Dorma 9800 Series User manual

I9800-1 4/2010
SURFACE VERTICAL ROD EXIT DEVICE
9800/F9800 SERIES
INSTALLATION INSTRUCTIONS
1135-233 95057472 www.dorma-usa.com 1-800-523-8483
Index:
Screw chart
Tools required
Outside trim options
"03" Additional door prep
Device installation
Optional bottom strikes
Rod cutting
Rod extension
Popper details
5400 retro-fit preparation
Options
Latch case templates
Chassis spotting template
1
2
3
4
5-12
13
14
14
14
15
16-17
18-21
22
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)
(10) 8-32 x 1/4" F.H.P.M.S.
Chassis Mounting
End Cap Bracket
Chassis Cover,
End Cap & Latch
Covers
Chassis Mounting
End Cap Bracket
#439 Bottom Strike
(Cement or Grout
In Place)
(3) #12 x 1" R.H.P.T.S. (Wood Door)
(2) 12-24 x 1/2" R.H.P.M.S. (Metal or Thru Bolts) Latch To Door
Latch To Door
(3) #12 x 1" R.H.P.T.S. (Wood Door)
(2) 12-24 x 1/2" R.H.P.M.S. (Metal or Thru Bolts) Latch To Door
Latch To Door
(1) 12-24 x 3/4" F.H.P.M.S. (Metal or Thru Bolts) Latch To Door
(1) 12-24 x 3/4" F.H.P.M.S. (Metal or Thru Bolts) Latch To Door
(4) #8 x 1 1/2" F.H.P.T.S. Rod Guide Mounting
(2) #12 x 1" F.H.P.T.S. (Wood)
(2) 12-24 x 3/4" O.H.P.M.S. (Metal) #426 Strike Pack
(2) 8-32 x 1/2" R.H.P.M.S. Rod Retaining Clip Mount
#426 Strike Pack

2
RHR LHR
9800
Series
Device
9800
Series
Device
9800
Series
Device
9700
Series
Device
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.
HANDING OF DOOR
TYPICAL APPLICATIONS
SPECIAL TOOLS FOR INSTALLATION
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 6)
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.
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.

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
9800/F9800
Surface 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
Strike
Pair of vertical rods
1/8"
Stile
Minimum
Backset
B
A
2 3/8"
9800 Vertical rod9700 Rim
RHR
Vertical ref.
Outside edge
1/2"
LHR
320
Edge
Guard
40 5/16"
Pull only
Type of
installation
Single door 1/2"
blade stop
Pairs and
double egress
1 3/8"
1 5/8"
"Z" trim
2 1/8""
2 " 2 3/16"
1
2
Minimum Stile
Paired with
9700 rim
1 1/4"
1 5/8" 2 1/2"
2 3/16"
Finished floor,
if using threshold
measure from top
of threshold.
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 5400 see page 15 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.
Backset or vertical reference is measured from
outer edge of door as shown. Minimum stile is
less glass stop.
Chassis template
located at rear of
booklet. Cut and
tape in place.
Lay out horizontal
and vertical refer-
ence lines.
3
Hang door(s) in opening, ensure they are square and plumb.

6
REASSEMBLE
DISASSEMBLE LHR
(Left Hand Reverse)
RHR
(Right Hand Reverse)
a
b
c
d
f
e Longer leg
down.
Rotate chassis
180 Degrees
g
4
If not done layout device on door using drilling template T9800 located at rear of booklet.
For additional templates contact DORMA at 1-800-523-8483 or www.dorma-usa.com
5
Hand reversal of chassis ( if required). 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

7
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. 9800BB
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.
6
Prepare to install touch bar and rail on door.
7
Secure chassis to door as shown.
Optional mounting
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.)
For 3 1/2" stiles or
less on aluminum
doors, place shim
under chassis prior
to mounting on door.
(Finished side to
outside face.)

8
Bracket should be
flush against door
and tight against
rear of rail.
No. 16 Drill - 12-24 Tap (Metal)
1/8" Drill 1" Deep (Wood)
3/8" Dia. (Thru bolts)
(2) 8-32 x 3/8" P.H.P.M.S.
8
Install touch bar and rail assembly and end cap to door.
Metal/thru-bolts - (2) 12-24 x 1" F.H.P.M.S.
Wood - (2) #12 x 1 1/4" F.H.P.T.S.
Remove two 8-32 screws from chassis,
slide touch bar and rail assembly under
rear of chassis. Note: If device has pre-
fix "ES" ensure that pins in lever bolt
align with slots in actuator located in-
side nose of touch bar. See instruction
sheet IES-7 packed with device. Install
(2) two 8-32 x 3/8" P.H.P.M.S. to
secure touchbar to chassis.
Hold rear mounting bracket tightly
against door and rear of rail. Mark
(2) two holes and drill per chart.
Secure with proper fasteners.
"Remove protective
covering from the
touchbar and rail
assembly prior to
installing on door."
NOTE: If carton label list pre-
fix; "ES", "MS", "LM", "BPA",
"BPAR", "DWA", "LM/MS/BP"
or "CD" prefix see Options
pages at rear.
9
Prop door open and layout and prep top and bottom latch case locations. Templates located at rear of booklet,
tear out, cut and tape to door as shown, mark and drill per chart.
2 5/8"
1 15/16"
5/8"
C
L
(3) Places
Edge of stop
1/4"
2 5/8"
5/8"
(3) PLACES
Finished floor or
1 1/16"
top of threshold. 1/4"
2 5/8"
5/8"
1 3/4"
(3) Places
Finished floor or
top of threshold.
No. 16 Drill - 12-24 Tap (Metal)
1/8" Drill 1" Deep (Wood)
3/8" Dia. (Thru bolts)
Metal/thru-bolts - (2) 12-24 x 1" F.H.P.M.S.
Wood - (2) #12 x 1 1/4" F.H.P.T.S.
Standard top
and bottom
latch preps.
Optional: Pulllman
bottom latch prep.
Note: For "LBR"
less bottom rod,
delete bottom
latch prep.
1/2" DIA.
ES105
For the following models prefixes:
"ES", "MS", "LM" or "DWA" drill an
additional 1/2" diameter hole as
shown. See options pages at rear
for addtional information.
(Required for above
options.)
Note: If installing on
frame with blade stop;
stop must be cut and
a spacer added to
mount strike or a longer
top rod will be required.

9
10
Install top and bottom latch case assemblies.
Insert screws at
angle thru cutout
in side of latch.
Mount behind
latch assembly.
Inter-locking strike angle
for fire rated doors over
8' and all fire rated LBR
(less bottom rod) devices.
12-24 x 1/2" R.H.P.M.S. (Metal)
No. 12 x 1" R.H.P.T.S. (Wood)
12-24 x 1 1/4" R.H.P. M.S. (Thru bolts)
Insert screws at
angle thru cutout
in side of latch.
11
Install top rod and adjust top latch.
Remove 8/32 x
1/2" phillips head
screw from retaining
plate as shown.
7' Standard
Top Rod
NOTE:
If horizontal reference line is
moved from the recommended
mounting height, new rods may
have to be ordered.
If cutting is required "Do Not Cut
Threaded End". (See Chart)
Use supplied drill jig and 1/8" drill
bit if new hole is required.
35 1/4"
24"
8' Optional
Top Rod
47 1/4"
Rods shipped cut to length for 7' door opening. Optional 8' door opening
available, (must be requested at time of ordering). For doors over 8' and up
to 10' request "ETR" package at time of ordering. For top rod length other
than "standard" see chart below. Order 8' option and cut to length.
6'8"
7'0"
7'2"
7'4"
7'6"
7'8"
7'10"
8'0"
DOOR
HEIGHT LENGTH
TOP ROD
6'10"
47 1/4"
45 1/4"
43 1/4"
41 1/4"
39 1/4"
37 1/4"
35 1/4"
31 1/4"
33 1/4"
"ETR"
Extended top
rod extension.
"Do not cut."
Depress tripping lever and ensure
that top latch is fully extended and
in dead locked position. Bolt should
not be able to be depressed. Bell-
crank of chassis should be com-
pletly down in home position.
Thread top rod onto adjusting bolt
until hole in bottom of rod aligns
with hole in rear of top portion of
bellcrank. Insert leg of retaining
plate through hole in rod and
hole in bellcrank, install 8-32 x
1/2" screw and tighten securely.
12"
Finished floor
"POPPER"
Cap plug
See additional instructions
packaged with "Popper" for
details.
Required for; "LBR"
(less bottom rod)
fire rated exit devices.