INSTALLATION & MAINTENANCE - Clopay Doorcdn.clopay.com/public/documents/103001-rev00 (801-802... · 2014-04-23 · Thank you again for choosing Clopay! Sincerely, ... • The brackets

INSTALLATION & MAINTENANCE Commercial Security & Screen Doors

Model: _______________ Serial No. __________________ Size: ____________________ (Provided on label on interior door surface)

Retain This Booklet For Future Reference This Manual Contains Important Safety Information

COMMERCIAL HOTLINE 1-800-526-4301

© Clopay Building Products Company, Inc. 2003 2

Table of Contents Safety Information .......................................................................... 3

Before You Begin ........................................................................... 5

Items Included ................................................................................. 5

Installation Procedure...................................................................... 6

Dual-Track Configuration......................................................... 6

Single-Track Configuration ...................................................... 7

Upper-Track Installation .......................................................... 8

Hardware Attachment.............................................................. 9

Counter-Balance System Installation....................................... 10

Finishing Up ............................................................................ 16

Dear Clopay Customer, Thank you for purchasing a Clopay Door. Your new Clopay Door was built to meet the highest industry standard and to provide you with years of dependable performance. This manual contains important safety, installation and maintenance instructions. Carefully follow the instructions and maintenance recommendations. Please keep this manual for future reference. If you should require any assistance or additional information, please call Clopay at 1-800-526-4301. Thank you again for choosing Clopay! Sincerely, Clopay Building Products Company


SAFETY INFORMATION

In the interest of safety this symbol means WARNING or CAUTION. Personal injury and/or property damage may occur unless instructions are followed carefully.

Commercial Security and Screen Doors are designed to work in conjunction with a sectional garage door AND share a single opening by either dual or single-track system.

The installation of this door system requires a working knowledge of overhead sectional door systems and should be performed only by a qualified door installer. Installation of this system will require alterations to the sectional overhead door track. • You can install your new Clopay security or screen door IF…

1. You have help (weight can vary from 150 lbs. up to 1,000 lbs.); 2. You have the right tools and reasonable mechanical aptitude or experience; and 3. You follow these instructions very carefully.

In particular, please note that:

• Security and screen door systems use torsion springs to balance them. Springs, cables, and

mounting fixtures are under strong spring tension. Do not attempt to loosen any fasteners on these components. You could suddenly release spring forces and risk severe injury.

• The brackets at the bottom corners of your garage door are under great tension. Do not attempt to loosen any bracket fasteners and/or any red-colored fasteners except when and as directed in

detail in the following instructions. Otherwise, the bracket could spring out with dangerous force. • When installing a door with torsion springs, always use solid steel winding bars. The use of

screwdrivers or any substitutes for winding bars will risk severe injury. • Keep hands and fingers clear of section joints, track, and other door parts when the door is opening

and closing to avoid injury. Use the pull down rope provided for safe operation as well as easy use. • Bolts must be installed at the rear end of horizontal tracks. These act to stop the rollers and keep

the door from rolling off the back of the track. • Only the track and hardware specified and supplied with the door should be used.

I M P O R T A N T !

To Protect Yourself From Injury, Carefully Read The Following Safety

Information And Warnings Before You Install Or Attempt To Repair Your New Clopay Door


SAFETY INFORMATION

• Track installations must use sway braces on rear track hangers to prevent sideways movement. If

the tracks are not firmly stabilized, they might spread, allowing the door to fall and cause severe injury and damage.

• Some security or screen doors use a center torsion spring system. The center torsion spring

assembly uses a wooden pad (2" x 6" x 12" minimum) or steel plates (one 1/4 " thick x 10" x 12" minimum) that must be of good quality and firmly attached to the wall. Four 3/8 " x 3" lag screws should be used to attach to wood structure. The wood needs to be a Grade 2 or better Southern Yellow Pine (also known as Southern Pine or Yellow Pine.) DO NOT use wood labeled as Spruce-Pine-Fir (or SPF). If the wood splits once the torsion spring is in place, a professional installer must replace it. Four 3/8” bolts should be used to attach assembly to steel plates. Four 3/8" masonry anchors should be used on concrete or block walls. Do not try to remove or repair a torsion spring assembly or any red-colored fasteners once the spring is wound.

• If the door and/or any of the supporting track are damaged, operating the door could be hazardous.

Call an authorized representative of the manufacturer or professional door repair service promptly. • Do not permit children to play beneath or with any door or electric operating controls. • Doors equipped with automatic door operators can cause serious injury or death if not properly

adjusted and operated. To insure safe operation:

a) interlock switches must be used if either door (sectional or security/screen) is motor operated and uses a single track configuration;

b) test the sensitivity of the operator’s safety reverse mechanism monthly; c) remove the pull rope; d) make sure the door remains unlocked; e) do not allow children to play with the controls.

• If repairs are ever required to your door, safe and trouble-free operation can be best assured by

using original replacement parts. • Express warranties apply only to doors installed using original, factory-supplied sections, parts, and

hardware, installed in strict accordance with these instructions. • Clopay Building Products Company disclaims all liability for any installation which is not in

compliance with applicable state, county, or local building codes.

I M P O R T A N T !

To Protect Yourself From Injury, Carefully Read The Following Safety

Information And Warnings Before You Install Or Attempt To Repair Your New Clopay Door


Things to Know Before You Begin Read instructions completely before starting installation of the door. Becoming familiar with the components before assembling the door will reduce installation time.

Springs and related hardware are under EXTREME spring tension and could cause SEVERE INJURY OR DEATH if mishandled. DO NOT ATTEMPT TO REPAIR OR ADJUST the springs, red fasteners, hardware, or structure to which they are attached.

IMPORTANT! Before Starting Installation: Step 1: Check all door dimensions to verify that the size of the security or screen door is the

same size as the sectional overhead door, and that it is the proper size for the opening. Wood jambs require the door to be the same size as the opening, with stop moldings nailed to inside of opening to seal the door. Steel jambs require the door to be two inches wider than the opening to allow a one-inch door overlap on each side. No stop moldings are required with this application. The opening must be plumb and square to assure a good fit.

Step 2: Check all materials for proper configuration. Any shortage report must be accompanied by

the Clopay contract number, as well as the quantity received. Step 3: Check for sufficient headroom and side room. Headroom is the distance between the top of

opening to the ceiling or the lowest obstruction. Step 4: The hardware package supplied with your door should include red fasteners for attachment

of the torsion spring mounting brackets and/or the bottom roller brackets. These fasteners must be securely attached as indicated in the installation manual.

Items Typically Included:

Door panels Hinges Outside bottom bracket fixtures Outside drums Cables RH and LH diverter switch (if required) Upper track

Lower track (if required) Shaft and springs Bearing plates Rollers Top fixtures Mounting hardware

WARNING


Installation Procedure This document does not include installation instructions for the exterior sectional door, which should be completed before proceeding to the next step. Dual-Track Configuration If the door is supplied with a Dual-Track configuration, raise the sectional overhead door several inches above the opening height and clamp securely in position. Install the steel jamb plates to the existing sectional door track via the track bolts. This will require the removal of existing track bolts in the sectional door track. Clamp the steel jamb plates on the outside of the track and against the back jamb. Drill ¼” holes through existing track bolt holes, and into steel jamb plates. Re-insert track bolts and fasten steel plate to the track. See Figure 1. (Note: The lock side of the door track will have be drilled or cut for locking access.) Once the steel plate and the sectional door track are securely attached, close the sectional door. Clamp the security / screen door track to the steel jamb plate with the same pitch angle as the sectional door track. Ensure that the second door track allows adequate clearance between the security / screen door and the sectional door to prevent interference with outside door struts or hardware. (Clearance dimension will vary depending on sectional door configuration.) Drill ¼” holes through the second door track bolt holes, into the steel plate. Attach security / screen door track to the steel jamb plate via track bolts. See Figure 1.

(Right-side jamb shown)

Header

8"

Steel Jamb Plate (Flush With Wall)

Security/Screen Door Track

Sectional Door Track

Opening Height

(2" Track Shown)

Space as RequiredFigure 1


Single-Track Configuration

If the door system is supplied with a single-track configuration (i.e. uses the sectional door lower- track) a diverter switch is supplied with the security or screen door. The upper section of the sectional door track may need to be modified on retrofit applications. (See Figure 2) Cut the specified amount off the bottom of the upper track if required. Clamp the diverter switch into position between the lower and upper sectional track as shown. Drill ¼” holes through the diverter switch and upper / lower track as shown. Attach diverter switch to the sectional track via track bolts.

Please note that the direction of the switch will be determined by the last door in the down position.

Right Hand Switch Illustrated

Retrofit Applications:Distance to becut from sectionaldoor upper track

8"

Header

Sectional DoorLower Track

Upper & Lower Track Splice Bracket

Sectional Door

Upper Track

NewUpperTrack

Diverter Switch

Assembly

11"

Figure 2


Upper Track Installation

Install the security or screen door upper track and bracing per configuration requirements. Fasten side bracing to standard track as required. Fasten backhang bracing to building structure. (Use Two braces per side on doors over 12’ high) Fasten bracing to prevent track sway as required. Fasten center support bracing for rear torsion counter-balance system if required.

Figure Notes:

1. Values shown are for 2” track only. 2. Bracing not shown in figures for clarity.

12"

DoorHeight

+6"

SectionalDoor

High Lift+7"

8"

8"

Track Mounting Plate

SectionalDoor

High Lift+7"

DUAL TRACK HIGH LIFTCONFIGURATION

SINGLE TRACK HIGH LIFT CONFIGURATION

Door Height+18"

23°

DUAL TRACK VERTICAL LIFTCONFIGURATION

12"

8"

11"

SINGLE TRACK VERTICAL LIFTCONFIGURATION

12"

11"

8" Diverter Switch

Security/Screen Door Counterbalance

(Outside Drums)

12"5-3/16"

23°

12"

Sectional Door Counterbalance (Inside Drums)


(Outside Drums)


5-3/16"

12"

12"Sectional

Door Header Clearence Required

12"Sectional

Door Header Clearence Required

Diverter Switch


(Outside Drums)




(Outside Drums)

Track Mounting Plate

Figure 3 Figure 4

Figure 6Figure 5


Hardware Attachment

Install the outside bottom bracket fixtures to the bottom of the first door panel using the red-colored fasteners. (Fig. 7) Install the rollers in the bottom fixtures and set first panel into the door opening. Add hinges to door section. Stack intermediate door sections on top of section below and attach hinges as required. (Note: Dual Track systems use all No. 1 hinges, Single Track systems use a hinge configuration closely matched to the sectional door.) Refer to Figures 8 and 10. Stack uppermost section on top of door section below, and attach top brackets. (Fig. 9)

Check to ensure all hinges are properly secured before proceeding.

Figure 9 Figure 7

Figure 8 Figure 10


Counter-Balance System Installation End Bearing Plates and Spring Anchor Bracket Installation Fasten end bearing plates and spring anchor bracket(s) to wall, track, or backhang bracing as required by the specific counter-balance configuration utilized. (Refer to figures 3-6 for mounting locations, and figures 11-15 for additional configuration details.) Use 5/16" x 1-5/8" red-colored lags (wood jambs) or 5/16” X 1” red coated self-tapping screws (steel jambs). See Figure 11. See warning below.

Fasten brackets and the spring components securely using red-colored fasteners. Never remove spring anchor bracket when springs are wound or serious injury could result.

Wall Mounted Torsion Springs

Torque Tube Installation Slide tube into one end bearing plate then back through the opposite one. Center the tube between end bearing plates. Slide drums on tube and loosen all set screws. Tube must be straight and level.

Slide left drum against the end bearing plate and tighten set screws. Bring cable up wall behind drum and into edge notch in drum. Turn drum and shaft until cable is tight. Make sure cable stop is seated against drum. Clamp locking pliers on shaft and against header to hold cable tight. Repeat process for setting cable on opposite side. Tighten all drum set screws. Cable tension must be equal on both drums. Install auxiliary shaft support(s) if required. Go to spring winding directions.

Solid Shaft Installation

Install shaft coupler on one end of the shaft. Insert key and tighten set screw. Slide shaft into one end bearing plate. Slide other shaft into opposite side and align shaft coupler. Clamp shaft-coupler together and fasten spring anchor brackets. Slide both drums on shaft against end bearings plate and insert 1/4" x 1/4" keys. Tighten drum set screws. Clamp locking pliers on shaft and against header to hold cable tight. Repeat process for setting cable on opposite side. Tighten all drum set screws. Cable tension must be equal on both drums. Install auxiliary shaft support(s) if required.

WARNING

End Bearing Plate

Auxiliary Support*

Spring Anchor Bracket

*Used on wide or heavy doors.

Spring Winding Cone

Spring Anchor Cone

Drum With Set Screws

Figure 11


SPRING TENSION IS DANGEROUS. A sudden release of the springs could result in severe injury. Proceed with caution, following these instructions carefully. Before winding any tension on springs, make sure door is securely locked down with a vise-grip placed on vertical track above a roller. Always use proper size winding bars. Never use screwdrivers or any tool too large or too small. They may break and cause serious injury. Stand to the side of winding bars while winding springs.

Spring Winding Draw a straight chalk line across spring. This will indicate the number of turns on spring as you wind. Springs will get longer when wound. Using two cold rolled steel winding bars (18" long minimum - not supplied) that fit snugly in the winding plug holes, wind the springs to achive a balanced door spring system.

Set Screws

Torque Tube: Tighten set screw enough to dimple shaft, approximately 1-1/4 turns after set screw contacts tube.

Solid Shaft: Tighten set screw enough to hold winding plug in place. Do not exceed 1/2 turn after set screw contacts shaft. Final spring tension adjustments should be made after installation is completed. Always adjust springs with door closed and locked.

WARNING


WARNINGAlways use good quality, snug fitting, constant diameter, solid steel winding bars when winding or adjusting springs. The use of any other object can result in severe injury. When winding the springs, the winding bar must be inserted into the full depth of the holes in the winding cone. Keep a firm grip on the winding bars at all times. Use a sturdy ladder and stand to the side of the winding bars.If your door has a torsion spring assembly, you must make sure that the wood anchor pad is firmly attached to the garage wall. Failure to securely attach the anchor pad could allow the springs to violently pull away from the garage wall, and could result in severe injury and/or property damage. In no case should nails be used.

SPRING CONFIGURATIONS ON STEEL TORSION TUBE

End Bearing Plate

Cable Drum (Red)

Black Winding Cone - Wind As Shown In

Detail "A"

Cable Drum (Black)

End Bearing

Plate

Wind as Shown in Detail "A"

Right Wound Spring

Left Wound Spring

Winding Bar (See Warning)

Winding Cone

DETAIL "A"

Wind Counterclockwise

End Bearing Plate

Righthand Cable Drum (Black)

Black Winding Cone - Wind As Shown In

Detail "A"

Figure 12


Bearing

Left Wound Spring


Bearing


End Bearing

Plate

(2) Set Screws

Red Winding Cone

Right Wound Spring


Split SolidSteel Shaft

SpringAnchor Plug

Coupler-See View

"C"


Warning Tag

LeftWoundSpring

(2) SetScrews

BlackWinding

Cone

Black Drum WithSet Screws

SPRING CONFIGURATION ON A SOLID SHAFT WITH COUPLER

VIEW "B" Solid Shaft

Drum

Solid Shaft KeyInserted Into Each Drum

(2) SetScrews

1) Insert Solid Shafts Into Coupler2) Insert Solid Shaft Keys3) Tighten Set Screws

Solid Shaft Key

Solid Shaft

Coupler(4) SetScrews

VIEW "C"

Bearing - some spring systems will require bearings to be bolted to plate. Use (4) 3/8" bolts and nuts - make sure that bolt heads are towards cable drum.

Red Drum-SeeView "B"

Figure 13


Rear Mount Torsion Spring Doors Rear torsion spring doors require that the spring assembly be placed at the rear of the horizontal track. Center support hanger(s) to be provided by installer. Center support hangers to be constructed of solid angle iron and be strong enough to withstand the torque of the springs. Rear of horizontal tracks must be securely fastened in the proper position before springs are wound or door is lifted. Horizontal tracks should be level and back hung on each side. Doors over 12' high will require two center backhangs. All backhang material is to be supplied by installer. See Figures 14 and 15. Install the lift cable pulley (supplied) near the horizontal track radius using carriage bolts. The fasteners used must be installed with the heads toward the inside of the track and the nuts facing outside as shown in Figure 15. The cable must be routed through the pulley saddle prior to attaching to drum. Install springs according to Figures 14 and 15. Push track towards jambs until door is tight against stop or steel jambs and tighten track bolts. Adjust top brackets by sliding it up or down on door in order to position top section correctly. Wind springs per details on page 11.

Left Wound Spring

Left (Black) Winding Cone Spring Anchor Cones

Right Wound Spring

(Red) Right Winding Cone

Right Rear BackhangCenter Rear Backhang

REAR MOUNT TORSION SPRING DOOR - REAR VIEW

Center Bearing

PlateLeft End

Bearing Plate

Left Rear Backhang

Right End Bearing Plate

Left Hand Cable Drum View (Backhang Not Shown)

(2) Set Screws

End Bearing Plate

Lift Cable

Drum (Red)

Winding Cone (Black)

Track

(2) Set Screws (3) 5/16" x 1-5/8" Screws (Attach To

Ceiling Joist)

(5) 5/16" x 1" Bolts & NutsCenter

Backhang

Center Bearing

Plate

Spring Anchor ConeCenter View

Right Hand Cable Drum View (Backhang Not

Shown)

Red Winding Cone

End Bearing Plate

Set Screws(2)

Track

Lift Cable

Drum (Black)

Cable

Drum (Black)

Cable Drum (Red)

Figure 14


REAR MOUNT TORSION SPRING DOOR - SIDE VIEW

This Backhang To Be Mounted Halfway Between Header & Rear

Backhang. (See View "G")

Bottom of Backhang may need to be cut to prevent interference

with the Lift Cable.

Pulley (See View F)

Lift Cable

Flangle Nut

Starter Angle

Pulley Washer

Track

Carriage Bolt

Cable Drum WIND UP

(Cable Drum not Shown)(Backhang not Shown)

VIEW E

Carriage Bolts Through End Bearing Plate & Track. Drill holes in Tracks to fasten End Bearing Plate Level with the

track.

Horizontal Angle

Track(2) 3/8" Flange Nuts

End Bearing Plate (See View "E")

Left Rear Backhang

(See View H)

End Bearing Plate

Pulley InstallationVIEW F

MID - HORIZONTAL BACKHANG

(3) 5/16" x 1-5/8" Screws - Attach to

Ceiling Joist

3/8" x 1"/min. Bolts & Nuts

(3) 5/16" Nuts

(3) 5/16" x 1" Bolts

Horizontal Angle

Backhang

(5) 5/16" x 1" Bolts and Nuts

REAR BACKHANG

(3) 5/16" x 1-5/8" Screws - Attach to

Ceiling Joist

VIEW G

Figure 15

VIEW H


Finishing Up

Install optional lifting devices at this time.

Check door operation for proper spring tension. Raise the Security or Screen door to full open position and lower existing sectional door to insure proper operation. Install slide bolt lock at location necessary to engage into track slot. See Figure 16. Fasten lock to the end stile using four #14 x 5/8 " sheet metal screws. Lubricate all moving parts (hinges, rollers, bearings, springs, etc.) with lightweight oil. Do so when installed and thereafter about every six months. High use doors will require more frequent lubricating.

Door Maintenance

Do not attempt to adjust door components unless you are a qualified door mechanic.

Inspect and/or repair the following door items every six months:

• Frayed cables • Torsion spring plugs and spring anchors • Bearings in end plates • Rollers and hinges • Track alignment • Backhang angle and anti-sway brace attachments • Damaged or loose fasteners (i.e. screws, nuts, bolts, etc.)

D/N: 103001

Rev: 12/10/03

WARNING

Figure 16

Documents

INSTALLATION & MAINTENANCE - Clopay Doorcdn.clopay.com/public/documents/103001-rev00 (801-802... · 2014-04-23 · Thank you again for choosing Clopay! Sincerely, ... • The brackets