Wayne-dalton Firestar 540 User manual

Installation Instructions for FireStar®

Rolling Steel Fire Shutter

Models 540 and 550

Rolling Fire Doors may be mounted on openings in re walls of

masonry construction and non-masonry construction.

IMPORTANT NOTICE !!

READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO REMOVE EXISTING SHUTTER OR INSTALLING THIS SHUTTER. PAY

CLOSE ATTENTION TO ALL WARNING LABELS AND THE IMPORTANT SAFETY NOTICES ON THE FOLLOWING PAGE.

THIS MANUAL MUST BE ATTACHED TO THE WALL IN CLOSE PROXIMITY TO THE SHUTTER.

IMPORTANT SAFETY INSTRUCTIONS

Read the Installation Instructions/Owner’s Manual carefully before attempting installation. A trained rolling re door systems technician must

install this door or make any adjustments/repairs.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

3. Installation MUST comply fully with ALL provisions of NFPA 80 regulations and nal approval must be obtained from the authority having

jurisdiction. This is the installer’s responsibility.

4. Operate the door ONLY when it is properly adjusted and free of all obstructions.

5. The door is constantly under EXTREME SPRING TENSION. DO NOT attempt any adjustments, repairs, alterations or removal of any part of this

door, ESPECIALLY TO SPRINGS OR PARTS UNDER SPRING TENSION. Such work must ONLY be performed by a trained rolling re door systems

technician.

6. Do not allow children to play near the shutter. Children could get caught between the shutter and the oor or countertop, causing severe or

fatal injury.

7. To avoid possible severe or fatal injury, DO NOT stand in the open doorway or walk through the doorway while the shutter is moving.

8. Should the shutter become dicult to operate or completely inoperative, trained rolling re door systems technician should be contacted to

correct the problem to prevent possible injuries or door damage.

9. Visually check all bolted connections monthly to insure they are secure. Adjustments or repairs must ONLY be performed by a trained rolling

re door systems technician.

10. To prevent injuries, never place hands or ngers between curtain & guides while door is moving.

11. If the building design and door installation create potential pinch points to users, owner is responsible for the installation of appropriate

guarding, in compliance with OSHA regulations.

12. This manual is NOT intended to provide“take-down” instructions for existing door. Consult your local Wayne-Dalton dealer if existing door

needs to be removed.

13. Thoroughly familiarize yourself with the construction codes in your region before initiating work.

14. Wear proper protective safety gear at all times when installing, repairing and/or adjusting doors.

15. Use a multi-person crew for installing, adjusting and/or repairing larger shutters.

DANGER: Indicates an imminently hazardous situation which, if NOT avoided, will result in death or serious injury.

WARNING: Indicates a potentially 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 injury or property damage.

NOTE: Indicates important steps to be followed or important considerations.

IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS.

POTENTIAL

HAZARD EFFECT PREVENTION

MOVING DOOR

WARNING

Could result in death or

serious injury.

Keep people clear of opening while Door is moving.

Do NOT allow children to play with the Door Operator.

Do NOT operate a Door that jams or one that has a broken spring.

ELECTRICAL SHOCK

WARNING

Could result in death or

serious injury.

Turn OFF power before removing operator cover.

When replacing cover, make sure wires are not pinching or near moving parts.

Operator must be properly grounded.

HIGH SPRING TENSION

WARNING

Could result in death or

serious injury.

Do NOT try to remove, install, repair or adjust springs or anything to which door spring parts are fastened, such

as, wood blocks, steel brackets, cables or other like items.

Repairs and adjustments must be made by a trained door system technician using proper tools and instructions.

WARNING

THIS IS THE SAFETY ALERT SYMBOL. THIS SYMBOL ALERTS YOU TO POTENTIAL HAZARDS THAT CAN KILL OR HURT YOU AND OTHERS. ALL

SAFETY MESSAGES WILL FOLLOW THE SAFETY ALERT SYMBOL AND THE WORD “DANGER”, “WARNING”, OR “CAUTION”.

Introduction

This manual’s main function is to assist the installer in correctly mounting shutters with due regard for safety, operation, and sound construction practices. NFPA 80 and local

re and building codes take precedence with regard to any discrepancies among them.

All Wayne-Dalton FireStar Rolling Fire Shutters follow the general guidelines set forth herein. Additional installation information for each shutter shipped is found in

the packing slip and supplementary drawings. There are also bolt and small parts bags sealed separately with accessory lists describing which parts are to be in-

stalled.

PREPARATION

Read the installation instructions to become familiar with the names of the various components and their relation to each other. It is a necessity for the installer to

determine the following:

• The type of mounting (above lintel or under lintel).

• Method of operation (crank, motor, tube motor, or push-up).

• The hand of operation determined from the coil side (right or left).

• Type of jamb on which the shutter guides mount and the fasteners required.

• The dimensions for the opening width, opening height, head room, and side room.

MATERIAL

Inspect your shutter prior to leaving for job site for possible damage or shortage of parts. Report any claims or shortages to your door supplier immediately.

CLEARANCES

The installation drawings supplied in the hardware bag contain information on bracket size and head and side room for each shutter. Be sure that the dimensions are correct

for the opening you are working on. Take special note of the“C” dimension (Figure 4, p9). THIS DIMENSION MUST BE AS SPECIFIED IN ORDER TO PREVENT INTERFERENCE WITH

THE PROPER OPERATION OF THE SHUTTER WHILE BEING CLOSED. Measure and verify the required clearances shown on page 8 are available prior to installation.

WARNING

A POWER SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING

PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING TENSION.

REQUIRED TOOLS

Electric drill with 3/8” or 1/2” chuck Cable cutters and diagonal cutters Level and String level

Masonry drill or impact hammer and bits Screwdrivers Chalk line

Chain hoist and sling Hammer Plumb line

Ladders and scaolding Center punch Vice grips or C-Clamps

Wrenches Tape measure Leather gloves

Two hardened steel bars, 1/2” dia. and approx. 18” long. Step Ladder Safety glasses

SECTION 1  SUPPLIED PARTS LIST

MAJOR COMPONENTS AND ASSEMBLIES

AWNING CRANK WINDING SHAFT CURTAIN ASSEMBLY

BETWEEN JAMBS GUIDEFACE MOUNTED GUIDE

BOTTOM BAR ASSEMBLY BARREL ASSEMBLY

HOOD STRAPS

OPTIONAL AWNING

CRANK

BRACKET

HOUSING

LIFTUP/CRANK TOP

MOUNT OPPERATOR

BRACKET ASSEMBLY

LIFTUP/CRANK BOTTOM MOUNT

OPERATOR BRACKET ASSEMBLY

ADJUSTING

WHEEL

FRONT HOOD

ADJUSTING BRACKET

ASSEMBLY

TUBE MOTOR OPERATOR

BRACKET ASSEMBLY

BOTTOM

BAR STOP

CURTAIN

LOCK

LIFTUP/CRANK DROP

MECHANISM COMPONENTS

SECTION 2  SUPPLIED PARTS LIST

BRACKET ASSEMBLIES AND COMPONENTS

MASONRY

(THROUGH BOLTS REQUIRED)

DRYWALL OVER

WOOD STUD

MASONRY

(CONCRETE FILLED)

DRYWALL OVER

STEEL STUD

BRICK OR

CONCRETE

STEEL

CHANNEL

OPTIONAL FUSE LINK HOUSING

FUSIBLE LINK

AW PIN TEST HANDLE

FUSE CABLE

NICO PRESS

FITTING

COTTER PIN“S” HOOKTURNBUCKLE

SECTION 3  SUPPLIED PARTS LIST

BRACKET ASSEMBLIES AND COMPONENTS

TYPICAL JAMB TYPES:

STEP 1

OPENING CHECKS

Refer to Figure 3. Check the opening width“A” and the opening height “B” or “F” and compare

with the installation drawing to be sure the opening is the proper size for the shutter. Verify the

clearances available meet or exceed those given on the installation drawing.

Rope o the opening prior to beginning work!

Figure 3

STEP 2

GUIDE MOUNTING  FACE MOUNTED BRACKETS ABOVE LINTEL SHUTTERS SKIP TO “BETWEEN JAMBS....”SECTION FOR BRACKETS MOUNTED BELOW LINTEL

The inner and outer guides are factory assembled, but must be disassembled in order to be installed (See Figure #5A). Group the parts of each guide together as they are not

interchangeable.

Refer to Figure #4. To determine the location of the “bolt line” (BL) for the guide mounting bolts on the wall, rst locate and mark the center of the opening. Obtain the “C”

dimension from the installation drawing and subtract 1.75” for masonry jambs or 3” for steel jambs to determine the bolt line (BL).

“C” Dimension (from Dwg) __________________

- 1.75” (Masonry) or -3” (Steel)

Bolt line (BL) _____________________________

Divide BL in half (BL/2) and measure this distance either side of the opening center mark to obtain the bolt line on each

jamb. Drop a plumb line down and make a second mark on the wall at the bottom of each jamb. Using a chalk line, snap a

vertical line the length of the “F” dimension.

After determining guides are plumb, level and properly spaced, mark the location of the guide mounting slots on each

jamb.

NOTE: restar re shutters are designed to expand upward. For this reason, mounting bolts must be located at the top of

the slots.

IMPORTANT: THE GALVANIZED WASHERS MUST BE INSTALLED TO ENSURE PROPER GUIDE EXPANSION IN EVENT OF FIRE.

WARNING

GUIDE ASSEMBLIES ARE EXTREMELY HEAVY. TO AVOID POSSIBLE INJURY, PERSONS WITH LIFTING LIMITATIONS SHOULD NOT PERFORM THIS NEXT STEP.

Figure 4

WARNING

WELDING THE GUIDES TO THE JAMBS IS NOT ALLOWED DUE TO THE VERTICAL EXPANSION REQUIRED FOR THE

SHUTTER TO FUNCTION PROPERLY.

Remove the guides and drill the appropriate size mounting holes for the fasteners provided (listed as “Guides-to-Wall” on hardware shipping list). Locate them in the TOP of

the slot. Repeat this process for the remaining holes. Install top and bottom bolts in both guides with hardware provided. Check the “C” dimension and compare with the

installation drawing.

IMPORTANT: THE GUIDE TO GUIDE DISTANCE, OR “C” DIMENSION ON THE INSTALLATION DRAWING MUST BE AS SPECIFIED. (See Figure #4.)

Using a string and a level, ensure that the guides are parallel to each other, shimming if necessary to achieve vertical and horizontal leveling. Now install the remaining bolts.

IMPORTANT: THE FASTENERS SUPPLIED MEET ALL NFPA 80 REQUIREMENTS SET FORTH. USE OF ANY OTHER TYPE FASTENER MUST BE ON THE APPROVED SUBSTITUTION LIST

IN NFPA 80 AND CANNOT BE OF A LESSER DIAMETER.

Between Jambs (Brackets Under Lintel) Shutters:

The inner and outer guides are factory assembled, but must be disassembled in order to be installed.

Note that“pack-out” angles are also required, and are slotted to match the guides. Group the parts of

each guide together since they are handed and not interchangeable. Next, determine the location of the

“bolt line”(BL) for the guide mounting bolts on the wall. (Follow this procedure for either masonry or steel

jambs-see Figure #4.)

Choose one guide/packout angle to be used as a template. Temporarily clamp the assembly in the proper

jamb (i.e., left assembly in left jamb) at the exact location in the opening the shutter is to be mounted.

After determining that the guide outer channel is plumb, level and properly spaced into the opening,

carefully scribe the location of each packout angle mounting slot on the jamb. Repeat this procedure for

the opposite side making sure that the channel is located at exactly the same distance into the opening.

Remove the guide angle assembly and drill the appropriate size mounting holes for the fasteners

provided (listed as“Guides-to-Wall” on hardware shipping list). Locate them in the TOP of the slot. Repeat

this process for the remaining holes. It is a good practice to align a chalk line with the center of the top

and bottom slot, and snap a line to better locate the drill.

Install both the pack-out angle and outer guide angle together on each jamb starting with the top and

bottom bolts using the hardware provided. Using a string and a level, ensure that the guides are parallel

to each other, shimming if necessary to achieve vertical and horizontal leveling. Now install the remaining

bolts.

BOLT

GALVANIZED WASHER

MOUNTING BOLTS DEPENDENT

UPON JAMB CONDITION

LOCATE BOLTS IN

TOP OF SLOTS

PACKED OUT EXPLODED VIEW

LEFT HAND SHOWN

STEP 3

LOCATE HOOD STRAPS & FLAME BAFFLE

This Section Applies to Between Jambs (Brackets Under Lintel) Shutters Only:

(Skip to Step #4 if Shutter is “face mounted” i.e., brackets above lintel.)

If the brackets are “under lintel”, the mounting holes for the hood straps and ame bae must be drilled prior to erecting the barrel and curtain assembly. Temporarily attach

the brackets to the guides. (Refer to Figure 6A). Position each hood strap tightly against and ush with the front and bottom of each bracket as shown in Figure #6A. The back

of the hood strap should loop over the top and back side of the guide.

NOTE: A 1”TO 11/2” SPACE EXISTS BETWEEN THE TOP OF THE BRACKET AND THE BOTTOM OF THE LINTEL, SINCE FIRESTAR SHUTTERS ARE DESIGNED TO

EXPAND UPWARD SEE INSTALLATION DRAWING FOR EXACT DIMENSION.

Clamp the hood straps to the guides temporarily and use the straps as a template to scribe the location of the mounting holes under the lintel. Position the ame bae (if

provided) under the lintel as shown in Figure #6B with the hinge to the back and centered between the hood straps. A clearance of 1/8”should be held from edge of the

bae to the inside face of the hood straps (see Figure #6B). Check to see that the bae swings down freely and also will catch on the ame bae fuse (attached to the front

hood) which supports it. Mark the position under the lintel for three equidistant holes through the hinge. Remove the ame bae, hood straps, and brackets and drill the

marked holes in the lintel.

Figure 6A Figure 6B

STEP 4A

BARREL/BRACKET ASSEMBLY  MANUAL LIFTUP AND AWNING CRANK OPERATED.

Lay the barrel assembly in front of the opening. Note the sticker located on the barrel. This sticker will indicate the operated end, the direction the curtain uncoils to close the

shutter, and the spring turns required to balance the shutter. Slide the set collar, and then the thrush bearing, onto the push down shaft. Slide the brackets onto the barrel

shaft extensions and place the brackets on wood blocks. Install a cotter pin onto the barrel shaft extension (with the at) (do not install the adjusting wheel at this time).

Install the sprocket, ¼” shaft key, and snap ring onto the shaft. Locate the sprocket so that it contacts the snap ring, and tighten the set screws. Next, move the inner set collar

and thrust bearing (between the barrel and inside surface of the bracket) against the inside bearing race on the bracket, and tighten the set screws (prevents lateral barrel

shaft movement).

IMPORTANT: DETERMINE PROPER ORIENTATION OF

BARREL AS INDICATED BY STICKER ON BARREL

EXAMPLES BELOW.

Right Hand Sticker

Left Hand Sticker

WARNING

SPRINGS ARE CLOSER TO ONE SIDE OF BARREL ASSEMBLY, CAUSING THAT SIDE TO BE HEAVIER. BARREL ASSEMBLY WILL FALL IF LIFTED FROM CENTER. TO AVOID

POSSIBLE SEVERE OR FATAL INJURY, CAREFULLY DETERMINE BALANCE POINT, PRIOR TO LIFTING BARREL ASSEMBLY, TO PREVENT BARREL ASSEMBLY FROM FALLING.

WARNING

BRACKET ASSEMBLIES CAN BE HEAVY. TO AVOID POSSIBLE INJURY, PERSONS WITH LIFTING LIMITATIONS SHOULD NOT PERFORM THIS NEXT STEP.

STEP 4B

BARREL/BRACKET ASSEMBLY TUBE MOTOR OPERATED.

Install the operating bracket assembly while the barrel is

still resting on the wooden blocks.

STEP 4C

BARREL/BRACKET ASSEMBLY GCX MOTOR OPERATED.

Slide the brackets onto the barrel shaft extensions and place the brackets on wood blocks. The GCX operator will be installed after the barrel and brackets are secured to the

guides. (Step 10C).

STEP 5

ATTACHING BRACKETS TO GUIDES.

Determine the best method of lifting the barrel and brackets to prevent damage during installation.

WARNING

SECURE BRACKET TO BARREL ASSEMBLY USING SUPPLIED COTTER PIN, OR VISE GRIPS, TO PREVENT IT FROM SLIDING OFF DURING LIFTING. FAILURE TO SECURE

BRACKET TO BARREL ASSEMBLY COULD RESULT IN SEVERE OR FATAL INJURY.

CAUTION

ALL PARTS (EXCEPT KEYS) ARE DESIGNED FOR A SLIP FIT. FORCING PARTS TOGETHER MAY RESULT IN DAMAGE LEADING TO MALFUNCTION.

WARNING

BRACKET AND BARREL ASSEMBLY ON LARGER SHUTTERS, PARTICULARLY WITH AN OPERATOR, CAN BE EXTREMELY HEAVY. PERSONS WITH BACK PROBLEMS OR OTHER

PHYSICAL CONDITIONS WHICH MAY LIMIT THEM FROM LIFTING HEAVY OBJECTS SHOULD NOT PERFORM THE NEXT STEP. USE A MULTI-PERSON CREW OR LIFTING

EQUIPMENT SUCH AS A FORKLIFT WHEN APPROPRIATE.

LEFT HAND TUBE MOTOR OPERATED SHOWN

Lift the barrel and brackets to the bracket mounting holes provided on the channel shaped outer guide. Bolt the bracket and guides together, making sure the bracket is posi-

tioned inside the guide.

IMPORTANT: THE BOLT HEADS MUST BE ON THE INSIDE

(THREADED SECTION OUT) TO PREVENT INTERFERENCE

WITH THE OPERATION OF THE COIL.

STEP 6

ATTACHING CURTAIN.

Position the curtain assembly parallel with the door opening so that the top attachment slat is in front of the rest of the curtain (the hinged part

away from the opening).

Lift curtain assembly (centered between guide assemblies) and suspend approximately one foot below the barrel assembly, using ropes or straps of adequate strength to

safely support curtain assembly weight. Remove steel banding from around curtain assembly.

WARNING

SECURE BRACKETS TO BARREL ASSEMBLY TO PREVENT IT FROM SLIDING OFF DURING LIFTING, POSSIBLY CAUSING SEVERE OR FATAL INJURY.

CAUTION

Do not attempt to slide forks of lift truck directly between oor and curtain. Permanent door damage may result.

WARNING

CURTAIN MUST BE SECURELY ATTACHED TO LIFTING MECHANISM. OTHERWISE, CURTAIN COULD FALL CAUSING POSSIBLE SEVERE OR FATAL INJURY.

WARNING

BANDING IS UNDER TENSION. TO AVOID POSSIBLE INJURY, WEAR EYE PROTECTION AND DO NOT STAND IN FRONT OF BANDING WHEN CUTTING IT.

Rotate barrel assembly until top slat attachment point is accessible. Feed top slat around back side of barrel assembly until top slat is out in front of barrel assembly. Install the

top slat attachment bolts and nuts, verifying that the curtain is centered between the brackets.

Continue rolling the curtain up around the barrel assembly until the entire curtain is coiled onto the barrel assembly. Clamp or block the guide assembly approximately 6”

down from the top of the guides. Loosen the safety ropes enough to let the curtain feed into the guide grooves.

STEP 7

INSTALLING INNER GUIDE ASSEMBLY

With the curtain and barrel assembly (not shown for clarity) now mounted to the guides and secured to prevent curtain from dropping, proceed to install the inner guide

assembly. Position the bottom bar inside the channel shaped outer guides approximately 3”-4” below the top of the guide opening.

Install the bottom bar stops to the inner guides as shown in Detail‘B’.

Position the correct inner guide into the outer guide so that the inner angle holes line up with the outer guide slots. Attach the inner guide using the truss head bolts and

acorn nuts that were shipped installed in the guide assembly.

Repeat this procedure with the opposite guide assembly.

Install the slide lock strike tabs (if ordered with locks).

WARNING

NO TENSION HAS YET BEEN APPLIED TO DOOR. IF CURTAIN IS ALLOWED TO ROTATE AND FREE FALL, SEVERE OR FATAL INJURY COULD RESULT. KEEP THE CURTAIN

SECURE AND PREVENT FROM ROTATING.

STEP 8

APPLYING COUNTERBALANCE SPRING TENSION (MANUAL LIFT-UP, CRANK, AND GCX MOTOR OPERATION ONLY).

The amount of initial revolutions (IR’s) as indicated on the installation drawing and on the barrel“rev tag”is the THEORETICAL STARTING POINT for the required spring tension.

In most cases this gure is correct, but due to variations in steel, springs, friction, etc., slight adjustments may be required.

Install the adjusting wheel and cotter pin as shown. Using approved winding bar, rotate the adjusting wheel (AW) slightly in both directions to de-

termine the neutral point of the tension shaft. Insert the two winding bars securely into the holes in the AW as shown on page 18.

CAUTION

ALWAYS WIND COUNTERBALANCE SPRING TENSION WHEN THE SHUTTER IS IN THE UP POSITION. THE SPRINGS ARE UNDER THE LEAST AMOUNT OF TENSION AT THIS

POINT.

WARNING

VERIFY THAT AT THIS POINT, THE ADJUSTING WHEEL IS FREE AND THERE IS NO SPRING TENSION.

INNER GUIDE ASSEMBLY

DETAIL A

DETAIL B

IMPORTANT: TENSION IS APPLIED IN THE DIRECTION AS THE SHUTTER WOULD TURN AS IT COILS UPWARD OPPOSITE THE DIRECTION OF THE ARROW ON THE“REV

TAG”.

Hint: If conditions permit, use wall as brace for winding bar for a safe procedure of installing the AW pin as shown.

NOTE: Apply the initial revolutions (IR’s) marked on the rev tag and installation drawing. The IR’s are the required number of turns (of the spring) to hold the curtain in the

open position.

While holding the winding bar rmly in one hand, insert the AW pin with the other hand

through the lug in the bracket and into the hole in the AW to lock the AW at the specied

number of revs. Remove winding bars.

IMPORTANT: APPLY ONLY ENOUGH TENSION TO HOLD THE SHUTTER IN THE UP POSITION

AGAINST THE BOTTOM BAR STOPS. THIS IS THE OPTIMUM SETTING, AS TOO MUCH TENSION

COULD PREVENT THE SHUTTER FROM DROPPING WHEN THE RELEASE LEVER OR FUSIBLE LINK

IS ACTIVATED.

STEP 9

TESTING THE SHUTTER BALANCE (Manual Lift-Up, Crank, GCX Motor Operator Only)

With the adjusting wheel locked, operate the shutter through several cycles to check shutter balance. If the shutter does not balance properly and requires further spring

adjustment, repeat the procedure for“Applying Tension”to add or remove spring tension. Ideally, the shutter should have sucient spring tension to just allow the shutter to

stay up in the open position and no more.

WARNING

EXERCISE CAUTION WHEN APPLYING OR ADJUSTING SPRING TENSION. CONTACT WITH RAPIDLY ROTATING ADJUSTING WHEEL OR EXPELLED WINDING BAR CAN CAUSE

SERIOUS INJURY OR DEATH. USE TWO (NOT PROVIDED) WINDING BARS 1/2”DIAMETER STEEL ROD, MINIMUM 18 INCHES LONG.

CAUTION

INCREASING THE INITIAL TENSION WILL REDUCE THE LIFT EFFORT BUT CAN PREVENT AUTOMATIC CLOSURE WHEN REQUIRED TO DO SO UNDER ACTUAL FIRE

CONDITIONS. DO NOT OVERWIND.

STEP 10

LEVEL DOOR (IF NEEDED)—If during previous step the door rolled up level and straight, skip this step.

A. Check that guides are plum, square, level, and are properly mounted onto oor and wall.

B. Check that the pipe is level.

C. Check that the attachment of the curtain is straight on the pipe.

If all of the above is correct and the door still rolls up out of level, a shim may need to be added, as shown in

Figure 19.

Shim materials:

• A piece of rubber is the desired material for a shim.

• A piece of cardboard could be used but may deteriorate over time.

• Use a 1/8” x 6” x 6” thick piece of material and increase thickness or pieces depending on the result acquired,

as shown in Figure 20.

Application of shim:

• To determine the side in which the shim will be applied, the door will need to be in the open position.

• When facing the door, the bottom bar will be unleveled. The lower side of the bottom bar will be the side in

which the shim needs to be placed.

• The hood may need to be loosened or removed for the application of the shim.

To apply the shim, two laborers might be required.

Installing the shim:

D. Close the door fully.

E. When door is at bottom make sure door is in hand chain mode.

F. Turn o the power to the motor (if applicable) to ensure safe application of the shim.

G. Backwind the door using the chain. Lock chain in place using chain keeper.

H. As the curtain is wound backwards apply the shim to the lower side between the pipe and slats or on the

ring of the low side.

I. Restore power to the motor (if applicable).

J. Check the level of the bottom bar while door is in the open position. If it is not level, add a second shim and

check again.

NOTE: If the door has wind locks there may be some stacking interference in the wind locks as the door is

wrapping during operation. This is a normal characteristic. For wind lock applications the doors bottom bar

should be level at the open position.

WARNING

When the door is wound backwards there is a force in which the door will want to wind forward.

Secure the door in this position by locking hand chain onto chain keeper to prevent injury.

Bottom Bar Not Level

Figure 19

Shim

Curtain

RingPipe

Figure 20

STEP 11A

MANUAL LIFT-UP AND CRANK OPERATION: Installing the drop mechanism components.

IMPORTANT: STEP 8, WINDING THE COUNTERBALANCE SPRING, MUST BE COMPLETED PRIOR TO PERFORMING THESE NEXT STEPS. DOOR MUST BE IN FULLY CLOSED

POSITION FOR STEP 11A.

Install the clutch disks onto the 3/4” diameter shaft. Install the slotted sprocket, spacer, ¼” shaft key and ratchet tension wheel as shown. Fasten the cotter pin in the end of

the 3/4” shaft, to secure the components from moving laterally. Tighten all set screws on the door sprocket and inner set collar. Verify that the clutch disks rotate freely. Orient

the clutch disks and slotted sprocket as shown below:

STOPS ON CLUTCH DISKS (MUST BE ORIENTED AS SHOWN)

NUT (FACTORY INSTALLED ON SLOTTED SPROCKET)

ROTATE THE SLOTTED SPROCKET CLOCKWISE

(LOOKING AT END OF OPERATOR BRACKET)

UNTIL ALL THE NUTS ON THE TWO SPROCKETS

AND CLUTCH DISKS ARE IN CONTACT.

BRACKET SHOWN

CUT AWAY

NUT (FACTORY

INSTALLED

ON SPROCKET)

RIGHT HAND OPERATED

SLOTTED SPROCKET

Install the chain from the slotted sprocket to the idler sprocket, and if crank operated, install the chain from the drive sprocket on the awning crank to the door sprocket.

Adjust each chain so that there is 1/4” to 1/2” of

slack as shown for proper operation and automatic

closure functionality. The idler sprocket and chain

tension is adjustable by loosening the mounting

bolts on the opposite side. (If the idler sprocket

location is adjusted, the centrifugal clutch chain

tension will also require adjustment). Re-tighten all

bolts & nuts.

Now, the push-down spring (connected to the 3/4” diameter shaft) must be wound. The shutter must be in the CLOSED position. Install the test handle, fusible links, turn-

buckles and cable and attach to the release lever (per Step 11). Rotate the release lever upwards and secure it so that the ratchet tooth engages the tension wheel

NO CHAIN OR CRANK

FOR LIFT-UP DOOR

CHAIN INSTALLATION FOR LIFTUP AND CRANK DOORS

INSTALL CHAIN

IDLER SPROCKET

MOUNTING BOLTS

CENTRIFUGAL CLUTCH MOUNTING BOLTS

STOPS ON CLUTCH DISKS (MUST BE ORIENTED AS SHOWN)

NUT (FACTORY INSTALLED ON SLOTTED SPROCKET)

ROTATE THE SLOTTED SPROCKET COUNTERCLOCKWISE

(LOOKING AT END OF OPERATOR BRACKET)

UNTIL ALL THE NUTS ON THE TWO SPROCKETS