Wayne-Dalton DS-350 User manual

DS-350 COMMERCIAL ROLL-UP DOORS
WINDLOAD RATED
INSTALLATION INSTRUCTIONS
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.
©Copyright 2002 Wayne-Dalton
P/N 291341, DOC #101-0093-1 REV 03

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. To prevent injury or death due to falling, use scaffolding or mechanical lifts, rather than ladders, when
installing, adjusting, and/or repairing larger doors.
14. 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.
2
CAUTION
CAUTION
WARNING 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! IMPORTANT! indicates a required step for safe and proper
door operation.
NOTE:
NOTE: indicates information assuring proper installation of the door.
HINT: HINT: indicates a suggested step to simplify installation based on experience.

3
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-350 Windload Rated Commercial Roll-Up Doors follow the general instructions contained
herein. Additional installation information for the specific door shipped is found with the packing slip 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:
Method of operation (push-up, hand chain, or motor operated).
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 on the Dimension Tables 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.
Chain hoist and sling for raising barrel and curtain assembly.
Scaffolding, Mechanical Lift, and/or Ladders (ladders not recommended for larger doors).
Hammer.
Channel Lock Pliers
Center punch.
Screwdrivers.
Drills.
Wrenches, vise grips, C-clamps, torque wrench, and a large pipe wrench.
Plumb line, tape measure, chalk line, and a water level.

STEP 1 UNPACKING DOORS
Doors shipped by common carrier arrive at the job site packed in cardboard. Before removing the door from the
packaging, inspect the door and packaging for visible signs of damage. If damage is noted, file a freight claimwith
the freight company immediately.
IMPORTANT! Do not remove cardboard or cut tape that holds door in a roll.
You will be told later when to do this.
No guarantee will be given by Wayne-Dalton 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 door jambs, header, and floor for plumb/level
condition. Check that there is sufficient clearance at jambs and head (see Dimension Tables below).
4
Left hand operated door shown above. Right hand is opposite.
DIMENSION TABLES - MINIMUM OVERHEAD CLEARANCE (B) INDICATED
OPERATION A
PUSH-UP 6”
DIRECT DRIVE CHAIN/MOTOR 9”
REDUCED DRIVE CHAIN 8”
OPENING HEIGHT B C
UP TO 8’ HIGH 20” 10”
FROM 8’ TO 10’ HIGH 22” 11”
OVER 10’ HIGH 24” 12”
NOTE:

STEP 3 INSTALLING MOUNTING ANGLES, GUIDES, AND BOTTOM BAR STOPS
Obtain the appropriate Bolt Line (BL) measurement from the chart below. Use Opening Width listed on packing
slip. Any variation between the actual opening width and the width listed on the packing slip is to be ignored.
OPENING WIDTH BL
(STEEL) BL (MASONRY) ANGLE FACE TO ANGLE FACE
UP TO 10’ WIDE 1-9/16” 4-15/16” OPENING WIDTH + 6-11/16”
OVER 10’ WIDE 1-7/16” 4-7/8” OPENING WIDTH + 6-7/16”
IMPORTANT! 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 slots. Adjust the wall angle so
that it is level and tighten the clamp.
5
IMPORTANT!
IMPORTANT!
IMPORTANT!
, to achieve both vertical and horizontal
veling. Now install the remaining bolts in both wall angles.
.
building authority and cannot be
f lesser diameter or grade.
gle as
seen in the above picture or door will bind in guides.
Install wall angle fasteners in the
centers of the top and bottom slots
only and tighten.
Select the appropriate 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 the top and bottom
bolts 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 ensure that 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
le
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
o
Ensure guide is oriented properly on the mounting an

Align the guide slots with the slots in the wall angles and fasten guides with the interior
windlock return towards the door jamb using the 5/16-18 x 5/8” truss head bolts,
washers, and flange nuts. Slide guides to set the “H” dimension as shown above at 1-
3/4” prior to tightening the guide fasteners.
Install thebottom barstops with the same 5/16-18 x 5/8”
truss head bolts and flange nuts used to assemble the
guides (no washer). 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 INSTALL BRACKETS, DRIVE COMPONENTS, AND TENSIONERS
From the Dimension Tables on page 4, mark the width location of each bracket by using dimension A for the
operator side and 6” for the non-operator side. If the actual opening width varies fromthe packing slip width, adjust
these dimensions by adding or subtracting ½ of the difference to each dimension. Subtract if the opening is larger
and add if smaller. Mark the height location of the brackets by using dimension C. Verify the ceiling clearance
minimum from dimension B. Use a string and a level to verify that the brackets are level with each other. Adjust
bracket height as needed to level. Drill anchor holes and fasten the brackets with the anchors provided.
Brackets must be level to each other with respect to height.
Failure to level bracket heights will prevent door from
operating properly.
IMPORTANT!
If the door is to be chain hoist or motor operated, install the components shown below to the operator side of the
curtain at this time. Do not tighten set screws at this time, you will be instructed to tighten these in step #9.
6
Keep loose clothing, fingers, hands and arms away from all
moving mechanisms, or serious injury or death could result.
WARNING

7
WARNING
IMPORTANT!
IMPORTANT!
wall on the device will point to the wall when the door is installed.
hat the arrow on the device points to the
wall.
Tension holding assemblies must be oriented correctly in order
STE O
Lift the curtain assembly up to the support brackets. Align tensioner devices with the brackets so that when door is
lowered h d
without er
he curtain roll. Now, remove the cardboard packaging from the door.
y or death, never walk, stand, or work
KETS
E s
se c
s snug.
close to header as possible per
NSIONTO THEDOOR SPRINGS
St t
ap he he amount of tension required may vary slightly. Final adjustment, if
ne .
before operating the
oor.
the curtain down into the guides on both sides until the
ottom bar is below the bottom bar stops.Do not pry on the bottom bar stops to get bottom bar past, loosen fasteners
After installing the brackets and drive components, install the axle
tensioner devices. On the non-operator side of the curtain slide the
tensioner device on the axle and ensure the arrow pointing to the
Next, slide the tensioner support device on the opposite side of the
axle, again making sure t
IMPORTANT! to hold tension on the door.
OR ASSEMBLYP 5 LIFTING THE D
Door assembly is extremely heavy. Do not allow door
assembly to fall from lifting mechanism, or serious injury or
death could result.
WARNING
down to the brackets, bot
scraping against door head evices will sit on top of the brackets. Be sure that the door is able to revolve or guides. Rotate curtain assembly so that bottombar angle is at the bottom of
t
To avoid serious injur
below door assembly before it is secured to support brackets.
STEP 6 SECURE TENSIONERS TO BRAC
nsure that the bottom bar angle i
cure the tension devices to the bra
ashers, and washers. Tighten bolt
at the bottom of the curtain roll and
kets using the (2) 3/8”x1” bolts, lock
w ½ turn past
Tensioners must be installed as
step #5.
STEP7 APPLY INITIALTE
art with the bottom bar angle a
proximately 1 turn to pre-tension t
cessary, will be made in Step #10
the bottom of the curtain roll and use a pipe wrench to rotate the axle
door. T
Tighten the set screws on both tensioners
d
Always stand to one side of wrench when applying tension, to
avoid injury if you lose control of wrench.
Cut the tape that holds the door in a roll and gently pull
WARNING
b

8
WARNING
until bottom bar angle easily clears sto ps. If the
door has a tendency to rise, secure in oving, tighten
blies.
in roll to rotate rapidly.
Securely
IDE BOLT LOCKS
lip will need to be installed. Only one bolt is
quired to secure the stop-clip to the bottom bar
hen attaching a lift handle on that side. Repeat
ssembly procedure for opposite side. Install lift
andle and pull rope at the center of the bottom bar.
ar.
his ensures smooth operation of the slide bolt. Place the
ide bolt lock so that the slot rides on the flange nuts.
hen, add the stop-clip and attach, using the flanged nuts.
Repeat assembly procedure for opposite side. Install lift
Lubricate the insides of the guides and wearstrips with weather resistant lubricating spray. Be sure to spray lubricant
over the flares at the tops of the guides. 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.
ps. If the door has a tendency to close, secure in position using clam
position using a wood prop. While the door is secured from m
the bottom bar stop fasteners on both guide assem
Spring tension can cause curta
hold curtain roll from rotating while applying
pretension or serious injury or death could result.
STEP 8 INSTALL STOP CLIPS AND SL
I: ‘C’ Stop-Clip Attachment:
For doors with an aluminumbottom bar, a ‘C’ stop-
c
re
w
a
h
II: ‘C’ Stop-Clip w/ Inside Slide Bolt Attachment:
For doors with inside slide bolt locks, install the ‘C’ stop-
clips as shown on the right. The bottombar will have (4)
carriage bolts & flange nuts pre-attached. Verifythatthe
flat sides of the nuts are horizontal to the bottom b
(4) ¼ - 20 carriage bolts
T
sl
T
handle and pull rope at the center of the bottom bar.
(4) ¼ - 20
flange nuts
(2) ‘C’ stop-clips
(4) ¼ - 20 carriage bolts
(4) ¼ - 20 flange nuts
*pre-attached to btm bar
(
2
)
‘C’ sto
p
-cli
p
s
(
2
)
inside slide
(
4
)
¼ - 20 flan
g
e
Failure to properly install stop-clips to the bottom of the door
WARNING may result in serious injury or death
STEP 9 LUBRICATE AND ADJUST THE GUIDES

S
9
WARNING
bar. Then, loosen
ock the axle in place
tightene s in
, door may raise or
resulting in serious
.
Springs can cause serious injury
. Open the door until the marked
re do r.
not installed on a corrugation as shown.
TEP 10 CHECK AND ADJUST SPRING BAL
Lower and raise the door to check the counterbalance. 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. First, open the door fully and
sten vise grips to guides below bottom
ANCE
fa
the set screws on both tensioners.
To remove tension, slightly pull down on the pipe wrench
to unlock the tensioner. Then, pull and hold the small rod
on the top of the tensioner to completely disengage the
tensioner. Slowly release tension by allowing the wrench
rotate. Release the tensioner rod to lto
while re-adjusting the pipe wrench.
efore operating the door, re-tighten the set screws on the tensioners. Remember to tighten all 3 square-headedB
locking bolts on the tensioner devices when finished to maintain desired adjustment.
Repeat the above procedure if further adjustments are required. Once all adjustments have been made and the door
is operating properly, recheck all fasteners and bolted connections to ensure that they are in place and properly
d. Verify that all set screw the components installed in step #4 have been tightened.
Securely hold door curtain until bottom bar stop fasteners
have been tightened. If not securely held
drop, possibly causing injury or death.
Never remove bottom bar stops when adjusting tension,
therwise, door can spin uncontrollably
WARNING o
injury or death.
nce the tensioner rod is disengaged, hold wrench securelyO if not controlled properly.
STEP 11 INSTALLATION OF TOP DRAFT STOP
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
eader, mark the one just aboveh
corrugation is accessible.
Stretch the top draft stop across the door and attach it to the curtain on the
marked corrugation using the #8 x ½” self-drilling screws, locating the
screws every 12" on center. Trim the Top Draft Stop to clear the guides if
quired. When the or is closed, the draft-stop should seal on the heade
Top Draft Stop may not seal on header if
NOTE:
WARNING

REDUCED DRIVE CHAIN HOIST INSTALLATION INSTRUCTIONS (if applicable)
STEP 11 ALIGN THE SPROCKETS
Feed the hand chain through the pocket wheel assembly (installed in step #4),
around the cast iron hand chain wheel, and connect the two end links.
Align the chain hoist so that the 41B9 sprocket on the pocket wheel assembly is
in line with the 41A40 sprocket bolted to the barrel. Next, tighten the hoist-
locking bolts to lock the pocket wheel assembly to the shaft to prevent it from
shifting or rocking.
Hoist locking bolts must be tight to ensure hoist cannot shift
and permit roller chain to come off, thereby allowing door to
drop possibly causing severe injury or death.
Next, connect the #41 roller chain between the pocket wheel assembly sprocket and the barrel sprocket. Now run
the door up and down several times to ensure that the roller chain does not come off. If it does, go back and check
the alignment of the sprockets.
WARNING
WARNING
Keep loose clothing, fingers, hands, and arms away from all
moving mechanisms and places where chain meets either
sprocket, or serious injury or death could result.
STEP 12 INSTALL THE CHAIN KEEPER
10
Now install the hand chain keeper to the wall
approximately four feet above the finished floor with the
hardware provided. Refer to the figure in step #7 of this
manual for an additional view.

Roll-Up Sheet Door
LIMITED WARRANTY
Wayne-Dalton
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 by its 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 than Manufacturer’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,BUTNOTLIMITED TO,THE WARRANTY OFMERCHANTABILITY ORFITNESS FORPARTICULARPURPOSE),
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 material or 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, somestates donotallowlimitations 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
Door & Systems Division
2589 County Road 168
Dundee, OH 44624
1-800-795-5095
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