Dorma 9600 Series User manual

I9600-1 4/2010
CONCEALED VERTICAL ROD EXIT DEVICE
9600/F9600 SERIES
INSTALLATION INSTRUCTIONS
1135-231 95057470 www.dorma-usa.com 1-800-523-8483
Index:
Screw chart
Tools required
Outside trim options
"03" Additional door prep
Device installation
Frame & strike preps
Final rod adjustment
Options available
Wood door preparation
5100 retro-fit preparation
Metal edge guard
Spotting template
1
2
3
4
5-10
11-12
13
14-16
17
18
19
20
Note: One set of instructions should be left
with building owner after device has been
installed.

1
SCREW CHART
(2) #12 x 1 1/4" F.H.P.T.S. (Wood door)
(2) 12-24 x 1 1/2" F.H.P.M.S. (Metal or thru bolts)
(2) #12 x 1 1/4" R.H.P.T.S. (Wood door)
(2) 12-24 x 1" R.H.P.M.S. (Metal or thru Bolts)
(12) 8-32 x 1/4" F.H.P.M.S.
Optional "WD" mounting brackets (4)
(wood, steel and fire)
(4) 10-32 x 1/4" F.H.P.M.S. (Aluminum)
(12) #10 x 1" F.H.P.T.S. (Wood door)
(12) 10-32 x 3/8" F.H.P.M.S. (Metal door)
Adjusting screw
(2) 3/32 x 10-32 x 1/2" Allen Head (wrench supplied)
(2) 10-32 x 3/8" F.H.P.M.S.
(6) 8-32 x 1/4" F.H.P.M.S.
Chassis mounting
End cap bracket
Bracket to latch
Bracket to door
Locking screw
#418 Strike pack
Chassis cover
& end cap
Chassis mounting
End cap bracket
Bracket to door
Bracket to door
#439 Bottom strike
(cement or grout
in place)
(4) 10-32 x 1/4" F.H.P.M.S. (Aluminum) Bracket to toor
Standard "NS"
latch assembly
(2) Rod retaining clips Rod installation
Optional: "ALD" Mounting Bracket (2)
(Medium Stile Aluminum Doors)

2
RHR LHR
9600
Series
Device
9600
Series
Device
9700
Series
Device
9600
Series
Device
9600
Series
Device
Read the entire instruction sheet prior to installation.
Before Installing Hardware:
1. Verify door width, handing and product with carton label for correct exit device and length. (See Step 9)
2. For hand reversal of chassis see page 6, for outside lever trim see page (3).
3. For less bottom rod device, delete bottom latch installation steps.
4. Device installation and preliminary adjustments should be made prior to hanging door.
Note: Less bottom rod device is not recommended where security is a primary concern.
Note: If device is to be installed over glass lite panels, shim kit may be required, order GK9200.
12-24 Tap, 10-32 Tap
Drill bits: 1/8", 3/8", #25, #16, #21
Hole saw 1 1/4" diameter for trim (if required) or jig saw.
5/32" Allen wrench for lever trim.
3/32" Allen wrench (supplied)
HANDING OF DOOR
TYPICAL APPLICATIONS
SPECIAL TOOLS FOR INSTALLATION

LHRB TRIM SHOWN RHRB OPPOSITE
All trims are free wheeling.
(Handle will rotate when locked.)
Note: When used with narrow
stiles, consult door manufacturer
for compatibilty.
TRIM INSTRUCTIONS
TYPICAL OUTSIDE
OP02 ZODT ZP25 ZP02 ZP03/04 ZP11/ZP12
ZR23
ZK23 ZK08/09 ZC23 ZT23
ZG23 ZR08/09
ZC08/09 ZT08/09
ZG08/09
1 1/8"
21/32" 61/64"
"09" Cam
For functions "09" & "12"
operation a DORMA #09
cam is required. Remove
key, install cylinder as
shown then cam as shown,
legs of cam stradle actuator.
Key removed.
3
Locked
position
IMPORTANT
Note: All lever handles except for
"clutch" are shipped unattached. To
install; Place handle in desired
position and attach with allen screw
located in bcak of trim plate. 5/32"
Allen wrench required.
To change hand on "clutch" trim
rotate and "break" lever around to
desired hand.
Tighten
Securely
Conventional 1 1/8" rim cylinder
#80R20SC with tail piece, keyed
differently to a random combina-
tion supplied with functions "03"
& "04" trim unless otherwise
noted.
Conventional 1 1/8" mortise
cylinder #90X13SC118 supplied
with DORMA #13 cam, keyed
differently to a random combina-
tion supplied with functions "08"
& "11" trim unless otherwise
noted.

(DEVICE SIDE ONLY)
3/8" DIA. HOLE
INSIDE FACE
OF DOOR
HORIZONTAL REF. LINE
DIA. (2) PLACES
1/4"
7/32" DIA. HOLE 13/16"
VERTICAL REF. LINE
(CENTERLINE OF CHASSIS)
1 3/16" DIA. HOLE
(TRIM SIDE ONLY)
OF DOOR
OUTSIDE FACE
OF
STOP
EDGE
(SEE STEP 2)
OR
MULLION
(DEVICE SIDE) (TRIM SIDE)
1/4"
NOTE: If using 80CK
cyinder adapter kit with
trim; hole diameter re-
quired is 1 3/8".
VERTICAL REF. LINE
(CENTERLINE OF CHASSIS)
(SEE STEP 2)
4
9600/F9600
Concealed Vertical Rod Exit Device
RHR Shown
LHR Opposite
Required for "03" & "04" function on device
with cylinder only and no trim.
(NOT TO SCALE)
ADDITIONAL DOOR PREP REQUIREMENTS
IMPORTANT NOTE:
NOTE: "04" function not
available on fire rate device.
"Fire rated devices can not
be dogged."
Hole dimensions may
vary, when using cylinder
by other manufacturer's
use backplate supplied
with cylinder as drilling
template.

5
1/8" Pilot for wood
40 5/16"
Pull only
Type of
installation
Single door 1/2"
blade stop
Pairs and
double egress
1 1/4"
2"
"Z" trim
2 1/8"
2 1/16" 2 5/16"
1
2
Based on 1/2"
threshold and 3/16"
clearance between
threshold and door
after door is hung.
Minimum Stile
1 1/32"
2"
Minimum
Fire rated
& wood door
1 1/4"
2" 2 7/8"
2 5/8"
Typical pair of doors
Finished floor
With door lying on saw horses, open box, layout all parts and verify prior to starting installation. See page (1) one
for parts.
Note: If this is a retro-fit from current 5100 see page 18 prior to proceeding.
Door preperation
Chassis
horizontal
ref. line
Chassis
vertical
ref. line
Min. Stile Min. Stile
Beveled edge door
Rounded edge door
Minimum
vertical
ref. of
chassis
Vert. ref.
Vert. ref.
Latch case prep (Top & Bottom)
1/8"
Top of Door
3/8" 3/4"
1 1/2" 3 5/16"
7/32" Dia. hole
82 degree countersink
to 3/8" dia. (2) places 7/16" 10-32 Tap
(6) Places
2 7/8"
1 1/2"
3/4"
7/8"
C
L
Latch
3/4"
1 1/2"
1 1/8"
C
L
Latch & chassis
1 7/16"
7/8"
Backset or vertical reference is measured from
outer edge of door as shown. Minimum stile is
less glass stop.
"Cutout" Top
C
L
Latch
Panic device (metal and wood door)
Fire device (metal and wood door)
of door only.
Panic device (aluminum door)
Chassis template
located at rear of
booklet. Cut and
tape in place.
Lay out horizontal
and vertical refer-
ence lines.
Note: Metal edge may be required on
fire door applications.
Note: On narrow stile,
vertical center line of
chassis may not be
on same center line
as latch.
Narrow stile

6
REASSEMBLE
DISASSEMBLE LHR
(Left Hand Reverse)
RHR
(Right Hand Reverse)
ab
c
d
f
e
Longer leg
down.
Rotate chassis
180 Degrees
g
3
If not done layout device on door using drilling template T9600 located at rear of booklet.
For additional templates contact DORMA at 1-800-523-8483 or www.dorma-usa.com
Remove parts Reinstall parts
NOTE:
4
Hand reversal of chassis. Follow steps in alphabetical sequence.
7 1/2"
HORIZONTAL REF. LINE
VERTICAL REF. LINE
Refer to carton label for model and trim number prior to drilling.
Prepare mounting holes and cut-outs per template.
Verify all holes
prior to drilling.
(See Backsets on page 5.)
3/8"
No. 16
No. 25

Adjusting bolt
7
5/8"
*
*
Top latch
& rod
assembly.
Inner rod
assembly
1/2"
2"
Top and bottom rods and latches are shipped
unassembled and are adjustable for door opening
heights ranging from 6' 8" to 8' 0" and will fit up to
a 10' 0" door opening with the addition of a 2 foot
top rod extension (ETR). Follow instructions on
page to assemble the latch and rod assemblies.
"Standard" (NS) Narrow stile brackets are pre-
assembled in the top and bottom latch cases.
Optional: Angle brackets are available for steel
and wood door application, and are "required"
for all fire rated applications, install as shown
with proper fasteners.
Holes in outer rod are at 1/2" intervals and holes
in inner rod are at 2" intervals for door openings
under or over 7' (instructions are for 7' door
opening and standard mounting height).
For all other door sizes, see rod ajustment chart.
Slide inner rod assemblies into outer rods, locate
proper holes and insert rod retainer clip by;
inserting through both rods, rotating it and locking
it in place as shown.
For "LBR" less bottom rod device skip bottom rod
and latch assembly instructions.
Additional "Popper" required for "LBR" fire
rated openings. See details to left.
Standard (NS)
Narrow stile
aluminum door
mounting bracket
(installed at
factory).
Optional:"WD" "L" shaped mounting
brackets for steel and wood door
applications and all fire doors.
NOTE: requires a new top fire latch
assembly as well. Secure to latch
using (6) 8-32 x 1/4" F.H.P.M.S.
Bottom
latch
& rod
assembly.
Inner rod
assembly
Optional:
Pullman
latch.
Thread on
Optional: "WD" "L" shaped mounting
brackets for steel and wood door
applications and all fire doors.
NOTE: requires a new bottom fire
latch assembly as well. Secure to
latch using (6) 8-32 x 1/4" F.H.P.M.S.
Optional: "ALD" bracket
Optional: "ALD" bracket
12"
Finished floor
"POPPER"
Cap plug
Rod
retaining
clip.
5
Assemble rods, latches and adjust to preliminary length.
Outer
rod
4th hole
for top rod
on 7' door
opening.
Insert pin
through
proper holes,
flip over and
lock in place.
Top latch
assembly
Outer
rod
*
2nd hole
from link
on 7' door
opening.
*
Middle
hole for
bottom
outer rod
on 7' door
opening.
Insert pin
through
proper holes,
flip over and
lock in place.
Thread on
leave aprox.
1/8" of thread
showing.
See additional instructions
packaged with "Popper" for
details.
Required for; "LBR"
(less bottom rod)
fire rated exit devices.
4th hole
for top rod
on 7' door
opening.
Thread on
leave aprox.
1/2" of thread
showing with
pullman latch.
"Use 4th
hole using
pullman
latch".

8
Bell crank down
in home position.
C
L
Bell Crank
Adjusting
Screws
Locking
Screws
Top
Bottom
6
Install rods in door and chassis as shown.
C
L
Pivot connecting links
down as shown and slide
latch assemblies into door.
As linkages reach cut outs in door guide them through as shown;
Optional: "WD"
(steel, wood & fire applications).
Attached "L" shaped mounting
brackets to latch and install in
door with proper fasteners as
shown.
Steel - (6) 10-32 x 3/8" F.H.P.M.S.
Wood - (6) #10 x 1" F.H.P.T.S.
Fire Rated Devices Require
(2) "WD" "L" Shaped Brackets.
"Loosen only"; (2) two 3/32" Allen head locking screws using Allen wrench
supplied, remove two adjusting screws shown.
(Do not remove)
3/32" Allen wrench (supplied)
Chassis Assembly
Adjusting Screws Locking screws
Shim
(Glass doors only.)
Place shim on door as shown (polished side facing outside) aligning holes and
cut outs as required with holes and cut outs in door. Then place chassis on door
allowing connecting links to extend through shim and into bellcrank of chassis as
shown. NOTE: Connecting link brackets should stradle mounting screws,
shaft of thru-bolts, or stand-offs of trim as device is secured to door. See
detail to right.
(4) 10-32 x 1/4" F.H.P.H.M.S.
(Do not use any other screw.)
Metal - (2) 12-24 x 1 1/2" F.H.P.M.S.
Wood - (2) #12 x 1 1/4" F.H.P.T.S.
(For other options; trim, thru bolts, etc.
see below.)
7
Secure chassis and latches to door as shown.
Note: Top
latch fully
extended
and dead
locked.
Optional mounting
Note: Top
latch fully
extended
and dead
locked.
For 3 1/2" stiles or
less on aluminum
doors, place shim
under chassis prior
to mounting on door.
(Finished side to
outside face.)

9
a
b
bcc
bc
C
LC
L
c
b
90
Top latch bolt should be fully extended and dead locked. Bell crank
should be in full down position (home position).
Connecting links should be about in center of cut out in bell crank.
Install top and bottom adjusting screws (b) through both bell crank and
connecting link arms; bottom of adjusting screw head should bottom
out on bell crank.
Tighten Allen head locking screws with (supplied) 3/32" Allen wrench.
Both top and bottom connecting links should be 90 degrees to chassis.
NOTE: If chassis is being installed with outside trim, ensure spindle
of trim engages with cross hairs of cam located in rear of chassis.
2"
36" Door opening
NOTE: All dimensions are based on 1/2" stop height; Verify strikes, stile width, any trim and stop
height prior to making any cuts. If cutting is required follow instructions below.
Size AA:
Fits 48" door opening without cutting.
Can be cut to fit a 32 1/2" minimum door opening.
Size BB:
Fits 36" door opening without cutting.
Can be cut to fit a 26 1/2" minimum door opening.
Size CC:
Fits 36" door opening with out cutting.
Using a shorter touch pad then the standard "BB"
size allows it to be cut to 23 1/2" door opening.
Verify device length with box label; "AA", "BB" or "CC", ie. 9600BB
Note: If door opening width is less then standard touch bar will have
to be cut down. ie: door opening width 34" subtract 2" from rear of
touch bar and rail, tape and cut to length as shown.
Edge of stop
Edge of stop
Apx. 1/4"-3/16"
Example:
Standard "BB" touch bar and rail 31 1/2"
Touch bar
and rail assembly
Filler
Tape
IMPORTANT
Use caution when cutting
touchbar and rail to size on
models with "ES", "MS", "LM"
or "DWA" prefix options.
These units contain internal
wiring.
For models with prefix options
"BPA", BPAR" or "DE" remove
filler containing electronics be-
fore cutting.
Note: Models with prefix
options such as "ES", "DE"
etc. may not be cut down
to minimums shown to left.
Consult factory or catalog
for details.
Flush
Point in
groove of
adjusting
screw. Flush
90
8
Install adjusting screws and connecting links to chassis.
9
Prepare to install touch bar and rail on door.
Spindle
Cam