure the correct door is being installed.
e. Check the jambs of the opening for plumb. Check the head/lintel and floor for level.
Work Area:
a. The key to a smooth installation is a clean and well-prepared work environment. Once the
components have been inspected and the job construction drawings have been reviewed; lay out
the components in the order of installation.
b. The opening for the door should be cleaned and inspected for rough surfaces and construction
debris.
c. Lastly the mounting hardware supplied with the door should correspond with the surface and
construction features of the opening.
d. The basic assembly sequence is as follows: fascia hood plates, shaft support brackets, guides,
barrel assembly (brackets and tube motor), curtain, bottom bar, and hood.
Figure 5.1 – Opening Dimensions and Designations
JAMB
SILL/FLOOR
LINTEL/HEADER
OPENING
HEIGHT
OPENING WIDTH

Section 6 – Hardware
6
Section – 6 Torque Specifications
Table 6.1 – Torque Recommendations for Guide Assembly and Wall Fasteners
Bolt size/type
Torque (ft lbs) a
10-32
2.5
1/4-20
6
5/16-18
25
3/8-16
20
1/2-13 Grade 5 steel bolt
75
1/2-13 Grade 8 steel bolt
107
5/8-11 Grade 8 steel bolt
212
3/4-10 Grade 8 steel bolt
376
aThe recommended torque for steel bolts is based on a
plated bolt that has not been lubricated.
Table 6.2 – Torque Recommendations for Solid Masonry Wall Anchors
Manufacturer/Torque (ft lbs)a
Anchor Size
(nominal)
Simpson Wedge-All Hilti-Kwik Bolt 3
3/8
30
20
1/2
60
40
5/8
90
85
3/4
150
150
aTorque values for grout filled block are different, reference bolt
manufacturer for these values.

Section 7 – Maintenance
7
Section – 7 Installation
Installation Overview
Stainless Steel Face of Wall:
1. Mount coil side guide per Figure 7.3, page 10.
2. Mount hood fascia (if required) per Figure 7.33, page 41.
3. Mount wall bracket and hood support (if required) per Figure 7.6, page 12.
4. Assemble curtain/shaft/bracket assembly to wall bracket per Figure 7.14 through Figure
7.20 (pages 22 - 27) and ensure curtain is centered between brackets
5. Mount coil side guide per Figure 7.22, page 29.
6. Set curtain limits
7. If hoods are required, install coil side hood supports per Figure 7.32 and install hoods per
Figure 7.35 through Figure 7.41 (pages 40 - 46)
Stainless Steel Between Jambs:
1. Mount tubes per Figure 7.8 through Figure 7.11 (pages 16 - 19)
2. Mount coil side guide to tube per Figure 7.12, page 20
3. Mount hood support (if required) per Figure 7.32, page 40
4. Assemble curtain/shaft/bracket assembly to wall bracket per Figure 7.14 through Figure
7.20 (pages 22 - 27) and ensure curtain is centered between brackets
5. Mount fascia side guide per Figure 7.23, page 30
6. Set curtain limits
7. If hoods install per Figure 7.35 through Figure 7.41 (pages 40 - 46)
Aluminum Face of Wall:
1. Mount guide per Figure 7.4, page 11
2. Mount hood fascia (if required) per Figure 7.32, page 41
3. Mount wall bracket and hood support (if required) per Figure 7.6, page 13
4. Assemble curtain/shaft/bracket assembly to wall bracket per Figure 7.13 through Figure
7.19 (pages 22 - 27) and ensure curtain is centered between brackets
5. Reinstall removable bellmouth per Figure 7.23, page 31
6. Set curtain limits
7. If hoods are required, install coil side hood supports per Figure 7.31 and install hoods per
Figure 7.34 through Figure 7.40 (pages 40 - 46)
Aluminum Between Jambs:
1. Mount guide per Figure 7.13, page 21
2. Mount wall bracket and hood support (if required) per Figure 7.7, page 13
3. Assemble curtain/shaft/bracket assembly to wall bracket per Figure 7.14 through Figure
7.20 (pages 22 - 27) and ensure curtain is centered between brackets
4. Mount hood support (if required) per Figure 7.32, page 40
5. Reinstall removable bellmouth per Figure 7.24, page 31
6. Set curtain limits
7. If hoods are required install per Figure 7.35 through Figure 7.41 (pages 40 - 46)
Manual Locking:
1. Complete assembly before attaching hoods. See Figure 7.26 to Figure 7.31 (pages 36 -
39).

Section 7 – Maintenance
8
Determine which guide assemblies the unit has from the job construction drawings and compare to the
diagrams below.
Figure 7.1 – Face of Wall (FOW)
2.625
2.500
1.520
1.750
STAINLESS ALUMINUM
STAINLESS
ISO VIEW
COIL SIDE
FASCIA
SIDE

Section 7 – Maintenance
9
Figure 7.2 – Between Jambs (BJ)
5.625
3.000
3.000
GUIDE FLUSH WITH
TUBE ON COIL SIDE
MOUNT TUBE DIRECTLY
TO JAMBS FOR
WIND LOAD
APPLICATIONS
2.500
ALUMINUM
2.625 3.000
2.500
2.625
STAINLESS
COIL SIDE
FASCIA SIDE
STAINLESS
ISO VIEW

Section 7 – Maintenance
10
Guide Installation - Face of Wall (FOW) Units
Fascia Side Guide installation:
1. Stainless guides are 2 piece slide fit construction. For FOW units, the fascia side guide mounts
first.
2. If Wall anchors are required cut the threads down to the nut after tightening.
Note: Do not remove UHMW tape on guide flanges where curtain travels.
Figure 7.3 – Fascia Side Guide installation (Stainless Steel)
SET BACK
WALL FASTENER
SLIP FIT GUIDE
FASTENER
WALL ANCHOR
(IF REQUIRED)

Section 7 – Maintenance
11
3. Aluminum guides are 1 piece and mount directly to the wall.
Figure 7.4 – Aluminum Guide installation (FOW)
WALL FASTENER
SET BACK
4. Measure the wall opening and specified set back. This distance is referred to as the “Distance
between Guides”. Place mark on the floor at measured location. Check the distance between
these marks and compare with the job construction drawing.
If the measurement does not equal the dimensions on the job construction drawings, STOP.
Check the guide dimensions against those on the job construction drawings to be sure the correct
guides are being installed. If so, repeat previous step and re-check.
5. Scribe a plumb line on the wall from the marks on the floor.
6. Place the fascia side guide face against the scribed line, check the top of the guide for level, and
mark the location of the wall fastener mounting holes.
7. Drill mounting holes for the wall fasteners and fasten the guide with the hardware provided.
Check the job construction drawings for the wall fastener required. Tighten the wall fasteners to
the recommended installation torque in Torque Specification Tables in Section 6.

Section 7 – Maintenance
12
Wall Bracket Installation
1. Place the wall bracket on top of the already mounted coil side guide. Ensure slot on wall bracket
aligns with tab on guide. Check wall brackets for level, and mark the location of the wall fastener
mounting holes.
2. Drill mounting holes for the wall fasteners and fasten the wall bracket with the hardware provided.
Check the job construction drawings for the wall fastener required. Tighten the wall fasteners to the
recommended installation torque in Torque Specification Tables in Section 6.
Figure 7.5 – Wall Brackets
STAINLESS STEEL ALUMINUM
BELLMOUTH
Figure 7.6 – Wall Bracket Installation (Stainless Steel)
WALL BRACKET
FASCIA HOOD
(IF REQUIRED)
WALL
FASTENERS
ALIGN SLOT ON WALL BRACKET
WITH TAB ON GUIDE
FASCIA HOOD SUPPORT
(IF REQUIRED)

Section 7 – Maintenance
13
Figure 7.7 – Wall Brackets Installation (Aluminum)
WALL BRACKET
FASCIA HOOD
(IF REQUIRED)
WALL
FASTENERS
ALIGN SLOT ON WALL BRACKET
WITH TAB ON GUIDE
FASCIA HOOD SUPPORT
(IF REQUIRED)
Note: Check to see if a hood support will be required. If so, refer to the “Hood Support
Installation” section before proceeding to the barrel and brackets.

Section 7 – Maintenance
14
Guide Installation - Between Jamb (BJ) Units
1. BJ guides mount to 3” X 3” tubes. The tubes can either mount directly to the jamb or to saddles.
For wind load applications, tubes must attach directly to jambs.
2. For tubes attaching directly to jambs (wind load):
a. Measure the “Opening Width”, or the distance between jambs, and compare with the job
construction drawings provided. If this distance is not equal to the job construction
drawing dimension, do not proceed!! Be sure the correct unit is being installed. Contact
the project manager.
b. Determine where the fascia of the door will be located with respect to the header / lintel (if
one exists) and the jamb.
c. If a header/lintel exists, see the elevation view of the job construction drawings to
determine if the door is to be placed against the header. If so, project a plumb line from
the header to the floor. Mark the floor at this location.
d. If a header/lintel does not exist, or if the door is not going to be placed against the
header/lintel, contact the project manager to determine where the door will be located.
Mark the floor at this location and scribe a plumb line up the jambs.
e. Stand the tube up to the wall, holding the bottom of the tube on the mark while making
the tube plumb. Mark the location of the wall fastener mounting holes.
f. If possible, check the “Distance between Guides” 1dimension at this time.
If the “Distance between Guides” dimension does not equal the dimension on the job
construction drawings, STOP. Check the guide dimensions against those on the job construction
drawings to be sure the correct guide is being installed. If so, repeat the previous steps and check
the “Distance Between Guides” dimension again.
g. Attach tube directly to jamb with fasteners specified on shop drawing. Tighten the wall
fasteners to the recommended installation torque in Table 6.1 or Table 6.2.
3. For tubes mounting to saddles:
a. Measure the “Opening Width”, or the distance between jambs. Compare with the job
construction drawings provided.
If this distance is not equal to the job construction drawing dimension, do not proceed!! Be sure
the correct unit is being installed. Contact the project manager.
b. Determine where the fascia of the door will be located with respect to the header/lintel (if
one exists) and the jamb.
c. If a header/lintel exists, see the elevation view of the job construction drawings to
determine if the door is to be placed against the header. If so, project a plumb line from
the header to the floor. Mark the floor at this location.
d. If a header/lintel does not exist, or if the door is not going to be placed against the
header/lintel, contact the project manager to determine where the door will be located.
Mark the floor at this location.
1The “Distance between Guides” dimension may be taken from the tip of the inner or outer angle, depending on
which angle extends further into the opening. See the job construction drawing of the guide detail.

Section 7 – Maintenance
15
e. Locate the tube saddles (Figure 7.8 brackets to constrain tube at bottom).
f. Use the mark placed on the floor in the previous steps, to locate where the saddle will be
and mark the hole locations by placing the saddle on the floor.
g. Double check the width dimensions provided on the job construction drawings, then drill
holes for the saddle fasteners.
h. Install saddles using the provided hardware.
i. Guides mounting to tubes, sometimes require the use of a slip joint. There are (3)
mounting styles for slip joints, as detailed in Figure 7.9, Figure 7.10, Figure 7.11. Refer to
the job information to determine the correct mounting style for the unit. Locate the Slip
Joint Mounting Member(s).
Note: If the unit does not have slip joints and the top mounting for the tube is not provided by the
manufacturer, install as recommended by supplier, then proceed to page 20.
j. Use the job information and the marks made in the previous steps to determine the
correct Slip Joint Mounting Member location. Install using the provided hardware. Use
only enough fasteners to hold the Mounting Members securely in place (2), as they will
be removed in a later step.
k. Determine the required tube length.
i. Measure from the “Floor to Slip Joint Mounting Member” as shown in the
corresponding figure below. Record this measurement.
ii. Calculate the Tube Length: Tube Length = “Floor to Slip Joint Mounting
Member” – 3 ½”
iii. Cut the tubes to the calculated “Tube Length”. Make sure you cut the excess
tubing from the top. Otherwise you will cut off necessary mounting holes and/or
notches.
l. Remove the Slip Joint Mounting Member(s). Place the Slip Joint Mounting Members in
the tops of the tubes.
m. Orient the tubes (ensure the guides, mounting holes or notches are facing the correct
direction.) Place the bottom of the tube over the saddle. Stand the tube upright and
reattach the slip joint mounting member using the previously drilled/marked holes to
locate. Use all provided fasteners at this stage. Check that installed tube is plumb.

Section 7 – Maintenance
16
Figure 7.8 – Tube Saddle
TUBE
REF BJ GUIDE
SADDLE POSITION CRITICAL
FLANGE MUST BE PARALLEL
WITH OPENING
MARK ON FLOOR
PLUMB WITH HEADER

Section 7 – Maintenance
17
Figure 7.9 – Slip Joint – Between Floor and Ceiling Mounting Assembly
FASTENERS AT FLOOR
FLOOR (EXISTING)
5 MIN.
EMBEDMENT
FASTENERS
AT CEILING
3 1/2" OF HEIGHT
FOR EXPANSION
TUBE LENGTH
(CUT TO LENGTH
INFIELD AS REQ'D)
FLOOR MOUNTING
TUBE SADDLE
FLOOR TO
SLIP JOINT
MOUNTING
MEMBER

Section 7 – Maintenance
18
Figure 7.10 – Slip Joint – Floor to Wall with Plate Mounting Assembly
TUBE LENGTH
(CUT TO LENGTH
IN FIELD AS REQ'D)
3 1/2" OF HEIGHT
FOR EXPANSION
FASTENERS
AT FLOOR
FLOOR (EXISTING)
5 MIN.
EMBEDMENT
FASTENERS AT WALL
FLOOR MOUNTING
TUBE SADDLE
FLOOR TO
SLIP JOINT
MOUNTING
MEMBER
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