Wayne-Dalton DS-75 User manual

IMPORTANT NOTICE !!
Read the enclosed instructions carefully before attempting to install this door. Pay close
attention to all warnings and important safety notices.
This manual MUST be attached to the wall in close proximity of the door.
DS-75/DS-100 MINI ROLL-UP DOORS
INSTALLATION INSTRUCTIONS
©Copyright 2002 Wayne-Dalton Corp.
P/N 299013, DOC #101-0114-1 REV 00
WINDLOAD RATED

2
CAUTION
CAUTION
WARNING
IMPORTANT!
HINT:
NOTE:
IMPORTANT SAFETY NOTICES
Read the enclosed instructions carefully before attempting installation. If there are any
questions about any of the procedures, do not perform the work. Instead, have a qualified
door agency do the installation or repairs.
1. Operate the door ONLY when it is properly adjusted and free of all obstructions.
2. The door is constantly under EXTREME SPRING TENSION. Repairs, adjustments, installation and
removal, ESPECIALLY of SPRINGS AND RELATED PARTS, are dangerous so that such work should
be performed ONLY by qualified door service people.
3. DO NOT PERMIT children to play with the door. Children could get caught between the door and the
floor causing severe injury or death.
4. Avoid standing in the open doorway or walking through the doorway while the door is moving. One could
get caught between the door and the floor causing severe injury or death.
5. Should the door become hard to operate or completely inoperative, it is recommended that a qualified door
agency correct the problem to prevent possible injuries or door damage.
6. Avoid installing the door on windy days. The door could fall causing door damage or injury.
7. To prevent injuries due to loose components, at least monthly check all bolted connections to make sure they
are secure.
8. To prevent injuries, never place hands or fingers between the curtain and the guides while the door is being
operated.
9. This manual is not intended to provide "take-down" instructions for existing doors. Consult your local door
agency if this is required, before new doors are to be installed.
10. Thoroughly familiarize yourself with the construction codes in your region before initiating work.
11. Wear the proper protective safety gear at all times when installing, adjusting and/or repairing doors.
12. Consider using a 2-person (or larger) crew for installing, adjusting and/or repairing larger doors.
13. Definitions of key words used in this manual are as follows:
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
WARNING indicates a potential hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
IMPORTANT! indicates a required step for safe and proper
door operation.
NOTE: indicates information assuring proper installation of the door.
HINT: indicates a suggested step to simplify installation based on experience.

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INTRODUCTION
This manual's main function is to assist the installer in correctly mounting doors with due regard for safety,
operation, and sound construction practices. Reference must be made to construction codes in your area.
All Wayne-Dalton DS-75 and DS-100 Windload Rated Mini Roll-Up Doors follow the general instructions
contained herein. Additional installation information for the specific door shipped is found with thepackingslip and
on supplementary drawings. There are also bolt and small sealed parts bags with accessory lists, describing proper
application.
PREPARATION
Read the installation instructions thoroughly to become familiar with the names of the various components and their
relation to each other. It is necessary for the installer to determine the following:
Type of jamb (masonry or steel) on which the door mounting angles mount and the fasteners required.
The dimensions for the opening width, opening height, headroom, and side room.
MATERIAL
Inspect your door for possible damage or shortage of parts. Report any shortages to your door supplier immediately,
or transit related damage claims to your freight carrier.
CLEARANCES
Check the door opening dimensions and available clearances versus the dimensions listed on the packing slip. Be
sure that the dimensions are correct for the opening you are working on, taking special note of the opening width
and height. Be sure that the required clearances listed in the table in this manual are available prior to installation.
TOOLS
The tools recommended for proper installation of each door will vary, but commonly used tools are:
Electric drill with 3/8" or 1/2" chuck with nut driver bits.
Masonry drill or impact hammer and bits.
Ladders and/or scaffolding.
Hammer and pliers.
Large Pipe Wrench (if Tension-Pro bracket).
Center punch.
Screwdrivers.
Drill bits.
Wrenches, vise grips, and C-clamps.
Tape measure and a water level.

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STEP 1 UNPACKING DOORS
Before removing the door from any packaging, inspect the door and packaging for visible signs of damage. If
damage is noted, file a freight claim with the freight company immediately. Remove the door from the packaging.
Do not cut tape that holds door in a roll. You will be told in step
#7 when to cut tape.
No guarantee will be given byWayne-Dalton Corp. if the door is not erected as instructed. For best operation, follow
the instructions step by step. Please review all instructions thoroughly before starting installation.
STEP 2 CHECK THE DOOR OPENING
Verify the opening measurements with the door packing slip. Consult the factory if the actual opening width varies
from that shown on the packing slip by more than 2 inches. Check to make certain that the dooropeningis plum and
that the floor is level. Check to be certain there is sufficient clearance from the opening to the ceiling and the
sidewalls (see Required Clearances below).
REQUIRED CLEARANCES - MINIMUM INDICATED
OPENING HEIGHT HEADROOM (A) SIDE ROOM (B)
STEEL JAMBS
SIDE ROOM (B)
MASONRY JAMBS
UP TO 6’8” HIGH 13” 4-1/2” 6”
FROM 6’8-1/4” TO 8’ HIGH 14” 4-1/2” 6”
OVER 8’ HIGH 16” 4-1/2” 6”
IMPORTANT!

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STEP 3 INSTALLING MOUNTING ANGLES AND GUIDES
Obtain the appropriate Bolt Line (BL) measurement from the chart below. Use opening width listed on the
packing slip. Any variation between the actual opening width and the opening width listed on the packing slip is to
be ignored.
Use BL measurement to locate wall mounting angle for one
jamb only. Second angle will be located using Angle Face to
Angle Face Measurement.
Using the BL measurement, loosely
clamp the right hand wall angle to
the right hand jamb. Position the
wall angle such that the BL
measurement falls near the center of
the wall angle holes. Use a level to
adjust the angle so that it is level and
tighten the clamp. Install wall angle
fasteners in the top and bottom holes
only. Do not install fasteners in the
slots at the top of the wall angle at
this time. Fasteners will be installed
in these in step #4.
Obtain the Angle Face to Angle Face
equation from the chart above. Add
the opening width listed on the
packing slip to obtain the Angle Face to Angle Face measurement. Usethis measurement
to locate the left hand wall angle on the left hand jamb and clamp in place. Install bolts in
the top and bottom holes in the wall angle. Verify that both wall angles are level and
double check the angle to angle measurement at the top, middle, and bottom to ensurethat
the wall angles are properly located. Using a string and a level, ensure that the mounting
angles are parallel to each other, shimming if necessary, to achieve both vertical and
horizontal leveling.
Starting at the bottom of each wall angle, install the remaining fasteners such that no
distance between two fasteners exceeds 12”. Do not install fasteners in the slots at the top
of the wall angle at this time. Fasteners will be installed in these in step #4.
Angle Face to Angle Face measurement
must be held to ensure proper door
operation and resistance to windload.
Use of any other fasteners than those provided must be
approved by manufacturer or building authority and cannot
be of lesser diameter or grade.
Align the guide slots with the holes in the wall angles and fasten guides with the interior windlock return towardsthe
door jamb using the 5/16-18 x 5/8” truss head bolts, washers, and flange nuts. Verifythat the“H”dimension is set at
1” on each guide prior to tightening the guide fasteners.
BL (STEEL) BL (MASONRY) ANGLE FACE TO ANGLE FACE
1-3/4” 4” OPENING WIDTH + 5-11/16”
IMPORTANT!
IMPORTANT!
IMPORTANT!

6
Trim the top of each wear strip at a 45° angle as shown and clip onto the
appropriate leg of each guide. Be sure that trimmed edges of the wear strips end
just below the flare of the guides. Install the bottom bar stops with the same 5/16-
18 x 5/8” truss head bolts and flange nuts used to assemble the guides. Leave the
fasteners loose to allow the bottom bar stops to pivot out of the way of the bottom
bar angle when the curtain will be pulled into the guides. You will be instructed to
tighten the bottom bar stop fasteners in step #7.
STEP 4 BRACKET INSTALLATION
Install the brackets to the outside of
the wall mounting angles (awayfrom
the opening) using two 5/16-18 x
5/8” truss head bolts and flat
washers in the two slots at the top of
the mounting angles, as shown.
Loosely install the 5/16-18 flange
nuts on the bolts to hold the brackets
in place. For steel jambs, the bracket
flange will rest against the wall. For
masonry jambs, the bracket flange
will rest against the wall side leg of
the mounting angle with the two
holes in the bracket flange lining up
with two slots in the wall angle.
Check that the brackets are straight
and square with one another,
shimming if necessary, and install the appropriate wall mounting fasteners through the two holes in the bracket
flange. Tighten the flange nuts on each bracket. If mounted on steel jambs, install wall mounting fastener in the top
slot of each wall angle.
STEP 5 LIFTING THE CURTAIN ASSEMBLY
Door assembly may be heavy. Do not allow door assembly to
fall when lifting, or serious injury or death could result.
The left hand end of the curtain assembly (when installed) will be the end with the spring. Lift the curtain assembly
up to the brackets and insert the left hand axle end into the large hole in the left hand bracket. Be sure that the axle
collar rests against the bracket. While continuing to support the curtain assembly, insert the right hand axle end into
the right hand bracket in the same manner. It may be necessary to gently pry the right hand bracket out to allow
clearance for the curtain assembly axle end. Install the 1-7/16” ID washer onto the appropriate axle ends and secure
the curtain assembly in position by installing the cotter pins through the holes in each axle end.
The 1-7/16” ID washer is not required for bearing or Tension-Pro brackets.
See Step #13 for Tension-Pro bracket assembly instructions.
To avoid serious injury or death, never walk, stand or work below
door assembly before it is secured to support brackets.
WARNING
WARNING
NOTE:

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HINT:
STEP 6 SPRING ATTACHMENT
Rotate curtain assembly so that the bottom bar is at the top
of the curtain roll. While holding the door from rotating,
carefully stretch the spring end to the bracket to determine
the bracket hole nearest to the loop in the spring end.
Position the 5/16-18 x 1” hex head bolt and flat washer in
the spring loop and stretch the spring to insert the bolt into
the previously determined bracket hole. Loosely install the
lock washer and nut on the outside of the bracket to hold the
spring stretch. Rotate the spring until it is centered on the
bracket, with all bracket tabs inside the spring, and securely
tighten the spring attachment bolt.
See step #13 for Tension-Pro bracket spring attachment.
If installation permits, use vise grips to secure spring loop to bracket for a
stretch free method of installing the spring attachment bolt.
STEP 7 PRE-TENSION THE DOOR SPRING
Starting with the bottom bar angle at the top of the curtain roll, apply two
complete turns of pre-tension to the spring by rotating the curtain roll in the
direction shown. Depending on door size, it may be necessary to pry the
bottom bar past the guide flare. The amount of tension required may vary
slightly. Final adjustment, if necessary, will be made in Step #9.
Spring tension can cause curtain roll to rotate rapidly.
Securely hold curtain roll from rotating while applying
pretension or serious injury or death could result.
Securely hold door curtain until bottom bar stop fasteners
have been tightened. If not securely held, door may raise or
drop, possibly causing serious injury or death.
Cut the tape that holds the door in a roll and gently pull the curtain down into the guides on both sides until the
bottom bar is below the bottom bar stops. Do not pry on the bottom bar stops to get bottom bar past, loosen fasteners
until bottom bar angle easily clears stops. If the door has a tendency to close, secure in position using clamps. If the
door has a tendency to rise, secure in position using a wood prop.
While the door is secured from moving, tighten the bottom bar stop fasteners on both guide assemblies.
WARNING
WARNING
IMPORTANT!

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STEP 8 LUBRICATE AND ADJUST THE GUIDES
Lubricate the insides of guides and wearstrips with weather resistant lubricating spray. Be sure to spray lubricant
over the flares at the top of each guide. Move the door up and down to check for proper operation. Adjust the guides
and mounting angles if necessary to allow for proper clearance and operation.
If door is difficult to move up and/or down due to spring imbalance,
continue on to step #9 and return to step #8 once springs are properly
adjusted.
STEP 9 CHECK AND ADJUST SPRING BALANCE
Move the door up and down to check for proper spring tension. If
the door lowers easily and raises hard, more spring tension is
required. If the door lowers hard and raises easily, less spring
tension is required. If a tension adjustment is necessary, secure the
door in position and remove the bottom bar stops. Carefully roll
the curtain all the way up without letting go of the bottom bar. Tie
a rope around the curtain roll and slowly rotate the curtain roll in
the opposite direction as tension was applied until spring is
neutral. Change the location of the spring attachment bolt in the
required direction as shown. Repeat steps 6, 7, 8, and 9. See Step
#13 for Tension-Pro bracket spring tension adjustment.
Spring tension can cause curtain roll to rotate rapidly.
Securely hold curtain roll from rotating while applying
pretension or serious injury or death could result.
Securely hold door curtain until bottom bar stop fasteners
have been tightened. If not securely held, door may raise or
drop, possibly causing serious injury or death.
STEP 10 LIFT HANDLE INSTALLATION
Install a lift handle in the center of the bottom bar using1/4-20 x 5/8”
carriage bolts and flange nuts such that the nut is on the coil side, or
inside, of the door as shown. If a second lift handle was provided,
install in the same manner on the right hand side of the bottom bar
(outside looking in). Install 1/4-20 x 5/8” carriage bolt and flange nut
in any remaining vacant holes in the bottom bar at this time.
HINT:
WARNING
WARNING

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STEP 11 SLIDE BOLT LOCKS (if applicable)
Install slide bolt locks, if provided, as shown.
STEP 12 INSTALLATION OF TOP DRAFT STOP (if applicable)
Close the door and secure it in
the down position. Use a pencil
to mark the door panel
corrugation that is parallel with
the bottom of the header/lintel
from the outside of the opening.
If this corrugation protrudes
below the header, mark the one
just above. Open the door until
the marked corrugation is
accessible. Stretch the top draft
stop across the door and attach it
to the curtain on the marked
corrugation with the self-drilling
screws provided, locating the
screws every 12" on center. Trim
the Top Draft Stop to clear the
guides if required. When the
door is closed, the draft-stop
should seal on the header.
Top Draft Stop may not seal on the header if not installed on a corrugation
as shown.
NOTE:

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STEP 13 TENSION-PRO SPRING TENSION ADJUSTMENT BRACKET (if applicable)
STEP #1: Install the Tension-Pro bracket on the left hand side of the curtain assembly per step #4 of this manual.
Insert cotter pin through hole in the axle. Do not use large washer on the Tension-Pro bracket side axle end.
STEP #2:Stretch and attach spring end to the spring holder plate of the Tension-Pro bracket using the 5/16-18 nut,
washer and lock-washer. Bolt must be installed with the nut on the spring loop side.
STEP #3:Pretension the door per step #7 of this manual. Pull curtain into guides and install bottom bar stops.
STEP #4: Test door operation to determine if spring balance requires adjustment. Adjust tension as needed per the
following instructions.
Spring tension can cause death or injury. Repairs/adjustments
must be made by a trained door technician.
Spring tension increases as door closes. Door must be fully
opened when making spring tension adjustments.
Pipe wrench interference can prevent pawl engagement with
ratchet gear. Always adjust tension one “CLICK” (gear tooth) at
a time and reposition wrench for each adjustment or serious
injury or death could result.
Contact with rapidly rotating ratchet gear can cause death or
injury. If wrench slips when decreasing tension, release pawl
immediately. Do not secure pawl in disengaged position.
WARNING
WARNING
WARNING
IMPORTANT!

11
To Increase Spring Tension:
Move the door to the fully opened position and place clamps on the guides to prevent possible door closing. Usinga
large pipe wrench, grip the tensioning hex plate and rotate the ratchet gear assembly in the direction indicated above
until an audible “CLICK” is heard (one gear tooth). Operate the door to determine if the spring tension increase was
sufficient. Repeat spring tension increase procedure as needed to properly balance the door.
To Decrease Spring Tension:
Move the door to the fully opened position and place clamps on the guides to prevent possible door closing. Usinga
large pipe wrench, grip the tensioning hex plate and remove the spring tension force from the pawl. Grip the pawl
retention screw and pull the pawl in the direction indicated above to hold it from engagement. Slowlyback the force
off the pipe wrench until the ratchet gear begins to rotate in the direction indicated above (spring forcewill urge gear
in this direction). Once the stop face of the previouslyengaged tooth has passed the tip of the pawl, release the pawl
to allow it to follow the contour of the gear tooth until engagement has occurred with the next tooth. Operate the
door to determine if the spring tension decrease was sufficient. Repeat spring tension decrease procedure as needed
to properly balance the door.
STEP #5:Once spring tension has been adjusted and the door is properly balanced, lock the pawl in position by
tightening the pawl retention screw until it penetrates the bracket. Test that the pawl is locked in position by
attempting to add 1 “CLICK” of tension. If properly locked, the ratchet gear will not be ableto rotate. If ratchet gear
rotates, adjust tension back to desired position, verify that the pawl retention screw is lined up with the hole in the
bracket, and tighten the pawl retention screw further. Return to step #10 of this manual.
If not properly aligned, pawl retention screw can force pawl
out of engagement. Verify screw lines up with bracket hole
prior to tightening and do not drive screw with screw gun or
spring tension could be lost causing serious injury or death.
Spring tension could be released by door operation if pawl
retention screw does not penetrate bracket. Always verify
pawl is locked in position prior to operation or door could fall
uncontrollably causing serious injury or death.
Keep loose clothing, fingers, hands and arms away from all
moving mechanisms and points of engagement, otherwise
serious injury or death could result.
WARNING
WARNING
WARNING

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Roll-Up Sheet Door
LIMITED WARRANTY
Wayne-Dalton Corp
P.O. Box 67- Mt. Hope, Ohio 44660
The Manufacturer warrants the ROLL-UP SHEET DOOR and hardware fittings for a period of ONE YEAR from the time of
delivery against any defects in workmanship or material. Manufacturer shall, upon notification, correct such nonconformity at its option, by
repairing or replacing any defective part or parts.
NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THE FOREGOING
WARRANTIES IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.
The Manufacturer shall not be responsible for any damage resulting to or caused byits products by reason of installation, improper
storage, unauthorized service, alteration of products, neglect or abuse, or attempt to use the products for other than the customary usage or
for their intended purposes. The ROLL-UP SHEET DOOR warranty becomes null and void if other thanManufacturer’s specified holes are
drilled. The above warranty does not cover wear or any damage beyond Manufacturer’s control or replacement labor.
THIS WARRANTY COVERS A COMMERCIAL PRODUCT, THE FOREGOING WARRANTIES ARE IN LIEU OF ALL
OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESSED OR IMPLIED,
(INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE), ARE MADE BY MANUFACTURER IN CONNECTION WITH MANUFACTURE OR SALE OF ITS PRODUCTS.
Claims for defects in material and workmanship covered by this warranty shall be made in writing to the dealer from whom the
product was purchased within the warranty period. Manufacturer may either send a service representative or have the product returned to
the Manufacturer at Buyer’s expense for inspection. If judged by Manufacturer to be defective in materialor workmanship, the product will
be replaced or repaired at the option of Manufacturer, free from all charges except authorized transportation and replacement labor.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES.
THE LIABILITY OF MANUFACTURER, WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE,
SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART
FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE
LIABLE FOR COST OF REMOVAL OR INSTALLATION OR SHALL NOT BE RESPONSIBLE FOR ANY DIRECT, INDIRECT,
SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.
This warranty gives you specific legal rights which may vary from state to state. However, some states do not allowlimitations on
how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations or
exclusions may not apply to you.
Wayne-Dalton Corporation
Door & Systems Division
2589 County Road 168
Dundee, OH 44624
1-800-795-5095