Galebreaker Rollerdoor Electric User manual

Electric Rollerdoor
with ‘J’ Brackets
Installation Instructions
ENG

ELECTRIC ROLLERDOOR – J BRACKETS Introduction
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Figure 1, System Overview and Individual Components

ELECTRIC ROLLERDOOR – J BRACKETS Introduction
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ENG
INTRODUCTION
Parts List
REFERENCE QTY PRODUCT DESCRIPTION
A1 2 Top and Bottom Tubes
B1 1 Screen Material
C1 1 Bottom Flap
D1 1 Doors Over 5.5m Width Small Safety Spring (Orange tag)
E1 1 Doors Up to 5.0m Wide Free End bracket (with shaft)
E2 1 Doors up to 5.0m: Free End Collar
F1 1 Motor Bracket
H1 1 30cm Cowling
I1 1 Pair Cowling Pair of Ends
J1 2 6mm Nylon Insert For Bottom Flap (not shown)
K1 2 Insert Lockers
L1 2 100mm J Bracket Guide
M1 1 Left Hand 100mm Dia J Bracket Bzp
M2 1 Right Hand 100mm Dia J Bracket Bzp
N1 2 100mm Black Tube Cap/Insert
O1 1 Electric Motor Assembly
P1 1 Rotary Drive Switch - Optional
P2 1 Contactor Box and Drive Switches - Optional
Q1 1 80x80x5 Plastic Junction Box
R1 8 M8x30 HT Set screw
S1 10 M8 Nyloc Bzp
T1 8 M4.2x19 Posi-Pan Self Drill Screws
U1 4 M5.5x19 Hex Self Drill Coarse Screw
V1 2 Nylon Cable Tie 150 x 3.6mm (not shown)
X1 1 Wall Bracket Hole Template (not shown)
Y1 1 140x45mm Yellow template (not shown)
Z1 2 M8x20 HT Set screw and Nut
Your Safety
The larger doors will require a mechanical lift to mount the roller assembly onto the top
brackets. The respective weights are given in the table below based on standard material. Add
5% to this figure for doors supplied with ‘HP’ fabric, and 15% for doors supplied with black
Stockscreen and solid fabrics.
WIDTH/HEIGHT 3.1m 4.1m 5.1m
2.5m 25kg 26kg 27kg
3.0m 27kg 28kg 29kg
3.5m 29kg 30kg 31kg
4.0m 32kg 33kg 34kg
4.5m 34kg 35kg 36kg
5.0m 36kg 37kg 38kg
5.5m 45kg 46kg -----
6.0m 47kg 48kg -----
Table 1, Roller Assembly Weights

ELECTRIC ROLLERDOOR – J BRACKETS Introduction
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ENG
Pre-Installation Check
Figure 2 indicates space required to install your door with additional information for
mounting multiple doors in series.
Order Width
(m) Fabric Width (m)
Order Height
(m) Max Height (m)
2.5 2.5 3.1 3.10
3.0 3.0 4.1 4.10
3.5 3.5 5.1 5.05
4.0 4.0
4.5 4.5
5.0 5.0
5.5 5.5
6.0 6.0
Figure 2, Fitting Requirements
Adjacent Systems
Top Brackets J Brackets

ELECTRIC ROLLERDOOR – J BRACKETS Introduction
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CAUTION: To safeguard against any danger points, the minimum height ‘H’
of any door is 2.5m.
In the event of power or door failure, the door must not form the only means
of exit from the building to which it is fitted.
Wind Loadings
The structure to which the door is fitted needs to be of adequate strength to resist the
following wind loads.
Wind Speed
(km/hr) Wind Load (N)* Wind Load (Kg)*
70 = W x H x 233 = W x H x 24
100 = W x H x 481 = W x H x 49
140 = W x H x 933 = W x H x 95
*No allowance made for safety margins
Electrics
Only allow qualified electricians to work on the electrical connections of the door. This
document covers the key instructions with regards to bringing the Electric Drive into
service. Read the additional information from the supplier of the Electrical Motor and
Control Box for full installation instructions.
CAUTION: The power supply must be taken from a LOCKABLE isolation
switch positioned within 2m from the door.
Installer Competence
The installer should be able to demonstrate the required level of competence via
evidence of installing similar products or formal training. If competence cannot be
proven then they should not be allowed to install the product.
Product Description
The door is a power operated vertically moving rolling door comprising of a flexible
curtain capable of being rolled and for which the main intended uses are giving safe
access for goods and vehicles accompanied or driven by persons.

ELECTRIC ROLLERDOOR – J BRACKETS Introduction
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ENG
Noise Levels
A-weighted sound pressure level (dB) 50
C-weighted sound pressure level (dB) 60
Items Required By the Installer
Standard tool kit comprising:
Electric drill
Angle grinder
Sharp pair of scissors or knife
Bolts for fixing the brackets to steel are supplied, if fixing to a wooden or
concrete building you will require eight M8 fasteners.
Key Instructions
CAUTION: Potentially hazardous situation: must be avoided otherwise
injuries may result.
ATTENTION: Observe the given instructions otherwise the product or
adjacent items may be damaged
NOTE: Helpful comments and information to assist in installation or use of
your product
NOTE: Before starting the installation it is advisable to read
these instructions completely to help understand the general
procedure and options available.
NOTE: Colour versions of the installation instructions can be
downloaded from our website:
www.galebreaker.com

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
INSTALLATION
Door Assembly
1. Check the contents of your door against the parts list using Figure 1. Do not let
the screen material come into contact with any sharp objects or edges. The motor
can be mounted on either side of the top tube, for convenience the drawings
depict a door with the motor mounted on the left (Drive End = Left Hand Side)
To change drive orientation on-site refer to Appendix I for details of safety spring
conversion.
2. Using the yellow template (X1), drill M8 holes for the two top brackets. The
maximum recommended overlap for Post Fixing (Drive End) = 120mm, Post
Fixing (Free End) = 100mm and for lintel fixing = 175mm (Figure 3). It is essential
that the top brackets are level and upright.
Figure 3, Top Bracket Positioning
ATTENTION: To prevent abrasion and material fray, maximum
overlap between bracket face and edge of fixing must not
exceed that shown in Figure 3. If overlap exceeds these
recommendations ensure there are no sharp objects on the
building to damage the material, and rough surfaces such as
concrete is protected with PVC strip or similar.
Drive End Free End
Post Fix
Lintel Fix

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
3. Cutting lengths (Figure 4):
Figure 4a, Standard Cutting Lengths of Tubes and Fabric
Top Tube = Distance between centre of drilled holes -10mm (-0.010m)
Screen and Flap= Distance between centre of drilled holes -90mm (-0.090m)
(80mm shorter than top tube)
Bottom Tube = Distance between centre of drilled holes +10mm (0.010m)
(20mm longer than top tube)
NOTE: Cutting details are for standard installation where there
are no constraints on fixing the top brackets or J brackets. It is
possible to reduce the distance between top brackets if there
are space constraints (Figure 4b). This configuration however
results in a 5mm gap between the fabric and the door opening
Drive End Free End

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
Figure 4b, Minimum Cutting Lengths of Tubes and Fabric
4. Push the Flute Guide Insert over the end of the flute in the tube to protect the
fabric sheet as it is being fitted. When the fabric is inserted remove the Flute
Guide Insert form the end of the flute.
Slide the screen material (B1) into the flutes of the top and bottom tubes. Cut to
suit and slide nylon insert (J1) into the pocket of the flap (C1). Slide flap into
bottom flute and secure each end with insert lockers (K1), Figure 5a.
Drive End Free End
Please note when
using the minimum
dimensions there
will be a 5mm gap
between the fabric
and the opening
on each side of the
door

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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Figure 5a, Fabric Attached to Top and Bottom Tubes
Push end caps (N1) onto bottom tube making sure the drainage holes are located
vertically. Fix with two self-drilling screws (T1) to each cap
Figure 5b, Attach End Caps to Bottom Tube
i) Slide
screen in to
top tube
ii) Slide screen
in to bottom tube
iii) Slide bottom
flap in to bottom
tube
Nylon Insert (J1) inserted
into flap pocket
iv) Insert lockers
(K1) used to
locate bottom
flap
Drainage
holes
located
vertically

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
5. Roll the screen material fully onto the top tube, we recommend the fabric rolls off
the back of the top tube to minimise the gap between the fabric and building face.
Tie the tubes together as shown in Figure 6.
Figure 6, Roll Up Door Around Top Tube and Secure
6. Insert motor assembly into drive end of top tube, and then attach the drive end
wall bracket to the motor using the R-clip supplied, as shown in Figure 7.
Figure 7, Motor Inserted Into Top Tube and Drive Bracket Attached
Rope to tie tubes together
i) Slide motor (O1) into top
tube
ii) Attach drive bracket (F1)
R-Clip

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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7.1. Doors up to 5.0m wide, Figure 8a:
Fasten the free end bracket (E1) to the holes drilled in building at free end, using
the M8 fixings supplied. Push free end collar (E2) into the top tube at the free
end. Lift the assembly into position and slide top tube onto free end bracket.
When in position fasten drive bracket (F1) and motor cowling bracket (G1) to
building.
Figure 8a, Mounting Doors Up to 5.0m Wide to Building
CAUTION: Referring to Table 1 on page 4, ensure the building
is of sound construction and that the most suitable type of
fastener is used. Use only M8 bolts or greater to fit these items
and ensure they are securely fastened to the building. Failure
of these fixings will result in your door falling off the building,
potentially injuring operators and bystanders.
7.2. Doors over 5.5m wide, Figure 8b:
Slide safety spring (D1) into the top tube, opposite end to the motor. Lift the
assembly into position, and bolt both brackets on using the M8 fixings supplied.
NOTE: If you wish to fit the safety spring to the opposite side to
that ordered, refer to instructions in Appendix I.
The motor cowling bracket (G1) is fastened to the drive end at the same time.
Motor Wire

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
Figure 8b, Attaching Doors Over 5.5m Wide to Building
Powering Motor
8. Single Switch Control
Following the Becker operation instructions, secure the junction box (R1), switch
(P1) and wires to the building. Ensure all wires exiting from the drive bracket,
junction box and switch point down to form a drip-loop so that rain water cannot
enter the motor or switch. To prevent entrapment by the lower tube, route the
cable to the back of the top bracket and fasten with cable-tie supplied (V1),
Figure 8b(iii). Ensure the cable glands are correctly seated to prevent water
ingress. Wire the 4-core motor cable into the junction box as detailed in Figure 9a
for left hand drive or Figure 9b for right hand drive.
To operate the door, rotate the switch in the direction you want the door to travel
as indicated by the arrows on the front panel. To stop the door at any position,
return the switch to position ’0’.
CAUTION: For safety, position both switches in sight of the
door
Motor Wire
i) Insert safety
spring (D1) into top
tube
ii) Fasten brackets
to building
iii) Route motor wire

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Figure 9a, Motor Left
Figure 9b, Motor Right
L1 Brown
L2 Black
L1 Brown
L2 Black

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Double Control Switch
Secure the contactor box, secondary switches, and wires (P2) to the building.
Ensure all wires exiting from the drive bracket and motor switches point down to
form a drip-loop so that rain water cannot enter the motor or switches. To protect
the circuit board we advise the contactor box is mounted inside the building with
the glands face downwards. Ensure all cable glands are correctly seated to
prevent water ingress. Wire the 4-core motor cable into the contactor box (P2) as
detailed in Figure 9c. Re-fit lid checking that the seal is correctly seated to ensure
water does not damage the electronic controls. The switches operate in a ‘toggle’
fashion, i.e. with each press the motor will go one way, then stop, reverse, stop
again and so on.
Figure 9c, Contactor Box Wiring
CAUTION: For safety, position both switches in sight of the
door
Motor Left
Motor Right
Brown Black
Black Brown

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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ENG
ATTENTION: For maximum protection of the circuit board
inside the Contactor box, we advise this is mounted inside the
building away from direct rainfall. If outside operation is
required use the secondary switch for this location
‘J’ Bracket Installation
9.Fit one ‘J’ Bracket (M1) and Guide (L1) at the desired level with the M8 fixings
supplied (R1). Ensure there is 120mm clearance underneath for the tube to
engage into the bracket. Locate tube under bracket and at other end, rest
bracket over cap and press down until material is taut (Figure 10) and fix
bracket to building.
Figure 10, Attaching ‘J’ Bracket to Building
Setting Limit Switches
9. Follow the ‘Becker’ operation instructions to set the limit switches so that when
fully closed there should be just enough room above the bottom tube to locate in
the J Brackets.

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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Securing Fabric
10. Lower your door fully, centralise the screen and secure each corner using 19mm
self-drilling screws supplied (T1). It is important to tension sheet sideways before
fixing to remove creases (Figure 11).
Figure 11, Attaching J Bracket to Building
i) Tension fabric iii) Secure corners of
fabric, 4 locations
ii) Centralise door fabric

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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11. Attach the company detail label centrally to the front of the bottom tube.
Figure 12, Attaching Label
Installing Motor Cowling (Standard) or Door Cowling (Optional)
12. Fix the cowling end (G1) to the motor bracket using the M8x20 set screws (Z1)
and lock nuts (S1). Attach the motor cowling (H1) to the cowling end and to the
building at the free end using the screws (U1) as shown in Figure 13.
Figure 13, Motor Cowling Assembly

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13. Door Cowling (Optional at extra cost)
REF: QTY PART DESCRIPTION
CA1 * 1.75M Lengths of Cowling
CB1 1 pr Cowling End
CC1 2 M8x20 Hex bolt and Nut
CD1 24 M4.8 x 8 St Steel Rivets / per join
CE1 4 M5.5 x 19 Self Drilling Screws
CF1 1 5mm Drill for rivets (not shown)
Figure 14, Door Cowling Assembly
C1. Fit the cowling ends (CB1) to the end brackets using the M8x20 bolts and nuts,
similar to that used at the drive end as shown above in Figure 17.
C2. Join the main cowling (CA1) with a minimum overlap of 265mm, using the M4.8 x
8 rivets, (CD1) 6 in each of the four faces. Fix the cowling to the cowling ends,
using the M5.5 x 19 self-drilling screws (CE1), three per side.
NOTE: The Cowling is self-supporting and does not require
intermediate brackets.

ELECTRIC ROLLERDOOR – J BRACKETS Installation
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14. CE Marking Electrically Operated Products under Machinery Directive
It is the responsibility of the installer to check that the installation conforms to
the specific safety features detailed in the Manufacturer’s Installation
Instructions, to issue the CE Declaration of Conformity and mark a power
operated product under the Machinery Directive 2006/42/EC. To do this you will
require the following which should be delivered with the product:
1) This set of Installation Instructions (operating and maintenance instructions)
2) Maintenance Log Book, (including Installation Checklist and Customer Declaration of
Conformity)
3) 1 x Declaration of Conformity (Installer Copy) – to be completed
4) A CE Label
When CE marking a power operated Galebreaker product, it is vital to follow the
steps outlined below:
a) Install the product as per instructions, with no adaptations or modifications and
complete of the Health and Safety Checklist in the Maintenance Log Book.
b) Complete the two ‘Declarations of Conformity’ using the following:
Model Type: As shown on CE Label
Serial Number: As shown on CE Label
Installation Company: Your company name
Date Installed: Date Installed
Declaration made by: Responsible Person
Declaration and Instructions received by: Customer’s Signature
c) Fix the supplied CE label to the bottom tube. The label should be accessible /
visible. Where the serial number does not incorporate the door size, add the
Product width and Product height to the end of serial number using a permanent
marker pen. i.e. the full serial number should read
Serial Number: 1234 / RDE WX H
[W] Product Width (m)
[H] Product Height (m)