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CoFold Ultra 100 Fitting Instructions for top hung exterior outward folding doors SYSTEM CAPACITY Maximum leaf height - 3300mm Maximum leaf weight - 100kg Maximum leaf width - 1000mm Maximum leaf thickness- 48-68mm * For thicker or thinner doors please contact [email protected]. * If the hypotenues is more than the door width x 1.004 then a risk of camming exists. JAMB CAP GASKET WHEN USED IN CONJUNCTION WITH ALUMINIUM SUPPORT CHANNEL 94SC THE OUTER CHANNEL DIMENSIONS BECOME 23H x 25W JAMB CAP IN LINE WITH TRACK 52 212 140 34 39 JAMB CAP IN LINE WITH TRACK Diagram 1 Diagram 2 Diagram 3 INSIDE OUTSIDE Diagram 4 1 TRACK FIXING NOT BY COASTAL ALTERNATIVE ALUMINIUM THRESHOLD 94T BY COASTAL - COMES COMPLETE WITH 94P AND ENDCAPS AND IS PREDRILLED FOR DRAINAGE

CoFold Ultra Sliding Folding Door Gear Installation Instructions

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CoFold is the ultimate in exterior folding systems and opens up a wealth of new design possibilities. The CoFold System has been designed to maximise the flexibility of a room’s living space, removing barriers and enabling the user to have an indoor/outdoor experience by fully opening up exterior walls. The system which operates with effortless ease combines the benefits of folding doors with the ability to keep out the weather with no corrosion worries. This modern, contemporary feature will increase available living space whilst allowing natural light to envelop the room. System Capacity Maximum leaf height - 3300mm Maximum leaf weight - 100kg Maximum leaf width - 1000mm Leaf thickness - 35-68mm* * For thicker or thinner doors please contact Coastal Technical Team For doors between 35-47mm use an alternative flush bolt Applications 􀂚􀀁 Residential and commercial timber exterior folding applications 􀂚􀀁 Specially suited to coastal environments made from 316 stainless steel. 􀂚􀀁 End folding timber doors folding to one or both sides 􀂚􀀁 Standard folding configuration features doors folding outward. Inward folding doors can be used where the doors are not directly exposed to the weather. 􀂚􀀁 Premium security features 􀂚􀀁 Recognised weather resistance The folding unit is not hinged to post, but is pivoted in the track and floor. All door leaves are of equal width. A swing leaf can be included by incorporating an odd number of leaves. For full weather protection, doors, frame and track should incorporate the seals provided in the CoFold range. Cill and frame construction should be in accordance with the CoFold fixing instructions. Intermediate hangers and hinges are non rebated. www.coastal-group.com

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Page 1: CoFold Ultra Sliding Folding Door Gear Installation Instructions

CoFold Ultra 100Fitting Instructions for top hung exterior outward folding doors

SYSTEM CAPACITYMaximum leaf height - 3300mmMaximum leaf weight - 100kgMaximum leaf width - 1000mmMaximum leaf thickness- 48-68mm

* For thicker or thinner doors please contact [email protected].* If the hypotenues is more than the door width x 1.004 then a risk of

camming exists.

JAMB CAP GASKET

ALTERNATIVE ALUMINIUM THRESHOLD SF94T BY PCH - COMES COMPLETE WITH 94P ANDENDCAPS AND IS PREDRILLED FOR DRAINAGE

WHEN USED IN CONJUNCTION WITHALUMINIUM SUPPORT CHANNEL 94SCTHE OUTER CHANNEL DIMENSIONSBECOME 23H x 25W

JAMB CAP IN LINE WITH TRACK

52

212

140

34

39

JAMB CAPIN LINE WITH TRACK

Diagram 1

Diagram 2

Diagram 3

INSIDE OUTSIDE

Diagram 4

1

TRACK FIXINGNOT BY COASTAL

ALTERNATIVE ALUMINIUM THRESHOLD 94TBY COASTAL - COMES COMPLETE WITH 94P ANDENDCAPS AND IS PREDRILLED FOR DRAINAGE

Page 2: CoFold Ultra Sliding Folding Door Gear Installation Instructions

PREPARATIONU1 - Pivot Assembly Set2R - End Hanger Set Right Hand - for doors meeting a swing door and square-edged doors meeting2L - End Hanger Set Left Hand - for doors meeting a swing door and square-edged doors meetingU2R - End Hanger Set Right Hand - for doors folding to the frame (i.e. 2 leaf, 4 leaf and 6 leaf)U2L - End Hanger Set Left Hand - for doors folding to the frame (i.e. 2 leaf, 4 leaf and 6 leaf)3 - Hinge Set with HandleU4 - Intermediate Hanger Set7 - Hinge Set Offset Outward Opening8 - Rebated End Hanger MeetingU9 - Pivot Hinge required for Ultra security10 - Face Fix Handle (Optional)

Diagram 5

Diagram 6

U1 U4 U4 U4 2L U1 U1 U1 U1

U4 U4 U1

U1 U4 2L U4 U4 U4 U1 U1 U1 U1 U1

U4 2R U1

U9 U9

U9

U9 U9 U9 U9 U9 U9

U9 U9U9U9U9

U1

2

Page 3: CoFold Ultra Sliding Folding Door Gear Installation Instructions

Preparing the opening

Ensure the opening is square and all load bearing areas aresuitable for the weight of the system. Take particular care toensure there is sufficient strength in the structure above theopening to take the concentrated weight of the doors, when inthe open stacked position. The CoFold system provides +/-3mm of horizontal and vertical adjustment. Use a plumb line toensure that the centre line of the track and the centre line of thechannel are offset by 19mm.

Diagram 7

Diagram 8

Diagram 9

3

=

=

For details on installation ofthe U9 please refer to the U9

fitting instructions

Preparing the door frame

Preparing the door frame forU1, 2 & 9 face plates

INSIDE OUTSIDE

U9 Face Plate

Frame Support Plate

HingeComponent

7952

52

54

27

27

31

79

22

25

22

22

SILL

=

=

5050

70

26

R20R6

54 36

40

54

U1 Face Plate

U9 Face Plate

U1 Face Plate

Diagram 10

Diagram 11

Ø10 DRILL FOR DRAINAGE AT1000 CENTRES, 300 CENTRESFOR EXTREME CONDITIONSOR US ALUMINIUM THRESHOLDBY COASTAL

Page 4: CoFold Ultra Sliding Folding Door Gear Installation Instructions

ADD 10mm TOWIDTH OF ENDHANGER LEAFFOR REBATE

ADD 10mm TOWIDTH OF EACHLEAF TO CREATEREBATE

Preparing the door leaves

Door leaf width calculation1. Decide how many door leaves you want in the opening.2. Add together all the 3mm clearances required between door leaves and the jambs (there will be one more than the number of door

leaves). This is the total clearance figure.3. Measure the finished opening width (W) and deduct from this the total clearance figure.4. Divide this new figure (finished opening width minus total clearance) by the number of doors to produce the actual door width. (N.B.

all doors with the Cofold system are the same width).

For example: For a 4 door leaf system with a finished opening width of 2345mm the door leaf width would be 2345mm minus (5x3mm)divided by 4 (number of door leaves) = 582.5mm.

Door leaf height calculationLeaf height = finished opening height (see diagram 7) minus 66mm.

Diagram 12

Diagram 13

Diagram 14

Door SealsPrepare the door leaves to accept theAQ63B seal.

Meeting DoorsUse the 8 set for 2+2 rebated timber doorconfigurations. For all other configurationsuse 2L (left hand) or 2R (right hand) endhanger sets. For kit handing refer to diagram6.

4

PREPARING THE DOOR LEAF

AT THE JAMB BETWEEN DOOR EDGES

Page 5: CoFold Ultra Sliding Folding Door Gear Installation Instructions

U9

KIT U1 KIT U4 KIT U2L

7.5mm check In for U1, U2, 2 and 8

Door hardware positioning

End door leaf Preparation

Diagram 15

Diagram 16

5

Page 6: CoFold Ultra Sliding Folding Door Gear Installation Instructions

Door hardware attachment

Diagram 17

6

CHECK INFOR 9

23

1450

3

100

Ø13mm15mm deep

Ø 3mmPILOT HOLES

Kit U4

2 WHEEL ASSEMBLY

SIDE THRUST BEARING

FIXING SCREW (6 OFF)

HANGER BODY

COVER (SLIDE)

WASHER

HANGER BOLT

Kit U2L (or U2R)

Kit U1

BOTH SCREWS MUST BEFITTED UNDER THE COVERS OF

ALL THE END HINGES

IMPORTANT

18

3

22

100

50

15

Page 7: CoFold Ultra Sliding Folding Door Gear Installation Instructions

INSTALLATION

1. Ensure that you have all the required parts. Unpack thecomponents and identify the parts. Lay the parts on theground in the same configuration as they will be wheninstalled. It is recommended that a light smear of generalpurpose grease is applied to all bolts prior to assembly.

2. Cut the track to the required length and pre-drill forfixings in accordance with diagram 18. Please note that theextra fixings are required where the doors stack together.

3. Cut the channel to the required length and fit in the sill.Drill drainage holes (see diagram 1).

4. Remove all the wheel assemblies and pivot block fromthe hanger and pivot bolts, and disassemble top pivotblock assembly.

5. Slide the wheel assemblies and track pivot block intothe track in the correct order, orientation, and positionand fix the track in position. Reassemble top pivot blockassembly (see diagram 19).

6. Remove the bottom pivot assembly and guide rollerassembly (see diagram 20). Disassemble the bottom pivotassembly.

7. For installation, assemble leaves in pairs via the hinges.To improve the ease of installation pre-drill pilot holes forall hinge parts. Fit kits U1, 7,U4 and U9 (optional) to firstpair of leaves. Please ensure all 4 screws are fixed per end hinge.

8. Screw the bottom anchor of the bottom pivot assemblyto the base of the channel 11mm from the jamb. Pleasenote, the screw nearest the end of the bottom anchor isclosest to the jamb (see diagram 21). Reassemble the pivotassembly leaving the clamping screws loose (see diagram 25).

9. Suspend pairs of leaves by engaging top pivot andhanger bolts using 5mm Allen key supplied (see top ofdiagram 20).

10. Attach the bottom pivot and guide assembly to theirrespective hinges, adjust the bottom pivot side platesposition so that it engages with the hinge bolt. Tightenpivot and guide strap bolts (see diagram 22).

11. Lift the next pair of leaves into position and supporttheir weight by screwing the hanger strap bolt into thehanger wheel assembly and fixing the second and thirdleaves together.

12. Continue this procedure until all leaves are fitted.

Diagram 18

Diagram 20

Diagram 19

Diagram 21

BOTTOM ANCHOR

CHANNEL

TOP PIVOT SECURING BLOCK

PIVOT SECURING BLOCK HEXBOLTS

PIVOT CAM

PIVOT ADJUSTER

PIVOT CLAMP PLATE

ADJUSTMENT LOCK OFFBOLTS

JAMB

Diagram 22

7

Page 8: CoFold Ultra Sliding Folding Door Gear Installation Instructions

Diagram 23

Diagram 24

Diagram 25

ADJUSTMENT

8

ADJUSTMENT

CLAMP SCREW

BOTTOM ANCHOR

JAMB SIDE

BOTTOM SIDEPLATE

CLAMP SCREW

CLAMP SCREW

CLAMP SCREW

ADJUSTMENT CAM

TIGHTENGRUB SCREW

ADJUSTMENT CAM

LOCKING HANGERGRUB SCREW

ON INSIDE OF DOOR

INSIDE

U4 ILLUSTRATED.SAME METHOD OFADJUSTMENT APPLIEDTO U1, U2L, U2R AND 8.

LOCKING PIVOTGRUB SCREW

ON INSIDE OFDOOR

Height Adjustment (± 3mm)

1. Close leaves and adjust the door height to achieve anequal gap between the top of the leaves and the track (a9mm gap is recommended). (see diagram 23).

2. Once the adjustment is complete use the Allen key totighten the locking hanger grub screw until secure.

Lateral Adjustment

1. With the unit still in the closed position, slide the set ofleaves towards the jamb to obtain the desired gapbetween the jamb and the pivot door. A gap of 3mm isrecommended using the adjustment cam. Once inposition tighten the clamp screws. (see diagram 25).

2. Fold the leaves and adjust the bottom side plate usingthe Allen key provided so that the gap between the doorand the jamb is the same over the full length of the door.

3. Tighten the two clamping screws to lock the side plateto the bottom anchor.

4. Once the pivot door is in the correct position insertand tighten the locking pivot grub screw from the insideposition. (as shown in diagram 24)

Locking Off

Tighten grub screws on hangers, guides and pivots.

CARE AND MAINTENANCE

To provide years of trouble free operation, it isrecommended that the track is kept free from dirt anddebris. Periodically replace the general purpose grease onall bolts. To prolong the appearance of the exposed hingeparts, it is recommended they are periodically washedwith soap and water. Maintenance is required on allcomponents including stainless steel to validatemanufacturers warranty. For further maintenance detailsplease refer to our website.

INSIDE

Page 9: CoFold Ultra Sliding Folding Door Gear Installation Instructions

Aluminium Threshold Jamb Kit

(All dimensions in mm)

94

140 51

52 39

21

25

25.5

25.551

Jamb Cap

Jamb Cap Gasket

Endcap

94

21

25

25.5

25.551

140 51

52 39

2

Jamb Cap

Jamb Cap Gasket

Endcap

Jamb Cap

Jamb Cap Gasket

Endcap

Jamb Cap

Jamb Cap Gasket

Endcap

34

23

15

51

19

8

158

34

27

27

83

83

2.5

2.5

2.5

2.5

Threshold 94T

Pre-drilled 10mm diameter drainageholes at 300mm centres

9

Page 10: CoFold Ultra Sliding Folding Door Gear Installation Instructions

U9 Intermediate Pivot Set10

U1

U1

INSIDE OUTSIDE

U9

17.5

R17.5

Diagram 2.Diagram 1.

Diagram 3.

1. The CoFold U9 intermediate pivot set shown in Diagram 1, should be fitted to the pivot door mid way between the U1 top and bottom pivot assemblies. The U9 hinge must be positioned on the same centre line as the U1 top and bottom pivot hinge bodies.

2. Rout the door and drill the pilot holes as shown on Diagram 2. Fit the hinge body using the four screws provided.

3. Using Diagram 3, 4 and 6 locate the position of the threaded link arm receiving hole on the the opening frame. Starting from the central point of the threaded link arm receiving hole (as indicated on Diagrams 4 and 5) mark the location of the two screw holes for the face plate. Using the face plate as a template mark out the routing detail for the face plate and rout.

4. Drill the Ø12mm hole for the threaded link arm receiving hole and rout the opening frame to mount the Frame Support Plate flush if required (Diagram 3).

5. Screw the frame support plate and the face plate onto the opening frame preparation, as shown in Diagrams 3 and 5.

6. Fit the pivot door into position using the U1 pivot set.

7. Fit the U9 cover sleeve on to the U9 hinge body and drop the main strap bolt into position, as shown in Diagram 6.

8. Screw the threaded link arm fully into the frame support plate. The centre of the threaded hole in the link arm should be positioned to receive the strap bolt. Screw the strap bolt in to the link arm until there is a 2mm gap between the head of the strap bolt and the hinge body, as shown in Diagram 6.

9. Adjust the U9 pivot set to ensure the clearance between the pivot door and the frame is uniform (Diagram 7).

7.5

Main strap bolt

Cover plate

Cover sleeve

25mm

36 18

26

R12.5R6

Pilot holes

Hole centre todoor face 8mm

Optional 2.5deep rebatefor face plate

Door in closedposition

Opening frame

28mm

Ø12 Threaded linkarm receiving hole

Ø1228mm deep hole

2.5mm deep41mm

Hinge body

100

Note: These fitting instructions should be used in conjunction with the CoFold Ultra Fitting Instructions

Page 11: CoFold Ultra Sliding Folding Door Gear Installation Instructions

Diagram 5.

Diagram 4. Diagram 7.

Adjustment:3mm in to the frame6mm out to the frame

Line from bottomof the hinge body

Locating and drilling guide for U9 face place

Main strapbolt

Threaded link arm

Frame support plate

Screw the frame support plate and the faceplate onto the opening frame preparation,as shown in Diagrams 3 and 4.

2mm gap

Face plate

Face plate

Threaded link armreceiving hole

Frame supportplate

2mm gap

8mm

20mm

Door shown in the open position

Door shown in the open position

22

53

31

Ø6

Diagram 6.

50

HALF DOORHEIGHT +79mm

INSIDE OUTSIDE

53

31

22

100

100

50

Threaded link armreceiving hole

Frame supportplate

Page 12: CoFold Ultra Sliding Folding Door Gear Installation Instructions

For top hung exterior folding doors. For use in conjunction with standard outward opening fittinginstructions. Follow routing instructions for the bolt keep and flush bolt length to be fitted, fit both withthe screws supplied. Suitable pilot holes for screws are recommended.

TOP FLUSHBOLT

BOTTOMFLUSHBOLT

SILL

(All dimensions in mm)

HEAD BOARD

LINTEL

FASC

IA

SILLREBATE

18

Enlarged detail showing thesectional routing dimensions

for all 3 bolt sizes

Note: Routing detail is the same for both locking and non-locking flush bolts.

Section through door showingflush bolt rebate detail

Routing detail for bolt keep sockets

Door height

Upto 2200mm

Upto 2450mm

Over 2450mm

RecommendedBolt length for top of door

190mm

450mm

600mm

RecommendedBolt length for bottom of door

190mm

190mm

190mm

Routing detail for190mm Top Flush Bolt

Routing detail for450mm Top Flush Bolt

Routing detail for600mm Top Flush Bolt

30

18

30

190

190

170

170

450

430

600

580

404

12.512.5

12.5

12.5

Ø18

Ø18

10 10

40

4010

25

65

12

40

22

4

17

Bottom Flush Bolt into SillTop Flush Bolt into Head

Fixing screw centres

Routing detail for190mm Bottom

Flush BoltPLATE

PLATE

KEEP LINER

40mm fixing screw centres - Use fixing plate as drilling template

OU

TSI

DE

INSI

DE

Outward Opening Flush Bolt11

Coastal Joinery Hardware, Global House, Bojea Industrial Estate, Trethowel, St Austell, Cornwall, PL25 5RJ.Tel: 01726 871726 Fax: 01726 871731 Email: [email protected]

Part No: 220946Issue 8 - January 2013

Page 13: CoFold Ultra Sliding Folding Door Gear Installation Instructions

1. Opening Size: Width: mm

2. Door Configuration:Number of leaves sliding (viewed from the outside)

3. Outward Opening: YesDue to weathering, outward opening Is Nohighly recomended.

4. Locking None

5. Finish Satin Stainless Steel PVD Brass Polished Stainless Steel

6. System CoFold CoFold Ultra (High Security)

7. Gear Types MorticeChoice only applies to CoFold system & Non Morticenot the CoFold Ultra.

8. Weatherseal Required: None

Height:

System Capacity: Maximum Leaf Height: 3300mm Maximum Leaf Width: 1000mm

Maximum Leaf Weight: 100kgLeaf Thickness: 35mm-68mm

ENQ

UIRY

FORM

FOR

BI-FOLD

DO

ORS

SPECIFICATION SHEET

Your Details/FAO

Address

Telephone: Fax: Email:

PRE-TENSIONCoastal Group | T 01726 871726 | F 01726 871731Email [email protected] | Visit www.coastal-group.com

BI-FOLD DOORS

Please enter your address here:

PROJECT TITLE: LOCATION:

Espagnolette

Brown White

Sash lock

RH

LH

mm