Dorma 9800FL Series User manual

DORMA Gmbh + Co. KG Postfach 4009 D - 58247 Ennepetal Telefon [phone]
95062921 I9800FL-1 8/2011
9800FL AAA028
2011
DORMA Architectural Hardware
1003 West Broadway
Steeleville, IL 62288
BS EN 1125 : 2008
European Norm Standard for Panic
Exit Devices Operated By A Horizontal Bar.
Product Classification 3,7,6,0,1,3,2,2,B,A
Certification Body Ref Nr : 1121
9800FL SERIES PANIC BOLT
EN 1125 CLASSIFICATION NUMBER FOR THIS PRODUCT
3 7 6 B 1 3 2 2 B A
Index:
Screw chart
Tools required
Outside trim options
"03" Additional door prep
Device installation
Optional bottom strikes
Rod cutting
Rod extension
Options
AD4400 retro-fit
Annex pages
Latch case templates
Chassis spotting template
2
3
4
5
6-13
14
15
15
16-18
19
20-21
22-25
26
Note: One set of instructions should be left
with building owner after device has been
installed.

2
SCREW CHART
(10) 8-32 x 6 F.H.P.M.S. Chassis Cover,
End Cap & Latch
Covers
#AD439 Bottom Keep
(Cement or Grout
In Place)
Latch To Door
Latch To Door
(3) #12 x 25 R.H.P.T.S. (Wood Door)
(2) 12 -24 x 19 R.H.P.M.S. (Metal or Thru Bolts) Latch To Door
Latch To Door
(3) M5 x 12 P.H.P.M.S. (Metal door metric version) Latch To Door
Latch To Door
(4) #8 x 38 F.H.P.T.S. Rod Guide Mounting
(2) #12 x 25 F.H.P.T.S. (Wood)
(2) M5 O.H.P.M.S. (Metal) #AD426 Keep Pack
(2) 8-32 x 13 R.H.P.M.S. Rod Retaining Clip Mount
#AD426 Keep Pack
(2) #12 x 1 1/4" R.H.P.T.S. (Wood Door)
(2) 12-24 x 1 1/4" F.H.P.M.S. (Trim or Thru Bolts) Chassis Mounting
Chassis Mounting
(2) M5 x 20 F.H.P.M.S. (Metal door metric version) Chassis Mounting
(2) #12 x 1 1/4" R.H.P.T.S. (Wood Door)
(2) 12-24 x 1" R.H.P.M.S. (Trim or Thru Bolts) End Cap Bracket
End Cap Bracket
(2) M5 x 20 R.H.P.M.S. (Metal door metric version) End Cap Bracket
(3) #12 x 25 R.H.P.T.S. (Wood Door)
(2) 12 -24 x 19 R.H.P.M.S. (Metal or Thru Bolts)
(3) M5 x 12 P.H.P.M.S. (Metal door metric version)
(2) #10 x 25 F.H.P.T.S.
(2) 8-32 x 6 F.H.P.M.S. End Cap Mounting
End Cover Mounting
"FL" Full length touch bar & rail series.

3
RHR LHR
9800FL
Panic bolt
9800FL
Panic bolt
9800FL
Panic bolt
9700FL
Panic latch
Note: If device is to be installed over glass lite panels, shim kit may be required, order GK9200.
HANDING OF DOOR
TYPICAL DEVICE FIXING
SPECIAL TOOLS FOR FIXING
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 7, for outside lever trim see page (4).
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.
Centre Punch
M5 - Tap, M6 - Tap
Drill bits: 3.8mm, 4.2mm, 10mm, 13mm, 25mm & 38mm
5/32" Allen wrench for lever trim.
Cross point screw driver
Hack saw

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/ZP12EP
ZR23
ZK23 ZK08/09EP
ZC23
ZT23
ZG23
ZR08/09EP
ZC08/09EP
ZT08/09EP
ZG08/09EP
4
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 back of trim plate. 5/32"
Allen wrench required.
To change hand on "clutch" trim
rotate and "break" lever around to
desired hand.
Tighten
Securely
Fixing of "EP" cylinder
Insert "EP" cylinder into adapter,
secure with set screw supplied
with cylinder. Insert adapter/
cyilnder assembly thru trim and
secure assembly with (2)
8-32 screws as shown. For
"09" function (key only re-
movable when locked) insert
addtional 8-32 screw as shown.
Cylinder Mounting
Screw (2)
09 Function
Screw
"EP" adapter

(DEVICE SIDE ONLY)
9.5mm DIA. HOLE
INSIDE FACE
OF DOOR
HORIZONTAL REF. LINE
DIA. (2) PLACES
6mm
5.5mm DIA. HOLE 21mm
VERTICAL REF. LINE
(CENTERLINE OF CHASSIS)
30mm DIA. HOLE
(TRIM SIDE ONLY)
OF DOOR
OUTSIDE FACE
OF
STOP
EDGE
(SEE STEP 2)
OR
MULLION
(DEVICE SIDE) (TRIM SIDE)
6mm
NOTE: If using 80CK
cyinder adapter kit with
trim; hole diameter re-
quired is 35mm.
VERTICAL REF. LINE
(CENTERLINE OF CHASSIS)
(SEE STEP 2)
5
9800FL
Surface panic bolt
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:
Hole dimensions may
vary, when using cylinder
by other manufacturer's
use backplate supplied
with cylinder as drilling
template.

6
Strike
Pair of vertical rods
3mm
Stile
Minimum
Backset
B
A
70mm
9800 Vertical rod9700 Rim
RHR
Vertical ref.
Outside edge
13mm
LHR
320
Edge
Guard
1024mm
Pull only
Type of
installation
Single door 13mm
blade stop
Pairs and
double egress
35mm
41mm
"Z" trim
54mm
51mm 56mm
1
2
Minimum Stile
Paired with
9700 rim
32mm
41mm 64mm
56mm
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 (2) two
for parts.
Note: If this is a retro-fit from current AD4400 see page 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.

7
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.
191mm
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 6.)
10mm
4.2mm
3.8mm

8
915mm Door opening
NOTE: All dimensions are based on 13mm 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 1220mm door opening without cutting.
Can be cut to fit a 838mm minimum door opening.
Size BB:
Fits 915mm door opening without cutting.
Can be cut to fit a 686mm minimum door opening.
Size CC:
Fits 915 door opening with out cutting.
Using a shorter touch pad then the standard "BB"
size allows it to be cut to 610 door opening.
Verify device length with box label; "AA", "BB" or "CC", ie. 9800FL BB
Edge of stop
Edge of stop
Apx. 6 - 8mm
Example:
Standard "FL BB" touch bar and rail 800mm
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) M5 x 20 F.H.P.M.S.
Wood - (2) #12 x 32 F.H.P.T.S.
(For other options; trim, thru bolts, etc.
see below.)
For 89mm stiles or
less on aluminum
doors, place shim
under chassis prior
to mounting on door.
(Finished side to
outside face.)
Note: If door opening width is less or stops are different, then standard
touch bar will have to be cut down. ie: door opening width 863mm subtract
51mm from rear of rail, depress touch bar as shown, tape and cut to length
as shown. Touch bar should be approximately 5mm longer then rail once
it is released to upward position.
51mm
Touch bar
and rail assembly
Filler
Tape

9
8
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.
67mm
51mm
16mm
C
L
(3) Places
Edge of stop
3mm
(3) PLACES
Finished floor or
27mm
top of threshold.
16mm
(3) Places
Finished floor or
top of threshold.
Standard top
and bottom
latch preps.
Optional: Pulllman
bottom latch prep.
Note: For "LBR"
less bottom rod,
delete bottom
latch prep.
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.
Bracket should be
flush against door
and tight against
rear of rail.
13mm DIA.
4.2 x M5 Tap (Metal)
3.8 x 25mm Deep (Wood)
10mm (Thru bolts)
ES105
(2) 8-32 x 10mm P.H.P.M.S.
Install "FL" touch bar and rail assembly and end cap to door.
Metal/thru-bolts - (2) M5 x 20 F.H.P.M.S.
Wood - (2) #12 x 32 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 10mm 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.
For the following models prefixes:
"ES", "MS", "LM" or "DWA" drill an
additional 13mm diameter hole as
shown. See options pages at rear
for addtional information.
(Required for above
options.)
"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.
4.2 x M5 Tap (Metal)
3.8 x 25mm Deep (Wood)
10mm (Thru bolts)
Metal/thru-bolts - (2) M5 x 20 F.H.P.M.S.
Wood - (2) #12 x 32 F.H.P.T.S.
16mm
67mm 67mm
3mm
44mm

10
Note: Same for either standard or
FL series.
10
Install top and bottom latch case assemblies.
Insert screws at
angle thru cutout
in side of latch.
M5 R.H.P.M.S. (Metal)
No. 12 x 25 R.H.P.T.S. (Wood)
M5 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
13mm phillips head
screw from retaining
plate as shown.
2134mm
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 4.3mm drill
bit if new hole is required.
895mm
610mm
2438mm
Optional Top Rod
1200mm
Rods shipped cut to length for 2134mm door opening. Optional 2438mm
door opening available, (must be requested at time of ordering). For doors
over 2438mm and up to 3048mm request "ETR" package at time of
ordering. For top rod length other than "standard" see chart below. Order
2438mm option and cut to length.
2032mm
2134mm
2184mm
2235mm
2286mm
2337mm
2388mm
2438mm
DOOR
HEIGHT LENGTH
TOP ROD
2083mm
1200mm
1149mm
1099mm
1048mm
997mm
946mm
895mm
794mm
845mm
"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
13mm screw and tighten securely.