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Installation Manual - Doco insulated sectional garage doors

1. cd i gt _J m 180 kg max 13026 H 380 kg max 13027 75 165 4 10 7 Couplings The purpose of couplings is to create a connection between two shaft sections There are two types available namely fixed couplings and adjustable couplings Fixed coupling item 25017 item 25034 Adjustable coupling item 25042 UK V1 1 25 ofofdo Installation manual INTERNATIONAL 25017 Fixed Coupler 25034 Fixed Coupler 32 36 Nm 25042 Adjustable Coupler 32 36 Nm_ TEO TLT 25042 UK V1 1 26 Installation manual INTERNATIONAL 4 10 8 Torsion springs Individually calculated using Doco International DOOR PROCESSING computer programme Torsion springs are supplied in left handed and right handed versions A left handed spring can be identified as follows Follow the end of the spring back to its centre If it turns anti clockwise then it is a left handed spring If it goes in clockwise it is a right handed spring This is clarified in the figures below LWV RWV Springs are available in the following sizes diameter item series 50 8mm 2 1212 67mm 2 5 8 33 d 95 25mm 3 3 4 34 133 35mm 5 14 20 152 40mm 6 36 Checking the wire thickness a The best way is to count 10 windings b when untensi
2. 5 Commissioning This industrial gate should be commissioned by an experienced fitter Commissioning must be recorded in writing The person responsible for the installation should complete the certificate of conformity and affix the CE label Affixing the CE label certifies compliance with EN directives Affix CE lable bottom left or right to an end cover of the 2 section UK V1 1 43 ojJejdo Installation manual 6 Troubleshooting Check points for a defective unbalanced sectional gate Applicable to all lift systems Check 1 Check the weight of the door panel Check 2 Have the correct cable drums been supplied Check 3 Are the cable drums fitted correctly Check the following from inside to outside Left drum coded red and fitted on the left A Right drum coded black and fitted on the right sthe cable positioned in between construction wall and shaft Check the position of the cable going in Check 4 Check the correct torsion springs have been supplied and fitted Check the wire thickness Check the spring diameter Check the spring length excluding plugs and winders Check 5 When the door panel is closed there should not be too much friction The rollers should still turn Check 6 Are there any obstructions during opening closing of the door panel Check 7 Check the clearance between door panel and guide track it should be approx 30mm and the cable sh
3. i Electrically Operated Doors 150 mm 400 mm o For reduced sideroom requirements contact our technical department l 5 Q Inside 75min 75 nin 5 5 Notes 2 1 All internal faces must be flush and free from projections p o 2 The opening structure must be capable of withstanding S 5 all loads imposed by the door and fixings approx weight 8 o 25kg m2 5 5 3 Electrically operated doors require a 3 phase 400 volt 50hz with neutral 10 amp per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of Floor to be laid to fall away from door control panel and 0 9 to 1 7 metres above FFL to prevent water ingress at threshold FFL bll _ eu 1 y A Vertical Section nu Steelwork Elevation from Inside ote Specification For openings 6000 wide or above 75mm 100mm sideroom required wide jambs to be increased to 125 mm at jamb forcleardaor height for cable break Quantity of doors device clearance Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion ENS j e Stee DE Handing RH LH viewed from inside E gt pena Vision panels 85600 row of in panels o Over Wicket door Centrally located with cylinder lock lever handles and closer nih Inside 75mh Cable Break Device Yes No Electric Interlock Switch Yes No t Spring Break Device Yes N
4. 24620 14021 Lla 25016 25516 25018 4 10 3 Shafts Available shafts Hollow shaft with key way 25018 Solid black shaft 25016 Solid galvanized shaft 25516 4 10 4 Kevs The purpose of the key is to transmit drive power Depending on the selected shaft the correct key should be selected For the hollow shaft with key way 10 5 key height 25064 straight version 25073 bent version For the solid shaft 6 35 key height 25048 straight version 25062 bent version 6 35 10 5 UK V1 1 24 Installation manual 4 10 5 Spring break protection 25449 For detailed installation and maintenance instructions see Spring break protection manual 25449 4 10 6 Centre support consoles Centre support consoles are designed to give the shaft adequate support bearing so the shaft can turn freely without noticeable sagging General guideline 1 centre support console per 1 800mm bearing point PS spring break protections also count as bearing points Centre support consoles with fixed offset see figure on the right S 13013 offset 86 max load 130kg st 254 13014 offset 111 max load 120kg st 13015 offset 127 max load 110kg st de 13016 offset 152 max load 100kg st Offset Adjustable support console see figure below Max load 150kg each 1302 13025 13125 AISI 304
5. 0 300 kg use 4 braced track hangars 2 per track i 301 450 kg use 6 braced track hangars 3 per track lt 451 600 kg use 8 braced track hangars 4 per track E i Notes D Bracing bar bolted to tracks using bolis cleats provided 1 All internal faces must be flush and free from projections i i 2 The opening structure must be capable of withstanding Sideroom Details Plain Side Drive Side i imposed by the door and fixings approx weight Push Up Doors 150 mm 150 mm 3 Electrically operated doors require a 3 phase 400 volt 50hz with neutral 10 amp per phase supply Isolators Chain Operated Doors 150 mm 250 mm terminating with a 3 phase CEE socket within 0 5 metre of Electrically Operated Doors 150 mm 400 mm the control panel and 0 9 to 1 7 metres above FFL 9 a For reduced sideroom requirements contact our technical department 5 Inside 75min 75 nin Q Important Note T T g Track hangars should be no longer than 1000mm It is the installation g o m o e company s responsibility to ensure the adequacy of the support e framework and design for hangars in excess of 1000mm Floor to be laid to fall away from door to prevent water ingress at threshold FFL in Vertical Section Steelwork Elevation from Inside ime 100 sideroom required Specification Fo
6. control panel and 0 9 to 1 7 metres above FFL y Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door Ai se Inside Lhe oflntolover 75mh Op ingWid h Sectional Plan height for cable break device clearance Ll 75mn fkng fae widepom as tabe INTERNATIONAL part eoe Unit 4 The Metropolitan Centre 020 8813 2266 020 8813 2288 E sales doco international co uk Title Field Way Greenford Middlesex UB 8UN Ready To Fit Sectional Overhead Door High Lift With Pitched Tracks Customer Date Drawn By Site Drawing No Revision UK V1 1 11 Standard Drawing No 10007 v1 0 ofofdo INTERNATIONAL Installation manual 4 4 5 System drawing Vertical lift lt 3350mm 100 wide x 150 deep plate required for electrically operated doors fit RH or LH 1 as required DIL L1 jee E 2 9 p a als o E gp cio 5 E a 9 a E 3 Sideroom Details m o o Plain Side Drive Side 5 Push Up Doors 150 mm 150 mm E i Chain Operate
7. ofe do NTERNATIONAL Installation Manual Ready To Fit Overhead Sectional Doors Standard Lift High Lift Vertical Lift ojJejdo Installation manual Contents 1 Symbols and or warning signs 4 2 General 4 2 4 Safety requirements regarding installation and use 4 3 Directives and standards 5 3 Warranty and liability 5 4 Mounting 5 4 1 Application 5 4 1 1 Specifications 5 4 2 Scope of supply 6 4 3 Installation tools and accessories 7 4 4 Systems and system drawings I 4 4 1 System drawing Standard lift 8 9 4 4 2 System drawing Standard Lift Pitched Tracks 9 10 4 4 3 System drawing High Lift 1 4 4 4 System drawing High Lift Pitched Tracks 11 4 4 5 System drawing Vertical Lift 12 13 4 5 Installation details 14 4 6 General installation of vertical track sets 14 4 6 1 Standard lift 15 4 6 2 Standard lift pitched tracks 15 4 6 3 High lift 17 4 6 4 High Lift pitched tracks 18 4 6 5 Vertical lift FL 19 Connections between guide tracks and vertical angles 19 4 8 Drop down of the horizontal track set section 20 4 8 1 Track hangar requirements 20 4 9 Spring buffers 22 4 10 Spring set power unit 23 4 10 1 Configurations 23 4 10 2 Side bearing plates 24 4 10 3 Shafts 24 4 10 4 Keys 24 4 10 5 Spring break protection 25449 25 4 10 6 Centre support consoles 25 4 10 7 Coupling 25 4 10 8 Torsion springs 27 4 10 9 Cable drums 28 4 10 10 Spring set installation power unit
8. t Ta te Inside C Openng oflntolover udi 75min a Siderom a tale E E Sectional Plan epom as tabe fw INTERNATIONAL part Aver Unit K4 The Metropolitan Centre Field Way Greenford Middlesex UB6 8UN 020 8813 2266 020 8813 2288 sales doco international co uk Title Ready To Fit Sectional Overhead Door Vertical Lift For Openings Up To 6000mm High Customer Date Drawn By Site Drawing No Revision UK V1 1 13 Standard Drawing No 10010 v1 0 ojJejdo Installation manual 4 5 Installation details Make sure the opening for the track sets to be installed is level and that the construction is strong enough to carry the track sets p Ensure the floor is level and devoid of irregularities If not fill in H Before starting on the installation assess whether the mounting place fulfils the minimum requirements figurel W clear width H clear height a W z ha OH clearance above Z side clearance Fig 1 D installation depth Prior to commencing installation check that all components have been correctly supplied against the packing list bill of materials supplied located in hardware box supplied with door In the event of a discrepancy this must be reported to Doco International for
9. Clear zone for door e EMEN i i 2 degee IPE Pa mE 5 50 x 50 x 1000mm maximum long dexion hangars 0 300 kg use 4 braced track hangars 2 per track D 5 301 450 kg use 6 braced track hangars 3 per track g Di 2 451 600 kg use 8 braced track 4 per track 3 e 89 5 Bracing bar bolted to tracks using bolts cleats provided 2 e x Sideroom Details Plain Side Drive Side Push Up Doors 150 mm 150 mm I Chain Operated Doors 150 mm 250 mm Electrically Operated Doors 150 mm 400 mm X A Inside For reduced sideroom requirements contact our technical department 5 Important Note d Track hangars should be no longer than 1000mm It is the installation B company s responsibility to ensure the adequacy of the support framework and design for hangars in excess of 1000mm 8 Floor to be laid to fall away from door 1o prevent water ingress at threshold FFL Y ML For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm or Stucco Polyester Colour Push Up Chain Operated 3ph Electric Opertion RH LH 85600 Centra Yes No Yes No Spring Manua loaded shootbolt doors only fitted RH IS unless shown differently above viewed from inside row of in panels ly located with cylinder lock lever handles and closer Electric Interlock Switch Yes No
10. O 4999 Panel assembly using twin side hinges gt 5000 7000 A door width gt 5000 requires fitting twin side hinges double width end caps Doors gt 6000 require reinforcing profiles windbars on each panel See fig below UK V1 1 31 ofofdo Installation manual INTERNATIONAL Fit the cable break protection in accordance with Cable break protection manual 25450 or 25453 Cable break protection 25450 TUV certified up to 900 kg door weight Cable break protection 25453 TUV certified up to 450 kg door weight A Always ensure the rotation module with blade rotates freely at all times Fit the side hinges 5 and the centre hinges 8 holes for the centre hinges 8 are factory drilled See 4 11 1 for the correct 2 number of centre hinges Optional safe edge rubber version shown with bump stops 6 6 4 11 3 Intermediate section pre assembly Fit the side hinges 5 and the centre hinges 8 holes for the centre hinges 8 are factory drilled See 4 11 1 for the correct number of centre hinges 4 11 4 Positioning the bottom panel and intermediate sections Remove the cable break protection on one side A Position the roller without finger guard 25700 on the side of the cable break protection A Position the bottom section between the track angles Now fit the cable break protection including roller to the other side but without finger
11. 020 8813 2288 E sales doco international co uk Title Field Way Greenford Middlesex UB 8UN Ready To Fit Sectional Overhead Door High Lift Customer Date Drawn By Site Drawing No Revision 4 4 4 System drawin High lift with Standard itched back tracks Drawing No 10006 v1 0 Headroom Hoh lif Overal Trak Rojedion TP OH HL 70 250 min Clear zone for door Inside GlearO penng H ght O H Y Specification Quantity of doors Panel finish Operation Handing Vision panels Wicket door Cable Break Device Spring Break Device Locking Footstep Handle To preven FFL SA Vertical Section 50 x 50 x 1000mm maximum long dexion hangars 0 300 kg use 4 braced track hangars 2 per track 301 450 kg use 6 braced track hangars 3 per track 451 600 kg use 8 braced track hangars 4 per track Bracing bar bolted to tracks using bolts cleats provided Sideroom Details Plain Side Drive Side Push Up Doors 150mm 150 mm Chain Operated Doors 150mm 250 mm Electrically Operated Doors 150mm 400 mm For reduced sideroom requirements contact our technical department Important Note Track hangars should be no longer than 1000mm It is the installation company s responsibility to ensure the adequacy of the support framework and design for hangars in
12. 5 Spring Break Device Yes No Electric Interlock Switch Yes No Locking Spring loaded shootbolt X Electric Interlock Switch Yes No Sgeromn astabe CBar_Cpenng WEN z Heroomas table Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan D fe Unit 4 The Metropolitan Centre Title Customer Date Drawn By a s A Field Way Greenford Ready To Fit Sectional Overhead Middlesex UB 8UN P INTERN LETS O20 onda 0208n 13 D288 Door Standard Lift For Openings Drawing No Revision art of your Aver i ia sales doco international co uk Between 3601 and 5100 high UK V1 1 Standard Drawing No 10001 v1 0 ofefdo Installation manual INTERNATIONAL 4 4 1 System drawing Standard lift gt 5100mm high Overal Trak Rojedion 100 wide x 150 deep plate required for fa a electrically operated doors fit RH or LH as required awe Clear iu door e EN _ I _ _ i E gt E E rase E al 8 8 2 9 2degreesope _ amp 8 m 5 o T Q amp 8 8 50 x 50 x 1000mm maximum long dexion hangars
13. horizontal section comprises a track bend a stiffening profile c section These two sections are connected using a connection bracket See figure 5 Horizontal part 14023 2 14010 pF I Vertical part _ 14022 A 29 Li y 14010 Ge L Fig 5 UK V1 1 16 Installation manual 4 6 3 High lift HL A high lift system is characterized by the fact that when opened the door panel goes up first before it follows the horizontal section of the track The track set comprises 2 sections that are riveted bolted together For the correct connecting method see 4 7 Connections Installation The vertical section comprises the track angle with seal and guide track Assembly using 4 6 The horizontal section comprises a bend guide track and a stiffening profile c section These two sections are connected using a connection bracket See figure 4 Horizontal part Vertical part 14023 14010 Fig 6 UK V1 1 17 of ojgo Installation manual 4 6 4 High roofline lift HL pitched A high roofline system is characterized by the fact that the door panel first goes up vertically before it follows the horizontal section of the track set below the edge of the roof The track set comprises 2 sections that are riveted bolted together For the correct connecting meth
14. 29 4 11 Panels general 29 4 11 1 Hardware 30 4 11 2 Panel assembly 31 4 11 3 Intermediate sections 32 4 114 Positioning the bottom panel and intermediate sections 32 4 11 5 Positioning the top panel 33 4 12 Fitting the cable and positioning the cable drum 33 4 13 Tensioning the spring set 35 4 14 Correcting spring tension 35 4 15 Operation 36 4 15 1 operation manual operation 36 4 15 2 Chain operation 1 4 item 25025 36 37 4 15 3 Electric drive slip on motor and control 38 4 15 3 a Control Pulse control 38 4 15 3 b Control Dead man control 38 4 15 3 c Control Automatic or remote control 38 39 UK V1 1 2 ojJejdo Installation manual INTERNATIONAL 4 16 Options 40 4 16 1 Windows 40 4 16 2 Locks and bolts 41 4 16 2 1 Lock 25226 25228 4 4 16 3 Handles 43 5 Commissioning 43 6 Troubleshooting 44 7 Dismantling 45 7 1 Disposal 45 8 Appendices Appendix 1 Fixing vertical track sets 46 Appendix 2 Hardware panels 46 Appendix 5 EN 13241 1 classification 47 UK V1 1 3 This Installation Manual was written specifically for use by qualified personnel and is therefore not suitable for apprentices or DIY ers If anything regarding installation and or maintenance is not clear please contact Installation manual 1 Symbols and or warning signs General DANGER symbol ATTENTION symbol Carefully read the text when you see this symbol Carefully read the t
15. between guide tracks or track angles need to be fixed in such a way as to comply with EN 12424 wind force The guide tracks and or track angles are factory connected using rivets and or bolts UK V1 1 19 ofofdo Installation manual INTERNATIONAL 4 8 Drop down of the horizontal track set section The track hangars 1m long hangars max needed for mounting this track set to the roof construction are included in this fitting set The installer is responsible for ensuring that the structure is strong enough to carry the door The installer is responsible for supplying and installing the correct fixings for the structure brick concrete steel wood Once the vertical track set section has been mounted against the wall or construction the horizontal track set section can be mounted Paragraph 4 7 provided information about connecting the vertical and horizontal track set sections This paragraph gives information on how to fix the horizontal track set section to the roof construction A Position the horizontal track set section and fix it to the vertical track P set connection bracket n Support the end of the horizontal track set section by temporarily n hanging it from the roof construction using a rope see figure 9 Now fix the drop down track hangars to the horizontal track set section and then to the roof construction locating lock plates 24620 bolts and nuts 14021 14022 into c section on the back of the horizont
16. includes damage resulting from incorrect operation failure to follow the instructions in this manual and or poor maintenance and or care 4 Installation 4 1 Application DOCO International have developed Ready To Fit Doors designed for installation in industrial entrances exits to be used safely for vehicles and or people These doors contain the following features Steel hardware sets with front torsion springs fully balanced Compliance with the CE standard provided only International parts are used unless stated otherwise If the gate is switched to automatic or remote control extra measures need to be taken to guarantee safety See paragraph 4 16 3 c Control Automatic operation or via remote 4 1 1 Specifications Standard lift High lift 7 0m max width 7 0m max width 6 0m max height 6 0m max height Door surface 36m2 max High lift 4 1m max Weight 600kg max Door surface 36m2 max Installation area see system drawings Weight 600kg max Installation area see system drawings Vertical fitting 7 0m max width 6 0m max height Door surface 36m2 max Weight 600kg max Installation area see system drawings EN 13241 1 classification see appendix 5 This manual describes the installation of a sectional door using only DOCO International parts Any installation of parts not specified or other parts not described in this manual is the responsibility of the installer The installer is there
17. plate seat firmly against the top and bottom of the inner c section wall Now check the following the horizontal sections should be perpendicular to the door panel and or wall construction surface and X should be 90 degrees Measure C and D and ensure they are equal If not correct the angles Measure A and B and ensure they are equal If not correct the angles Your track set is now aligned see fig 12 C ta Fig 12 4 9 Spring bumpers Fix the spring bumpers using 2x 14021 bolts 24620 lock plates and 2 x 14022 nut The following spring bumpers may be used depending on track configuration refer to the bill of materials supplied with the door for the actual type used 25330 25326 universal short version unit C track or angle installation 253304 25341 universal short version unit C track or angle installation 25326 350 mm LN 25341 500 mm Qype Q N e 2533D0 When installed spring bumpers should be approximate 80 90 depressed for electrically operated doors and 50 depressed for manually operated doors when the door is in the fully open position adjustment to the spring bumper position may be required UK V1 1 22 Installation manual 4 10 Spring set spring assembl Depending on the size and weight of your sectional door the configuration of the spring assembly may look different Before starting the final installation we will first discuss
18. secure the cable by tightening the plain bolt not coloured red Then secure the cable drum including key onto the shaft by tightening the bolts red See 4 10 11 Once again Ensure the position of the left and right cable drum is the same and that the cable tension of both cables is equal UK V1 1 34 Installation manual 4 13 Tensioning the spring set Secure the door if necessary so it cannot rise for instance by fitting clamps to the vertical guide tracks Tension the springs according to the procedure below The number of turns for the spring is specified on the labels of the assembled spring and on he spring section of the bill of materials After tensioning secure the tensioning plug to the shaft using 27 to max 34Nm Procedure for tensioning a spring IMPORTANT Tensioned springs carry a high tension always be very careful especially when adjusting and make sure the tensioning rods 12025 are the right size and are well maintained 2 people minimum are required to tension springs Tension the springs from bottom to top Tensioning the spring will make it thinner and longer by the number of turns x wire thickness if this is not the case then the left and right springs have been swapped 1 Mark the spring by drawing a straight line 2 Insert the 1 tensioning rod into the tensioning plug 3 Turn the 1 tensioning rod a quarter turn in such a way as to tension the spri
19. the control panel and 0 9 to 1 7 metres above FFL framework and design for hangars in excess of 1000mm Floor to be laid to fall away from door 1o prevent water ingress at threshold FFL de _ fo 1 hee Vertical Section Steelwork Elevation from Inside Note For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm 100mm sideroom required at jamb for clear door Specification height for cable break r device clearance Quantity of doors Panel finish Plastisol or Stucco Polyester Colour _ M NDS E a ii Operation Push Up Chain Operated 3ph Electric Opertion a L lineof Intolover Handing RH LH viewed from inside ji Vision panels 85600 row of in panels Zn Inside nn Wicket door Centrally located with cylinder lock lever handles and closer Cable Break Device Yes No Electric Interlock Switch Yes No C bar Openhg With Spring Break Device Yes No Electric Interlock Switch Yes No Heroon asta amp Herpomas table Locking Spring loaded shootbolt X Electric Interlock Switch Yes No Footstep Handle Manual doors only fitted RH IS unless shown differently above sectional Flan fe Unit K4 The Metropolitan Centre Title Customer Date Drawn By 9 Field Way Greenford Ready To Fit Sectional Overhead INTERNATIONAL i aaa RUN Door Standard Lift For Openings
20. the various components needed to assemble the power unit First we will discuss the configurations followed by the various components 4 10 1 Configurations Shaft with one torsion spring Shaft with two torsion springs Shaft with four torsion springs Use the figures below to assess which is applicable to you Shaft with torsion spring Coupler optional dependant on width Shaft with two torsion 14 4 4 4 1 springs Coupler optional dependant on width Shaft with four torsion springs General description 1 p 3 4 5 6 Side bearing console Spring break protection units with or without offset plate Couplings fixed or adjustable supply dependant on door width Centre support consoles number required on door weight Right Wound Torsion Springs RHW Left Wound Torsion Springs LHW UK V1 1 23 Installation manual 13001 or 13025 25034 13013 13025 13026 27 25449 25042 13026 27 RHW LHW 13002 or 13025 13026 27 25448 4 25449 13003 or 13025 25017 or 2503413015 or 13025 P 13026 27 25448 25449 25042 13026 27 13004 or 13025 25017 or 25034 13016 or 13025 13026 27 25448 25449 br 25042 13026 27 13005 25448 25449 br 25042 13017 4 10 2 Side bearing plates Installation is carried out using lock plates 24620 with bolts 14021 and nuts 14022 14015 see figure X c7 ae 14022
21. to appendix 1 for diameter and number of fixings for vertical track sets UK V1 1 14 ofofdo Installation manual INTERNATIONAL OFESET For all systems The bottom offset depends on the cable break protection used see 4 12 3 For type 25450 OFFSET 40mm For type 25453 OFFSET 34mm 4 6 1 Standard lift system ST The standard lift system is distinguished by the fact that when opened the door panel immediately goes onto the horizontal section of the track set The track set comprises 2 sections that are riveted bolted together For the correct connecting method see 4 7 Connections Installation The vertical section comprises the track angle with seal and guide track The horizontal section comprises a track with bend and a stiffening profile c section These two sections are connected using a connection bracket See figure 4 Horizontal part Vertical part 4 6 2 Standard lift roofline system ST pitched A standard lift roofline system is identified by the fact that when opened the door panel immediately goes onto the horizontal section of the guide track under the roof The track set comprises 2 sections that are riveted bolted together For the correct connecting method see 4 7 Connections UK V1 1 15 INTERNATIONAL Installation manual Installation The vertical section comprises the track angle with seal and guide track Assembly using 4 6 The
22. 0 deep plate required for Clear zone for door electrically operated doors fit RH or LH as required m 1 B IF o 2 s E 5 BEN ues e 1 i 50x 50x 1000mm maximum long dexion hangars o 5 D 4 0 300 kg use 4 braced track hangars 2 per track 2 301 450 kg use 6 braced track hangars 3 per track 2 As S 3 451 600 kg use 8 braced track hangars 4 per track 1 Sideroom Details Plain Side Drive Side Push Up Doors 150 mm 150 mm Chain Operated Doors 150 mm 250 mm mE 1 All internal faces must be flush and free from projections 5 5 Electrically Operated Doors 150 mm 400 mm 2 The opening structure must be capable of withstanding Inside min ae 75 nin r T all loads imposed by the door and fixings approx weight p o For reduced sideroom requirements contact our technical department 25kg m2 5 3 Electrically operated doors require 3 phase 400 volt amp 8 Important Note 50hz with neutral 10 amp per phase supply Isolators g Track rangar should be no longer than 1000mm It is the installation terminating with a 3 phase CEE socket within 0 5 metre of 9 company s responsibility to ensure the adequacy of the support
23. Cable Break Device Yes No Electric Interlock Switch Yes No Spring Break Device Electric Interlock Switch S eroen astabb peiingWidth SHeroomas table Locking Spring loaded shootbolt X Electric Interlock Switch Yes No R Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan fe Unit K4 The Metropolitan Centre Title Customer Date Drawn By a 3 Field Way Greenford Ready To Fit Sectional Overhead INTERNATIONAL Sl Door Vertical Lift For Openings sie Drawing No Revision T 020 8813 2266 F 020 8813 2288 art of voar Apor i me Y E sales doco international co uk Up To 3350mm High Standard Drawing No 10008 v1 0 4 4 m drawing Vertical lif mm mm 100 wide x 150 deep plate required for electrically operated doors fit RH or LH as required at x s ay T S j i 8 9 eee n i we 8 SE iu o 8 o d Sr 9 T a 8 2 IS T 3 e Sideroom Details o o Plain Side Diive Side o Push Up Doors 150mm 150 mm 7 Chain Operated Doors 150 mm 250 mm To
24. Drawing No Revision of T 020 8813 2266 F 020 8813 2288 art ADE i Re nf E sales doco international co uk Up 3600mm High Standard Drawing No 10003 v1 0 UK V1 1 9 ofofdo INTERNATIONAL 4 4 2 System drawing Standard lift gt 3600 5100mm high with pitched back tracks O verallTrackPrgecton Bracing bar bolted to tracks using bolts cleats provided LA L 125mm 100 wide x 150 deep plate required for Cloorzona for door electrically operated doors fit RH or LH d as required D TTT 29 SS DI SS 5 eee D E E 8 E 50 x 50 x 1000mm maximum long dexion hangars 3 l 5 E 0 300 kg use 4 braced track hangars 2 per track 2 9 a 301 450 kg use 6 braced track hangars 3 per track o D 451 600 kg use 8 braced track hangars 4 per track 2 _ Y pee 9 4 Sideroom Details Plain Side Drive Side t 6 Push Up Doors 150 mm 150 mm Chain Operated Doors 150 mm 250 mm Notes 150 mm 400 mm 1 All internal faces must be flush and free from projections 5 Electrically Operated Doors 2 The opening structure must be capable of withstanding 2 Ine 1 all loads imposed
25. Electric Interlock Switch Yes No Electric Interlock Switch Yes No Sdgpom astab 100 wide x 150 deep plate required for electrically operated doors fit RH or LH as required Tr Y OTT nmm gt 7 7 m 4 e a me l o a B 5 2 2 I M 75min 75 T Notes T E 1 All internal faces must be flush and free from projections 2 The opening structure must be capable of withstanding all loads imposed by the door and fixings approx weight o 25kg m2 5 3 Electrically operated doors require a 3 phase 400 volt 50hz with neutral 10 amp per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of control panel and 0 9 to 1 7 metres above FFL 1 Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door height for cable break E FN FERRE SS 75 TES Inside oflntolover L 75mn Clear OpmingWidth e lt device clearance 2 li fkng face feram as take Sectional Plan ofe do INTERNATIONAL par Aver Unit K4 The Metropolitan Centre 020 8813 2266
26. Lock 25226 with black outer plate y 3x Lock 25228 with chrome outer plate Stroke approx 80mm Heavy duty version fitted to end cover Euro cylinder a Euro cylinder b Outer plate C Screws to fix outer plate d Lock screws don t undo Installation Screws coded D should NOT be undone 1 Install the lock at approx 850mm from the ground just above the side hinge of the bottom section 2 Using a jigsaw cut a 62mm hole in the panel and drill 1 1mm holes as in drawing Lock 25225 Shootbolt 25226 VL ow a al E 8 si Place the lock 1 in the hole cut at 2 TL and mark the fixing points using a iil marker pen Drill 4 5mm holes at these points UK V1 1 41 ofofdo Installation manual INTERNATIONAL 4 Attach the lock to the end cover using the 4 x No 2 Parker screws to 15Nm Then tighten the 1 x No 3 Parker screw to 10Nm 1 5 Fitthe outer plate to the outside and secure the outer plate to the lock using the crosshead screws 5 dr Sp lia LR Bi 6 Next drill two 210 holes in the L angle with guide track and remove the remaining material using a file as in the drawing 2 UK V1 1 42 D Q C c j Installation manual INTERNATIONAL 4 16 3 Handles Handle 25093 1 2
27. al extras Optional extras for installation Windows Locks bolts Handles 4 16 1 Windows DOCO windows have been approved in accordance with the EN 12600 standard of the EU and comply with Class 2 Approved windows 85101 PC rectangular click window black window size 680x370 cutting size 655x345 85102 ovalclick window black window size 725x325 cutting size 695x295 R70 85600 oval screw window black window size 665x345 cutting size 638x320 R100 85603 rectangular screw window black window size 637x332 cutting size 610x305 85606 PC rectangular screw window white window size 488x322 cutting size 466x300 85616 PC rectangular screw window black window size 488x322 cutting size 466x300 NOTE Depending on the model the window will either screw or click together and the spacer part may already be sealed to the outside frame Example Window 85606 Zaagmaat Cut out dimension Schneidemass Buitenframe Outside frame Rahmen Au enseite Schroeven A Screws Schrauben e Spacer met plastic glas Spacer with plastic glass Abstandhalter mit Glass Binnenframe Inside frame Rahmen Innenseite UK V1 1 40 ofofdo Installation manual INTERNATIONAL 4 16 2 Locks and bolts General Electrically operated doors may not be fitted with locks or bolts unless cut out switches are fitted 4 16 2 1 Lock 25226 25228 A Specifications gY
28. al tracks see figures 9 10 and 11 Detail A Detail A 4 8 1 Track hangar requirements 1 0 300kg use 4 braced track hangars fig 10 2 301 450kg use 6 braced track hangars fig 11 3 451 600kg use 8 braced track hangars fig 12 Fig 10 Detail A 301 450 kg 451 600 kg Fig 11 Fig 12 UK V1 1 20 ofofdo Installation manual INTERNATIONAL 4 8 1 Track hangar requirements continued 4 Ensure spring bumpers are fitted as 4 9 5 Recommended track hangar construction as detail A 6 Ensure that c section track bracing bar is fitted to prevent horizontal tracks from spreading Bracing bar should be fitted as shown in detail B These are fitted to the horizontal track c section using 2 no angle cleats 24621 lock plates 24620 bolts and nuts 14021 14023 14022 7 Use only M8 M10 bolts and nuts with steel quality 8 8 Rm 800 N mm2 min 8 For track hangars in excess of 1000mm it is the installation company s responsibility to ensure the adequacy of the support framework and design ees 1000mm max SU M10 nutlock ISO 10511 M10 8 8 8 nutlock ISO 10511 UK V1 1 21 Note ensure that all 24620 14021 lock plates and bolts are correctly fitted ensuring that after locating into the c section profile that the lock plate is turned clockwise the two shorter edges of the lock
29. allowed torque on the shaft 39 N mm The hand chain hoist 25025 comprises the following components Housing and transmission Hand chain approx 8 metres long Key Mounting bracket Chain holder Locking collar 2x Fixing bolt UK V1 1 36 ofofdo e rete Installation manual Fixing the hand chain hoist Ensure the chain runs freely in its housing Ensure the shaft protrudes 120mm minimum at the mounting side Slide one locking collar onto the shaft Slide the housing onto the shaft Fit the mounting bracket to the housing and then to the wall or end bearing plate using the cleat provided Fit the key Slide the other locking collar onto the shaft and secure both locking collars A Attach the chain locking cleat to the wall or construction at a height of approx 1200mm A Distance to bottom of chain approx 900mm f the chain 1 too short or too long it should be lengthened or shortened This is achieved by simply opening and closing a link Extra chain DOCO item 25020 1 Link DOCO item 25220 2 E XE h E LLL TID 1200 UK V1 1 37 ofofdo Installation manual INTERNATIONAL 4 15 3 Electric drive slip on motor and control Our fitting sets have been certified for the drives specified in the table below fitted with the specified safety bottom edges if specified Ins
30. by the door and fixings approx weight H4 gt E gt For reduced sideroom requirements contact our technical department T 92 99 9 9 T iE 25kg m2 3 Electrically operated doors require a 3 phase 400 volt o amp Important Note 5 Track hangars should be no longer than 1000mm It is the installation 50hz with neutral 10 amp per phase supply Isolators id 9 9 terminating with a 3 phase CEE socket within 0 5 metre of i ibili SOM AUS responsibility 1o ensure the adequacy of the support the control panel and 0 9 to 1 7 metres above FFL ramework and design for hangars in excess of 1000mm Floor to be laid to fall away from door 1o prevent water ingress at threshold FFL Loa __ Vertical Section Steelwork Elevation from Inside Note For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm M 100mm sideroom required Speisen at jamb for clear door height for cable break or doors device clearance Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion a Handing ile a 9 RH LH viewed from inside t ie oflirtol over Vision panels 85600 row of in panels Wicket door Centrally located with cylinder lock lever handles and closer hin Inside Z nin Cable Break Device Yes No Electri
31. c Interlock Switch Yes No pa Spring Break Device Yes No Electric Interlock Switch Yes No Locking Spring loaded shootbolt Electric Interlock Switch Yes No Aroomastazo eroomas table Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan fe Unit K4 The Metropolitan Centre Title Customer Date Drawn By OC o Feld Way Greenford Ready To Fit Sectional Overhead INTERNATIONAL Mede URG SUN Door Standard Lift For Openings sie Drowing No Revision 5 dai 020 8813 2266 020 8813 2288 3 pn door E sales doco international co uk Between 3601 and 5100 High Standard Drawing No 10004 v1 0 4 4 2 System drawing Standard lift gt 5100mm high with pitched back tracks Overall Track Propcton 250 min 100 wide x 150 deep plate required for electrically operated doors fit RH or LH Clear zone for door as required ue 5 c 2 E P 50x 50x 1000mm maximum long dexion hangars 5 5 8 Cal 0 300 kg use 4 braced track hangars 2 per track 9 E x 9 IN 8 lt 8 Y 1 na me c Sideroom Details Plain Side Driv
32. cally Operated Doors 150 mm 400 mm 2 The opening structure must be capable of withstanding 2 o Inside 75min ss 75 nin x all loads imposed by the door and fixings approx weight For reduced sideroom requirements contact our technical department lt 25kg m2 5 3 Electrically operated doors require a 3 phase 400 volt amp 8 Important Note 50hz with neutral 10 amp per phase supply Isolators E Track hangars should be no longer than 1000mm It is the installation terminating with a 3 phase socket within 0 5 metre of Oo company s responsibility to ensure the adequacy of the support the control panel and 0 9 to 1 7 metres above FFL framework and design for hangars in excess of 1000mm Floor to be laid to fall away from door to prevent water ingress at threshold FFL T Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door height for cable break r device clearance 75 nin ee Inside C Openng With ui Brin lineof Intolover Sieroon astabB Sectional Plan 5 table fh a INTERNATIONAL part rif your Aver Unit K4 The Metropolitan Centre Field Way Greenford Middlesex UB 8UN T 020 8813 2266 F 020 8813 2288 E sales doco international co uk Title Ready To Fit Sectional Overhead Doo
33. d Doors 150 mm 250 mm Electrically Operated Doors 150 mm 400 mm For reduced sideroom requirements contact our technical department Inside 75min 75 nin 5 Notes T 9 1 All internal faces must be flush and free from projections o E 4 c p 2 The opening structure must be capable of withstanding S all loads imposed by the door and fixings approx weight 8 25kg m2 9 3 Electrically operated doors require a 3 phase 400 volt 50hz with neutral 10 amp per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of Floor to be laid to fall away from door the control panel and 0 9 to 1 7 metres above FFL to prevent water ingress at threshold FFL uu Vertical Section NIS Steelwork Elevation from Inside Specification For openings 6000 wide or above 75mm M NARA at jamb for clear door wide jambs to be increased to 125 mm height for cable break Quantity of doors Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion zs cuc al x ali Handing RH LH viewed from inside c RS device clearance t Vision panels 85600 row of in panels lineof Intolover Wicket door Centrally located with cylinder lock lever handles and closer 5 nin Inside 75mh
34. de EN EM m Handing RH LH viewed from inside ie x icc lineof Intolover Vision panels 85600 row of in panels Wicket door Centrally located with cylinder lock lever handles and closer 75 nin Inside 75 nin Cable Break Device Yes No Electric Interlock Switch Yes No Spring Break Device Yes No Electric Interlock Switch Yes No C Openhg With Locking Spring loaded shootbolt Electric Interlock Switch Yes No Sdgroan_as tape amp Herpomas table Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan fe Unit K4 The Metropolitan Centre Title Customer Date Drawn By ojc loy Field Way Greenford Ready To Fit Sectional Overhead INTERNATIONAL OI Door Standard Lift For Openings Drawing No Revision abis 020 8813 2266 F 020 8813 2288 dr VO Jar J m sales doco international co uk Between 3601 and 5100 High UK V1 1 10 ofofdo INTERNATIONAL 4 4 3 System drawin High lift Overal TrackPojecton OH HL Specification Quantity of doors Panel finish Operation Handing Vision panels Wicket door Cable Break Device Spring Break Device Locking Footstep Handle Vertical Section Plastiso Note 250 min net 7
35. e Side R Push Up Doors 150 mm 150 mm Chain Operated Doors 150 mm 250 mm Notes 1 All internal faces must be flush and free from projections t 5 Electrically Operated Doors em 2 The opening structure must be capable of withstanding Inside Zmin demad dr um 75 nin I For reduced sideroom requirements contact our technical department T o OCOS IMPOR B 25kg m2 6 c x Important Note 8 a Has doors corti 1 o 5 Track hangars should be no longer than 1000mm It is the installation Ear oh Lee pe p 9 B DS terminating with a 3 phase CEE socket within 0 5 metre of company s responsibility to ensure the adequacy of the support 9 i A the control panel and 0 9 to 1 7 metres above FFL framework and design for hangars in excess of 1000mm Floor to be laid to fall away from door 1o prevent water ingress at threshold FFL Y _ liti o x kee Vertical Section Note Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door height for cable break Specification For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm Quantity of doors device clearance Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion i 2 E
36. excess of 1000mm Floor to be laid to fall away from door water ingress at threshold Note Above cbar opgheight OH HL TPx For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm Plastisol or Stucco Polyester Colour Push Up Chain Operated 3ph Electric Opertion RH LH viewed from inside 85600 row of in panels Centrally located with cylinder lock lever handles and closer Yes No Yes No Spring loaded shootbolt Electric Interlock Switch Yes No Yes No Electric Interlock Switch Electric Interlock Switch Yes No Manual doors only fitted RH IS unless shown differently above 5 tabe 100 wide x 150 deep plate required for electrically operated doors fit RH or LH as required 1 x inia 5 EI i 2 N l E o 5 2 8 2 c 2 a i R L 75mh 75mh Notes m 1 All internal faces must be flush and free from projections 2 The opening structure must be capable of withstanding 5 all loads imposed by the door and fixings approx weight amp 25kg m2 5 3 Electrically operated doors require a 3 phase 400 volt 5017 with neutral 10 amp per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of
37. ext when you see this symbol Symbol Risk of personal injury 2 General DOCO International To prevent serious personal injury all directions and instructions in this manual should be carefully read and observed This manual describes the installation of Ready To Fit Overhead Doors with torsion springs but it may be necessary to consult other installation manuals such as the one for the motor if fitted This Ready To Fit Overhead Door is designed in accordance with the latest European standards however you should check whether it complies with your local national standards A Adding or removing parts may have an adverse effect on the operation and thus the safety of the final sectional gate All instructions regarding handing right left installation are seen from the place of installation i e from the inside looking out A Unless stated otherwise all measurements are in millimetres A After installation check whether the CE mark has been affixed and completed This manual should be carefully stored Wereserve the right to modify specifications without written notice 2 1 Safety requirements regarding installation and use The Ready To Fit Overhead Door may only be installed connected and commisioned by skilled personnel When working on the electrics always ensure the power is and remains isolated Never bypass safety features Some parts have sharp edges use
38. fore responsible for the correct CE certification of the sectional door UK V1 1 5 m T V NORD CERT Installation manual International Limited has had the product testing of these doors carried out by the British Research Establishment in Watford United Kingdom registered as Notified Body No 1576 and the TUV North in Germany registered as Notified Body No 0032 This product testing does NOT include any wicket door If you DO install a wicket door additional product testing 15 needed This is the responsibility of the purchaser installer 4 2 Scope of supply The door supplied by us includes the following parts the details of which depend on the door dimensions and the type of lifting system Track set Vertical track set assembled Horizontal track set assembled Side seals Counterbalance assembly bearing plates Shaft Cable drums Steel cables Spring break protection devices Coupling Assembled torsion springs calculated for each individual door by our computer programme Hardware and panel related products Insulated door panels Cable break protection base console Side hinges Centre hinges covers Stiffening profiles dependant on width Rollers Aluminium bottom profile Aluminium top profile Bottom seal Top seal Spring bumpers Self tapping screws Back track hangars and track bracin
39. g bar Options Lock Handle A Chain hoist Drive and control unit Guthrie Douglas GFA Link Controls Kaba Garog Safety Bottom Edge Fraba set Fraba end stop set UK V1 1 6 4 3 Installation tools Here is a minimum list of the necessary tools Level hose Drill Battery drill Jigsaw Tensioning bars Flexible steel rule A Ratchet and cover 10mm 13mm Ring open ended spanner 10 11mm 12 13mm Gripper 2x A Blind rivet pliers A Ladder or scaffolding cherry picker scissor lift ron file A Allen keys Drill bits O9 210 Working gloves Safety goggles Safety boots Always wear safety goggles and gloves when drilling Use stable and safe ladders or scaffolding 4 4 Svstems and svstem drawings We use the following 5 systems lifts Standard system ST Standard roof line system ST pitch High system HL High roof line system HL pitch Vertical system VL The following pages feature system drawings for the systems mentioned UK V1 1 7 see 4 4 1 see 4 4 2 see 4 4 3 see 4 4 4 see 4 4 5 ofofdo INTERNATIONAL 4 4 1 System drawin Standard lift lt 3600mm high O verallTrackProbctbn Specification Quantity of doors Panel finish Operation Handing Vision panels Wicket door Cable Break Device Spr
40. guard 25700 Make the bottom section level see figure on the right A Position the intermediate sections 2 3 4 etc on top of the bottom sections and join them together using the hinges Adjust the rollers such that the nylon wheel runs in the curve of the track and that play between panel and side seal is minimal 24740 It should be possible to rotate the nylon roller wheel by hand See figure below right UK V1 1 32 ofofdo Installation manual INTERNATIONAL Pay attention to the installation of the finger guard 4 11 5 Positioning the top section Position the top section onto the intermediate sections and install the top roll holder 25005 in the correct position The correct position is determined by pressing the panel against the lintel seal Now take the top roll holder with roller including finger guard and measure the distance X Mark the positions for the Parker screws and secure See figures top roll holder 25005 shown Adjust the top roll by pressing the panel against the lintel seal and securing the screws in the roll holder Detail A 4 12 Fitting the cable and positioning the cable drum General Ensure the shaft is level A Fit the cable eye to the hook on the cable break device and feed the cable behind the roller shafts and up to the cable drum Slide the cable end through the cable fixing hole of the cable drum and ensure the position of the right and the left cab
41. ing Break Device Locking Footstep Handle Vertical Section Plastisol or Stucco Polyester Colour Push Up Chain Operated 3ph Electric Opertion RH LH viewed from inside 85600 row of in panels Centrally located with cylinder lock lever handles and closer Yes No Electric Interlock Switch Yes No Yes No Electric Interlock Switch Yes No Spring loaded shootbolt Electric Interlock Switch Yes No Manual doors only fitted RH IS unless shown differently above Note For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm Bracing bar bolted to tracks using bolts cleats provided 100 wide x 150 deep plate required for Clear zone for door electrically operated doors fit RH or LH as required 2 2 F z 2 2 FATE mm D a 50x 50x 1000mm maximum long dexion hangars 9 5 o E D 24 0 300 kg use 4 braced track hangars 2 per track 8 d 2 o 79 I o 301 450 kg use 6 braced track hangars 3 per track 2 9 3 451 600 kg use 8 braced track hangars 4 per track i X ZEE 1 c Sideroom Details Plain Side Drive Side E R Push Up Doors 150 mm 150 mm Chain Operated Doors 150 mm 250 mm pois _ 1 All internal faces must be flush and free from projections 5 Electri
42. itch Yes No Manual doors only fitted RH IS unless shown differently above as required ut Ar J T fi a e sp a Ne 1 l m 8 2 t 5 2 o 5 g E T Gi e to 5 o Sideroom Details 2 Plain Side Drive Side 8 Push Up Doors 150 mm 150 mm N Chain Operated Doors 150 mm 250 mm T Electrically Operated Doors 150 mm 400 mm 6 For reduced sideroom requirements contact our technical department l x Inside L 75mh 75mh t 5 9 1 All internal faces must be flush and free from projections E 2 2 The opening structure must be capable of withstanding B all loads imposed by the door and fixings approx weight 8 25kg m2 8 5 3 Electrically operated doors require a 3 phase 400 volt T 50hz with neutral 10 per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of Floor to be laid to fall away from door the control panel and 0 9 to 1 7 metres above FFL to prevent water ingress at threshold FFL pity _ l Y Note For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm x Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door height for cable break device clearance 75mn
43. le drum is the same When installing the cables ensure the cable tension for the right and left cable is the same UK V1 1 33 ofofdo Installation manual INTERNATIONAL Tensile strength Diameter Minimum break force Max door weight including 6 x safety 1770 N m 499 kg 166 kg max 1770 N m 887 kg 295 kg max 1770 N m 1390 kg 463 kg max 1770 N m 2000 kg 666 kg Determining the correct cable length To determine the exact point where the cable exits the drum when the sectional door is closed follow the procedure below Refer to Bill of materials Spring Department Look for cables and cable entry point Unroll the cable and measure from the bottom of the eye of the cable and mark the cables at the position given on the bill of materials Guide the cable through the cable break protection and behind the roller shafts to the cable drum slide the cable end through the cable fixing hole and through the cable entry on the end groove of the drum The mark on the cable should be at the point where the cable passes through the end groove of the drum The mark on the cable should be at the point where the cable passesthrough the end groove of the drum Ref TUV BB FTA MUC re sc 30604 torque doc 10 safety winding included within calculation which equals to 2 windings TUV approved A THIS ONLY APPLIES TO DOCO INTERNATIONAL CABLE DRUMS Pass slack cable through cable fixing hole and
44. le for processing the separated materials UK V1 1 45 DOO Installation manual INTERNATIONAL Appendix 1 Fixing vertical track sets Mi M10 lt Me Me ma LL me me ms Appendix 2 Hardware Panels B0612L 610 B0612L 610 B0612L 610 UK V1 1 46 D Q C c j Installation manual INTERNATIONAL Appendix 3 EN 13241 1 Classification Figures are given for guidance only for specific contract figures please contact our technical department in accordance with EN 12426 in accordance with EN 12425 in accordance with EN 12424 in accordance with EN 13241 1 appendix B EN 12428 door panel 3500 x 3000 UK V1 1 47
45. mm 728 kg Vertical lift 11009 3350 mm 386 kg Vertical lift 11010 5559 mm M 600 kg 5 mm 127 mm Vertical lift 11012 8534 mm Doe 1000 kg UK V1 1 28 ojJejdo Installation manual 4 10 10 Spring set assembly spring assembly Assemble the shafts on the ground as in 4 10 1 Slide the assembled shaft half 1 into the bearing of the side console and cable drum cable drum bolts facing the spring see detail A Slide the RHW spring onto shaft 1 and fit the spring break protection console to the stationary plug For detailed installation and maintenance instructions see Spring break protection manual 25449 Slide the end bearing plate onto the shaft Repeat for shaft 2 and fit both shaft halves together using the coupling Use SUITABLE plugs screws or bolts nuts for fixing to the building structure Use plugs of 8 or 10mm with hexagonal screws for wall mounting Use a minimum of M10 bolts and nuts for mounting to a steel construction not included a 1 35D MAX 350 MAX i i TC a Il L En 5 4 11 Panels general In general when using sandwich panels steel plates with PUR foam 4 0mm holes are drilled The complete door panel includi
46. ng 4 Hold the 1 tensioning rod secure and now position the 2 tensioning rod in the next hole of the tensioning plug 5 Turn the 2 tensioning rod a quarter turn 6 Hold the 2 tensioning rod secure taking over the tension and remove the 1 tensioning rod 7 Repeat step 3 4 5 6 until the correct tension is reached 8 Insert the steel key 9 Secure the tensioning plug to the shaft by tightening the bolts in the tensioning plug to 27 34Nm 10 Now remove the last tensioning rod 11 Now check the number of turns by counting the number of lines on the spring Remove the block on the shaft and vertical guide tracks and your sectional door is finished Ensure the door is properly balanced If not follow the instructions in 4 15 correcting the spring tension 4 14 Correcting the spring tension Block the shaft and the door panel Secure the door if necessary so it cannot rise for instance by fitting clamps to the vertical guide tracks IMPORTANT Tensioned springs carry a high tension always be very careful especially when adjusting and make use of the right size and well maintained tensioning rods 12025 2 people minimum are required to tension springs The maximum adjustment to the springs is 1 turn per spring Ensure both springs are adjusted equally 1 Insert the 1 tensioning rod in the tensioning plug 2 Turn the tensioning rod in the desired direction 3 Carefully undo the bolts in the tensi
47. ng aluminium profiles and bottom seal stop should comply with the following measurements W 40 UK V1 1 oodo installation manual INTERNATIONAL 4 11 1 Hardware The bottom of each panel is pre drilled to receive hinges in accordance with the following table The top of the panel is site drilled using the intermediate hinges screwed to the bottom of each panel as a template The recommended maximum torque for the various parts is detailed in table 2 Table 1 Table 2 Door width Number of centre hinges Metal screw Item 14017 0 2749 Bottom console 2749 3999 3999 4999 5000 5999 6000 7000 Side hinge Centre hinge Top roll holder Roller selection Door panel weight 15 kg m2 Door panel width 5000mm selection 25010 E Door panel weight 15 kg m2 Door panel width gt 5000 7000mm selection 2501 1 E Finger guards 25700 are fitted to each roller to a height of 2500mm except at cable break protection units 8 supplied per door Note the position of the roller with finger guard in the track Parts marked A should be positioned in the guide section of the track UK V1 1 30 ofofdo Installation manual 4 11 2 Panel assembl A door width of lt 4999 requires the use of single side hinges and end caps you don t need to use stiffening profiles Unless specified to meet an agreed wind load class Panel assembly using single side hinges up to doors 4999
48. o Electric Interlock Switch Yes No asta Clear OpeiingWidth Sileroomas tapje Locking Spring loaded shootbolt Electric Interlock Switch Yes No E t Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan Unit K4 The Metropolitan Centre Title Customer Date Drawn By Field Way Greenford Ready To Fit Sectional Overhead Middlesex UB 8UN 020 8813 2266 020 8813 2288 E sales doco international co uk Door Vertical Lift For Openings Drawing No Revision Up To 5500mm High part nf yar Ar Standard Drawing No 10009 v1 0 UK V1 1 12 ofofdo INTERNATIONAL 4 4 5 System drawing Vertical lift gt 5500mm lt 6000mm 100 wide x 150 deep plate required for electrically operated doors fit RH or LH Specification Quantity of doors Panel finish Operation Handing Vision panels Wicket door Cable Break Device Spring Break Device Locking Footstep Handle Vertical Section Plastisol or Stucco Polyester Colour Push Up Chain Operated 3ph Electric Opertion RH LH viewed from inside 85600 row of in panels Centrally located with cylinder lock lever handles and closer Yes No Electric Interlock Switch Yes No Yes No Electric Interlock Switch Yes No Spring loaded shootbolt X Electric Interlock Sw
49. od see 4 7 Connections Installation The vertical section comprises the track angle with seal and guide track Assembly using 4 6 The horizontal section comprises a bend guide track and a stiffening profile c section These two sections are connected using a connection bracket See figure 7 Horizontal part 14023 14010 fi fl Vertical part 14022 M T M 14010 gu Fig 7 UK V1 1 18 Installation manual 4 6 5 Vertical lift VL A vertical system is characterized by the fact that the door panel goes up vertically The track set only comprises 1 section that is riveted and bolted together For the correct connecting method see 4 7 Connections Installation The vertical section comprises the track angle with seal and guide track Assembly using 4 6 Depending on the height of this system it may be necessary to interconnect the track angles and guide tracks Joint type is used however joint type A may be used dependant on the top track offset required these joints are factory made see fig 8 4 7 Connections between guide tracks and vertical angles For connections between track angle and opening structure see 3 3 General installation of vertical track sets To make sure the track is stable the connections between guide tracks track angle or inter connections
50. oned and measure them Then divide this measured value by 10 the result a gives you the thickness of the wire See figure below Stationary Plug Winding Plug Manufactured torsion springs should be identified by a label attached to it This label will state the following left or right handed spring spring diameter d wire thickness wd Spring length L number of windings of the spring turns order number sectional door dimensions DMW x DMH your reference number see label UK V1 1 27 Installation manual 4 10 9 Cable drums A I Cable drums are based on 0 5 safety windings Equal to 2 windings SUD approved Ref TUV BB FTA MUC re sc 30604 Besch torque doc Cable drum Standard lift Shaft fixing red Screw 3 8 16 UNC Torque 27 34 Nm Socket wrench 7 16 Cable fixing blank Screw 3 8 16 UNC Torque 13 Nm Socket wrench 7 16 Cable drum high lift Shaft fixing red Screw 3 8 16 UNC Torque 27 34 Nm Socket wrench 7 16 Cable fixing blank Screw 3 8 16 UNC Torque 13 Nm Socket wrench 7 16 Cable drum vertical lift Shaft fixing red Screw 3 8 16 UNC Torque 27 34 Nm Socket wrench 7 16 Cable fixing blank Screw 3 8 16 UNC Torque 13 Nm Socket wrench 7 16 Standard 11002 5100 mm gt 680 kg 5 mm 86 mm High lift 11008 9755 HL mm 3050mm 1000 kg High lift 11004 14148 HL mm 4165
51. oning head and take over the spring tension 4 Remove the steel key 5 Hold the 1 tensioning rod secure and now position the 2 tensioning rod in the next hole of the tensioning plug 6 Turn the 2 tensioning rod a quarter turn in the desired direction 7 Hold the 2 tensioning rod secure taking over the tension and remove the 1 tensioning rod 8 Repeat step 4 5 6 until the desired tension is reached 9 Insert the steel key 10 Secure the tensioning plug to the shaft by tightening the bolts in the tensioning plug to 27 34Nm 11 Now remove the last tensioning rod UK V1 1 35 ofofdo Installation manual INTERNATIONAL Remove the block on the shaft and vertical guide tracks and your sectional door is finished 4 15 Operation The sectional door may be operated using the following methods 1 Pull chain operation manual operation 2 Chain operation 1 4 3 Hlectric drive slip on motor and control a Control pulse operation b Control dead man operation c Control automatic or remote operation 4 15 1 Chain pull operation manual operation Attach the chain to the cable break protection and to a point approx 1600mm from the bottom of the guide angle Rope length door height 1000mm 4 15 2 Chain operating 1 4 item 25025 The hand chain hoist 25025 may not be used for doors heavier then 600kg provided the sectional door is perfectly balanced Maximum allowed pulling force 16 kg Maximum
52. ould run freely Check 8 Are the guide tracks parallel in both vertical and horizontal direction Measure distance and height Additional to high and vertical lift systems Check 9 Check the cable exit point at the drum For high lift systems this should be checked by tracing the course of the cable As soon as the first roller goes round the bend the cable should be at the flat section of the cable drum also see 4 13 UK V1 1 44 ojJejdo Installation manual 7 Dismantling CAUTION DANGER Dismantling should only be performed by qualified installation disassembly personnel Ensure only installation dismantling personnel are present within the work area and keep others away if necessary by using appropriate barriers and safety devices Ensure no electric components are live Ensure adequate light when disassembling Especially when releasing the springs ensure the use of correct tools and stable footing A For details and drawings of the various parts to be dismantled please refer to the installation instructions in this manual Procedure Step 1 Release the torsion springs IMPORTANT Tensioned springs carry a high tension always be very careful and use the right size and well maintained tensioning rods 12025 2 people minimum are required to tension springs 1 Insert the 1 tensioning rod into the tensioning plug 2 Carefully undo the bolts in the tensioning plug and
53. ove clearopg heght 100 wide x 150 deep plate required for electrically operated doors fit RH or LH as required an m gt c ES 8 9 2 S S D i E Notes o 1 All internal faces must be flush and free from projections 2 The opening structure must be capable of withstanding all loads imposed by the door and fixings approx weight 25kg m2 3 Electrically operated doors require a 3 phase 400 volt 50hz with neutral 10 amp per phase supply Isolators terminating with a 3 phase CEE socket within 0 5 metre of control panel 0 9 to 1 7 metres above FFL 5 5 75min 75 nin E T I 8 5 2 Steelwork Elevation from Inside 100mm sideroom required at jamb for clear door height for cable break n EE L device clearance Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion c Handing RH LH viewed from inside B B Vision panels 85600 row of in panels 7 lineof Intolover Wicket door Centrally located with cylinder lock lever handles and closer Inside Cable Break Device Yes No Electric Interlock Switch Yes No 5
54. r Standard Lift For Openings Up To 3600mm High Customer Date Drawn By Drawing No Revision 4 4 1 System drawin Standard lift gt 3600 lt 5100mm high Standard Drawing No 10003 v1 0 Overal Trak Rojedion Specification Quantity of doors Vertical Section 500 min h n E o 3 Clear zone for door 2 294 Sezione i edili Siusi E 9 n uo 2degreesope _ 50 x 50 x 1000mm maximum long dexion hangars 8 0 300 kg use 4 braced track hangars 2 per track f 301 450 kg use 6 braced track hangars 3 per track 451 600 kg use 8 braced track hangars 4 per track Bracing bar bolted to tracks using bolts cleats provided Sideroom Details Plain Side Drive Side Push Up Doors 150mm 150 mm Chain Operated Doors 150mm 250 mm Electrically Operated Doors 150mm 400 mm E For reduced sideroom requirements contact our technical department Inside 8 Important Note 5 Track hangars should be no longer than 1000mm It is the installation company s responsibility to ensure the adequacy of the support framework and design for hangars in excess of 1000mm Floor to be laid to fall away from door 1o prevent water ingress at threshold FFL i Note For openings 6000 wide or above 75mm wide jambs to be increased to 125 mm Ab
55. r openings 6000 wide or above 75mm at jamb for clear door wide jambs to be increased to 125 mm height for cable break Quantity of doors FP device clearance Panel finish Plastisol or Stucco Polyester Colour Operation Push Up Chain Operated 3ph Electric Opertion ui Handing RH LH viewed from inside bc 7 Vision panels 85600 row of in panels lineof Intolover Wicket door Centrally located with cylinder lock lever handles and closer 8 Inside oin Cable Break Device Yes No Electric Interlock Switch Yes No Em Spring Break Device Yes No Electric Interlock Switch Yes No ideroan astab C bar Openhg With SHeroomas table Locking Spring loaded shootbolt Electric Interlock Switch Yes No Tene Footstep Handle Manual doors only fitted RH IS unless shown differently above Sectional Plan J fe Unit K4 The Metropolitan Centre Title Customer Date Drawn By ua 1 Field Way Greenford Ready To Fit Sectional Overhead INTERNATIONAL Door Standard Lift For Openings sic Drawing No Revision T 020 8813 2266 F 020 8813 2288 gt dn vae eon pars ef i eom E sales doco international co uk Above 5101 High Standard Drawing No 10002 v1 0 4 4 2 System drawing Standard lift lt 3600mm high with pitched back tracks Overall Track Propcton Bracing bar bolted to tracks using bolts cleats provided E A 250 min 100 wide x 15
56. remedial action prior to installation of the door 4 6 General installation of vertical track sets Mark line 1 on the wall Then draw line 2 using a spirit level Then add markings 3 and 4 for the bottom alignment 1 2 Mount the side seal to the already assembled vertical track set and if necessary cut to size Mount both vertical track set sections against the wall or construction 3 4 ensuring they are level at point 3 and 4 Make sure they run parallel and are level in both directions See figures 2 and 3 Ensure both track angles are parallel and at right angles with line 3 4 Fig 2 Dimension E fig 3 depends on the cable break protection used Cable break protection 25450 E 75 PT E Cable break protection 25453 E265 24740 Fixings for vertical track sets The fixings needed for mounting the track set to the wall or construction are not included with the door The installer is responsible for ensuring that the opening structure 15 structurally strong enough to carry the door The installer is also responsible for the correct fixings for the relevant structure brick concrete steel wood The value used for measurement depends on the wind load class and door size Fig 3 If class 2 620 Pa N m break load If class 3 965 Pa N m break load If class 4 1375 Pa N m break load Example door size 5000x4000 20m Wind load class 3 Force against door panel 20 620 193003 Refer
57. safety gloves Never operate the sectional gate if you see that the safety features are damaged During installation maintenance of the door wear at least gloves safety shoes and when drilling safety goggles Always ensure a stable footing when working Secure the installation maintenance area using appropriate safety devices to keep others at a distance Maintenance should only be performed by a specialist firm and or qualified personnel Provide adequate lighting Only use suitable tools especially for tensioning torsion springs UK V1 1 4 Installation manual INTERNATIONAL 3 Directives and standards The following directives and standards were used during the design production and installation of these tracks 98 37 EEC Machine Directive 9 106 EEC Construction Equipment Directive 89 336 Directive 73 23 EEC Low Voltage Directive EN 12604 2000 Mechanical aspects requirements and classification EN 12605 2000 Mechanical aspects testing methods EN 12445 2000 Safety for powered gates testing methods EN 12453 2000 Safety for powered gates requirements EN 13241 1 2003 Door and gate product standard 3 1 Warranty and liability Unprofessional installation unauthorized alterations other parts to the door or alterations to the drive that are not in compliance with this manual will invalidate the warranty and thus will release the manufacturers from any liability This also
58. take over the spring tension 3 Remove the steel key 4 Keep good grip on the 1 tensioning rod and carefully undo the bolts on the tensioning plug and transfer the spring tension 5 Now place the 24 tensioning rod in the next hole of the tensioning plug and carefully release the spring The spring is released from top to bottom 6 Again fit the 1 tensioning rod to the tensioning plug and release 7 Repeat steps 3 4 until the spring is released 8 Repeat steps 1 4 for the other spring springs Step 2 Remove the drive following the drive supplier s instructions Step 3 Undo the bolts in the cable drums and remove the steel cables from the cable drums Be careful for any residual tension the cables check the cables are slack Step 4 Remove the spring assembly Do this by first removing the coupling and then carefully sliding both shaft halves out of the bearing plates Be aware that components may slide along the shaft Step 5 Remove the panel sections from top to bottom Achieve this by removing the roller holders and centre hinges Step 6 Remove the horizontal section of the track set including the ceiling brackets Step 7 Remove the vertical track set section 7 1 Disposal parts of this industrial gate can be easily identified and recycled Separate the parts after dismantling Note Materials can only be recycled if they are returned separately Deliver the materials to the relevant body responsib
59. tallation of electric drive and control The installation of the electric drive and control must be carried out in accordance with the installation manual provided by the supplier of the electric drive and control Ensure the shaft protrudes approx 150mm at the electric drive side Then fit the slip on motor support plate and slide the slip on motor onto the shaft and fit the key supplied 4 15 3 a Control Pulse control GFASE GFA nr 30002685 This control performs one complete opening and closing movement of the door panel Always make sure you can see the door panel when using this control 4 15 3 b Control Dead man control This control will only operate the door panel as long as the activating button is pressed As soon as the activating button 1s released the door panel stops 4 15 3 c Control Automatic operation or via remote This control can be used to operate the door panel without having the door panel in sight If the control is switched this way or is changed to this mode later an optical safety bottom edge should be fitted together with a photoelectric cell This can be a reflection type or a one way photoelectric cell protection It should be positioned no more than 200mm from the door and no more than 300mm from the ground inside UK V1 1 38 ofofdo Installation manual INTERNATIONAL max 200 mm max 300 mm UK V1 1 39 ofofdo Installation manual INTERNATIONAL 4 16 Option

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