Fire Shutter
FS60, FS120, FS240
Installation, Operation &
Maintenance Instructions
Please follow these installation instructions carefully when installing the door.
This booklet should be left with the door for future reference.
Northern Sales, Distribution Centre & Production Warehouse
The Door Centre, Discovery Park, Crossley Road, Stockport, SK4 5BW
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Contents
Page
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17-18
19
20
21
22-23
Title
Technical Drawing
General Description
Safety Advice
Bill of Materials
Fixings & Considerations for the Substrate
Fixing the Angles
Fitting the Motor Barrel
Curtain Installation
Attaching Guide Channels
Set the Motor Limits
Fixing the Canopy
Final Inspection & Dismantling
Operation & Maintenance Instructions
General Instructions
Operation Instructions
Maintenance
Safety Devices
Service
Service & Repair Record
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Face fix & tubular motor
Reveal fix & tubular motor
General Description
The slats are solid cold-rolled slats in galvanised, or smooth semi-gloss powder coated
finishes; perforated slats giving up to 50% visibility.
Technical Specification - Standard
Shutter Curtain
The shutter curtain is formed from cold rolled galvanised steel laths, either 76mm x 22s swg (0.7mm),
20s swg (0.9mm), or 18swg (1.2mm) concave lath. Other gauges can be supplied depending on size.
Bottom Rail
The bottom rail consists of a ‘T’ section, again from a cold rolled galvanised section.
Side Guides
The side guides are supplied in various sizes, from 50mm to 100mm deep. Wind-lock guides are offered
for shutters exposed to windy conditions. All guides are supplied in galvanised finish.
Fixing Angles
Fixing angles are designed and supplied as standard in 75x50x5mm sizes, galvanised finish. However,
other formed / standard sizes are available depending on the application.
Bracket Plates
All bracket plates are manufactured from 5mm+ gauge galvanised sheet, the size of which is dependent
on the structural height and width. When outboard motors are utilised, an elongated plate will be required
on the motor side.
Roller Barrel
Each motor barrel is constructed from mild steel with a suitable diameter and wall thickness to suit
the shutter weight and also for resistance to fire/heating. The barrel encases the tubular motor (where
applicable) and all necessary motor brackets are pre-fixed to the bracket plates. All tubular motors are
230V, supplied with an emergency override crank and handle. Some shutters require outboard operators
when weight of the curtain requires this, or when the solenoid release/ fusible link, and other accessories
are required.
Operation
Controls available are rocker switches, key operated switches, and remote controls. Group command
units are available, allowing multiple shutter control at the push of one button. Safety devices to monitor
door closing is usually required for remote control shutters.
Coil Casings/ Fascias
Enclosures are an essential part of the FS fire shutter, manufactured from 0.9mm galvanised steel
(nominal).
Power Requirements
A fused spur within 1m of the opening is required to wire the motor cable; 13amp 3 pin plug socket will
suffice in default of this. 3-phase power is required or advised in some shutter configurations.
Finishes
As standard, the galvanised finish is offered; however, powder coating is available across the entire BS
and RAL colour ranges. A range of Plastisol finishes are also available.
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Safety Advice
Safety
The curtain roll is heavy and awkward to handle, it is recommended that fitting this shutter is
carried out by two or more people. Steel shutters often require lifting equipment, and a safe
system of work. It is highly advised that a plan or method statement is devised before beginning
work on shutters. Work at height, and excessive manual handling risk should be controlled or
avoided
Non-Tubular Motors
When installing large shutters with 3-phase type operators it is strongly advised that a
competent installation organisation is employed for the installation. Only trained and properly
equipped persons should attempt to install and commission a shutter over 10m2.
Step 1
Taking Delivery & Checking All Parts
Please check that the shutter is the correct size and all component parts are present.
The curtain will arrive split into sections. Lifting equipment should be used to raise and
attach the various parts of the curtain.
You should have:
1) Shutter curtain (This could be more than one bundle)
2) Shutter Guides x 2
3) Shutter Fixing Angles/ box sections x 2 fixed to top ‘flag’ brackets
4) Tube (This will have top hangers bolted on)
5) Motor (pre-fitted into the tube in the case of tubular motors)
6) Steel canopy
7) Controls. i.e. key switch, rocker switch etc
8) Any extra controls including interface panels, battery back-ups etc
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Installation, Operation & Maintenance – Fire Shutter
Issue: 004, 12.01.18
Typical shutter bill of materials. (Non-fire rated shutters do not include part 5c).
Typical shutter bill of materials. (Non-fire rated shutters do not include part 5c).
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Fixings & considerations
for the Substrate
Supporting Construction
Fire shutters should be fixed to appropriate masonry / concrete constructions that have a fire
resistance of at least that specified for the doorset and are capable of providing adequate
support to the doorset for the required period.
When fixing to structural steel members, these shout be clad with a proprietary fire protection
system such tat they have a fire resistance of at least that specified for the doorset, and are
capable of providing adequate support to the doorset for the required period. The minimum
yield strength for the steel supporting components is assumed to be 275N/mm2.
Fixings
M8 fixings are the minimum requirement for the purposes of fire resistance alone; larger fixings
should be used where required for reasons of supporting the shutter. M8 steel expansion bolt
fixings for concrete / masonry should engage within the structure for a depth of at least 60mm
for FS60 (1 hour) and FS120 (2 hour), and at least 75mm for fire rated shutters of the FS240
(4 hour) type. If the surface of the concrete or masonry structure is poor then the depth of
engagement should be increased to 100mm. M8 bolts should be of 8.8 grade minimum.
Fire Cladding Systems
The fixing of the doorset components to the steel members must not reduce the ability of
the fire cladding system to protect the members. Fixings through protection systems such
as boards and fibrous sprays should be fitted with steel sleeve spacers such that they do not
compress or crush the protection. Where the structural steel members are protected with an
intumescent coating additional fire protection must be added around the connected shutter
components to compensate for the area of coating that is trapped between the steel members
and the shutter components and therefore cannot intumesce. Any gaps between the fire
cladding system and the shutter components must be fitted with a fire rated seal system that
has been shown by test to be suitable for the application and the fire resistance period required.
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Installation, Operation & Maintenance – Fire Shutter
Issue: 004, 12.01.18
STEP 2 – FIXING THE ANGLES
Step 2
Fixing
thesite
Angles
Ensure
that the
is clear and that the fixing surfaces are free from loose plaster and
masonry. Ensure that the opening has no irregularities that could snag the curtain.
Ensure
that the
sitethe
is clear
and thatisthe
fixingBrickwork
surfaces are
free from
plaster
Finally,
ensure
that
substrate
level.
should
be loose
treated
withand
cement if
masonry.
Ensure
that
the
opening
has
no
irregularities
that
could
snag
the
curtain.
Finally,
this is not so. You are advised to double check the measurements of the opening before
ensure that the substrate is level. Brickwork should be treated with cement if this is not so. You
beginning
work.
are advised to double check the measurements of the opening before beginning work.
1) Refertopaperworkforsizesandlocation
Alwayscheckstructuralsizesagainsttheordered/manufacturedsizes
1) Refer2)
to paperwork
for sizes and location
2) Always check
structural sizes against the ordered / manufactured sizes
3)
Taketheguidesoffthefixingangles/boxsectionbyremovingscrewsand
3) Take the guides off the fixing angles / box section by removing screws and keep safe. Do not
keepsafe.DonotrefittheguidesuntilStep5.
refit the guides
until Step 5.
4) When you have measured your opening and matched sizes on the paperwork then proceed to
4) Whenyouhavemeasuredyouropeningandmatchedsizesonthepaperwork
install angles
/ box
thenproceedtoinstallangles/box
5) Recommended
fixing bolts are min. M8, see Note on Fixings, above.
you fit the angles / box, you will also be fitting the flag plates at the top since
6) Note: When
these are
into a single unit.
5)welded
Recommendedfixingboltsaremin.M8,seeNoteonFixings,above.
6) Note:Whenyoufittheangles/box,youwillalsobefittingtheflagplatesat
thetopsincetheseareweldedintoasingleunit.
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Installation, Operation & Maintenance – Fire Shutter
Issue: 004, 12.01.18
STEP 3 – FIT THE MOTOR BARREL
Step 3
1) Whentheanglesandtopflag-platesaresecure,fixthesteelroundtubeand
Fit the Motor
Barrel
motorendintothemotorplate,andensurethatthewholemotorsideis
firmlyscrewedtogether.
and top flag-plates are secure, fix the steel round tube and motor end into
1) When the angles
the motor plate,[For3-phasemotors,thecircularshaftboltonthemotorendwillpass
and ensure that the whole motor side is firmly screwed together.
throughtheplateintothemotorunititself.]
(For 3-phase motors, the circular shaft bolt on the motor end will pass through the plate into the
motor unit itself.)
Passthefloatinglost-bobbinintothesafetybrakeatthenon-driveend.
Pass the floating
lost-bobbin into the safety brake at the non-drive end.
[For3-phasemotors,thesafetybrakeisincorporatedintotheblockmotor
(For 3-phase motors,
the safety brake is incorporated into the block motor
itself.]Thedrawingsbelowshowafireshutterlostbobbinend,butasafety
itself.)
brakewillbefittedfornon-fireshutters.
The drawings below show a fire shutter lost bobbin end, but a safety brake will be fitted for non
fire shutters.
2) Ensurethatthehexagonal-shapedaperturefortheoverridebarisvertically
2) Ensure that the hexagonal-shaped aperture for the override bar is vertically facing, so that the
facing,sothatthehexagonalbaroftheoverrideeyeletwillhangdown.
hexagonal bar of the override eyelet will hang down.
3) Ifatestpower-leadisavailable,youcannowtestthemotorandthe
3) If a test power-lead
is available, you can now test the motor and the movement of the tube.
movementofthetube.
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tion, Operation & Maintenance – Fire Shutter
004, 12.01.18
Step 4
Curtain Installation
P 4 – CURTAIN
INSTALLATION
1) Hang the curtain using the lath hangers attached to the barrel. First hang the top section of
the curtain, then continue to connect the other bundles.
1) Hangthecurtainusingthelathhangersattachedtothebarrel.Firs
topsectionofthecurtain,thencontinuetoconnecttheotherbund
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Installation, Operation & Maintenance – Fire Shutter
Issue: 004, 12.01.18
Step
STEP 5 –5
ATTACH THE GUIDE CHANNELS
Attach the Guide Channels
1) Oncethecurtainisattached,youcannowre-attachtheguidechannels.Send
1) Once the curtain
is attached, you can now re-attach the guide channels. Send the shutter to
theshuttertotheopenposition,allowingyoutofixtheguidesbacktothe
the open position,
allowing
you to fix the guides back to the angles or box using the screws you
anglesorboxusingthescrewsyouremoved(Step2).
(Step 2).
removed
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Step 6
Set the Motor Limits
Motor limits can be set with either a test lead, or with the control switch installed.
A. Tubular motor limit setting
1) Site the push button station at a suitable height and location. (Final wiring should be coordinated with the site / customer requirements. Electrical work should be carried out by a qualified
electrician, while the equipment is shut down). Consult the relevant supplied instructions for key
switch, remote control, or other types of switch.
(Wiring to a building fire alarm system will also be carried out according to the site requirements and
the model of the control panel. A variety of control panels are available, and can include Audio-Visual
warning, programmed response to safety device activation, and so on.)
2) Fix the mains outlet at a suitable height and location
3) Secure the cabling, to prevent impeding the door operation.
4) The motor will have screw type limit switches. A straight line arrow pointing to the back of
the shutter, or to the top of the shutter, will be found next to one of the screw limits. This is the
Door Close limit switch. Turn the screw in the + (plus) direction to make the door close lower
down. The – (minus) direction will make the door stop short.
The straight arrow pointing next to the other screw is the sign for the Door
Opening limit; turn in the plus direction for more travel of the curtain upward,
and vice versa.
It is usually necessary to turn both screws in the ‘-‘ direction until the Stop point
is within the opening, meaning that the shutter stops short of the bottom and
top. Once you have found the Stop position for both up and down directions, it is
necessary only to add ‘+’ to the door travel, until it stops at the exact position
required.
B. 3-Phase / In line motor limit setting
A range of 3-phase motors are used for various applications. Limit setting processes will
depend on the kind of motor employed. See the installation instructions supplied with the
motor.
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STEP 7 – FIXING THE CANOPY
Step 7
1. Canopy
Situate the Canopy so that it sits with no uneven overhang.
Fixing the
2.
The Canopy has slots pre-drilled where it should be fixed to the subst
End
Plates.
1) Situate the Canopy the
so that
it sits
with no uneven overhang.
3.
An
aperture
for the override eyelet should be drilled / cut out.
2) The Canopy has slots pre-drilled where it should be fixed to the substrate and the End Plates.
4.
Using the apertures in the canopy, fix the top back of the Canopy into
3) An aperture for the override eyelet should be drilled / cut out.
substrate, and to the endplates. When fixing to brick use fixings of th
4) Using the apertures in the canopy, fix the top back of the Canopy into the substrate, and to
specified in Step 2.
the endplates. When fixing to brick use fixings of the type specified in Step 2.
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Step 8
Final Inspection
After connecting the motor and control, proper operation of the roller shutter must be tested.
When closing and opening the door ensure that no hitches or interferences occur. If unexpected
or loud noises occur, or the door seems to jam, the control has to be stopped immediately.
Check whether the guides are seated correctly and if the tube is level. Check that the slats enter
and house the guide properly. If none of these checks explains the failure, the manufacturer of
the product should be contacted.
Commissioning of the shutter for use as a fire shutter will sometimes mean integrating the
control panel belonging to the shutter into a building fire monitoring system. Proprietary fire
control panels should be selected and employed to this end, if required.
Dismantling
1) The door has to be rolled up completely while on the tube.
2) Turn-off the control and motor, and turn-off the current supply.
3) Dismantle the wiring so the electronic components, like the motor and safety brake, are
no longer connected to other components. In case of a tubular motor, the safety brake
has to be removed first. Subsequently, using a folk-lift truck or hoist, lift the (rolled up)
door off the end plates.
4) The consoles, side plates, and the guides can be
removed from the wall.
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Operating & Maintenance Instructions
Electrically Operated Roller Shutters
Date of Installation:
Installed by:
Contact Details:
To ensure compliance with the Machinery Directive this document must be
retained by the owner of the Door and held for future reference.
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General Instructions
Introduction
Your newly installed product should give you many years of trouble free service as it is designed
to require minimal maintenance and servicing. In order to prolong the life of your shutter and to
reduce the likelihood of problems, please adhere to the following instructions. (Please note all
products should only be operated by trained personnel).
Electrically Operated Products
Only operate your shutter when it is in view making sure it is not obstructed. Ensure the curtain
is running in the guides and that you and any other persons stand clear of the curtain and keep
hands etc. away from moving parts.
Note: Fire shutters can in some situations, be required to descend without consideration for
safety of users. Unless fitted with a Photoelectric Cell beam or similar safety system, the
fire shutter should be considered a hazard when closing for this reason. A range of optional
accessories should therefore be evaluated by the installer / surveyor / end user, depending
on their requirements and a health and safety risk assessment. Reduction of the hazard can
be achieved with Audio-Visual alarms, safety beam and a control panel programmed to re-try
closing when beam has been interrupted, etc.
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Operation Instructions
These operating instructions apply to a Roller Shutter Door, which is operated via a tubular
motor drive mounted within the barrel assembly.
To Open the Shutter
Check the shutter is not locked in any way and that there are no obstructions that may prevent
the shutter from opening.
Do Not Attempt to Operate the Shutter Until All
Obstructions Have Been Removed
Apply continued pressure to the “UP” button, positioned at the side of the shutter, and the
shutter will travel vertically until it reaches its upper limit switch. At any point the button is
released, the shutter will stop at its current position.
To restart the open operation, simply press the “UP” button again. If an additional means
of safety is supplied with the shutter, such as a photoelectric safety beam, then continued
pressure would not be required on the button. If at any time you need to stop the shutter simply
press the red emergency “STOP” button.
If a key switch is supplied in lieu of push buttons, enter key into cylinder and turn towards “UP”
to activate the shutter. The key switch will require continued pressure, as it is spring loaded to
its “OFF” position.
To Close the Shutter
Check the shutter is not locked in any way and that there are no obstructions that may prevent
the shutter from closing. Check that the area is clear of all personnel.
Do Not Attempt to Operate the Shutter Until All
Obstructions Have Been Removed
Apply continued pressure to the “DOWN” button, positioned at the side of the shutter, and the
shutter will travel vertically until it reaches its lower limit switch and fully closed position. If at
any point the button is released, the shutter will stop at its current position.
To restart the close operation, simply press the “DOWN” button again. If an additional means of
safety is supplied with the shutter, such as a safety edge or photoelectric safety beam, then
continued pressure will not be required on the button. If at any time you need to stop the
shutter, simply press the red emergency “STOP” button.
If a key switch is supplied in lieu of push buttons, enter key into cylinder and turn towards
“DOWN” to activate the shutter. The key switch will require continued pressure as it is spring
loaded to its “OFF” position.
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The panel is activated by a volt free signal from the fire alarm and once activated it will power
this shutter down at a controlled speed. The relay will reset once the signal ceases, leaving the
shutter operational in the normal manner.
If no fire signal is available, a fusible link micro switch will be used, which is activated at a
temperature of 64° C. This will power the shutter to the closed position and will leave the
shutter inoperable until the link is replaced.
UPS Battery Back-Up
In the event of power failure a battery back-up unit can be used (and is recommended). This will
close the shutter via the fire signal or fusible link micro switch.
Manual Reset Solenoid
The solenoid is activated by a signal from the fire alarm or a smoke detector, and once
activated, it will release the clutch in the drive unit and the shutter will self-gravity close at a
controlled speed. If activated, the solenoid must be reset via the rest pull ring located adjacent
to the drive unit at high level. A firm pull on the pull ring will reset the solenoid and the shutter
can then be activated in the normal manner.
Electric Reset Solenoid
(Electrically Operated Shutters Only)
The solenoid is activated by a signal from the fire alarm or a smoke detector, and once
activated; it will release the clutch in the drive unit and the shutter will self-gravity close at a
controlled speed. If activated, the solenoid will reset as soon as the “OPEN” button is pressed.
This will return the shutter to normal operation.
Troubleshooting
Fault
Cause
Solution
The shutter/door fails
to operate when the
button is pressed /
key is turned
1) There has been a power failure
2) The wrong direction has been selected on the control equipment
3) The thermal trip in the motor may
have activated if the door has been
operated several times recently
1) Wait for power to come back on or
operate the shutter/door with the manual
override if installed
2) Select the correct direction
3) Allow the motor to cool for approximately 30 minutes before attempting to
operatethe shutter/door again
The shutter / door
The limits in the motor have failed to
stops before fully
operate or may not have been set coropening or closing,
rectly
or fails to stop when
reaching its final open
or closed position
Contact your installer
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Maintenance
Cleaning Methods
Galvanised Steel / Aluminium Self Colour Or Powder Coated. Some shutter sections are
designed for external applications and require little or no maintenance under normal operating
conditions. Any general build up of dust or grime should be removed with a sponge using a
soap and water mixture.
Plastisol Faced Steel
Some shutter sections are manufactured from HP 200 plastisol coated steel, which require little
maintenance under normal conditions. Any general build up of dust or grime should be removed
with a sponge using a soap and water mixture.
Winding Gear, Motor Unit, Barrel Assemblies
Winding gear, motor units (electric shutters), an barrel assemblies are generally under cover at
high level and do not require regular cleaning between planned maintenance periods.
Cleaning Materials, Solvents Etc
White spirit may be used to remove graffiti but the shutter should be thoroughly washed and
rinsed using a sponge with a soap and water mix afterwards.
Maintenance By The User
On a daily basis the user should ensure that:
1) There is no damage to any parts of the shutter
2) Excessive force is not required to operate the shutter
3) Any damage to the shutter or excessive force needed to operate the shutter is reported and
action taken as necessary to put the shutter in good working order
4) Components of the shutter and the guides are free from dirt and dust build up likely to affect
the operation
5) The shutter operation continues to comply with the safety requirements
Maintenance Must be Carried Out by
Trained Personnel Only
A specialist service engineer in accordance with the service work instructions and task sheets
should carry out the service and maintenance in accordance with the recommended service
intervals.
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Safety Devices
Safety Brake
Roller shutter doors may be fitted with a safety brake as an anti-fall back device. The brake is
normally installed at the opposite end to the drive system on the end plate at high level. The
brake works centrifugally and will stop the shutter completely if the shutter curtain travels too
quickly in the downward mode. Once activated, a qualified engineer will be required to reset the
brake.
Direct Drive Operator
Roller shutter doors are fitted with a direct drive motor operator. This type of shutter does not
have counterbalance springs fitted and therefore the direct drive unit is designed to take the full
weight of the shutter curtain. The direct drive unit has a built in safety brake which will activate
if there is a failure in the motor drive. Once activated, the direct drive operator will stop the
shutter completely and would have to be replaced by a qualified engineer.
Safety Beam
A photoelectric safety beam may be fitted to the shutter. If the beam is broken, the shutter will
not close. If the beam is broken during closing, the shutter will stop and re-open to its fully open
position. Please note that if the beam is out of alignment, the shutter will not operate.
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Service
It is essential that the shutter operation remains functioning in accordance with the operating
instructions. To ensure this happens a documented maintenance regime should be established
and maintained by the employer in accordance with Regulation 5 of the Workplace (Health,
Safety and Welfare) Regulations 1992.
Failure to do so may result in prosecution in the event of an accident.
Service Intervals
Note: Failure to keep the shutter regularly maintained will invalidate the warranty.
The following recommendations are for maintenance to ensure that the shutter remains in
full working order throughout its service life. To ensure safe and reliable operation regular
inspection and maintenance is essential. The intervals are dependent on the use.
Shutter Cycles per Day
1 Cycle = Open or Close
Recommended Maintenance Period
Up to 16
6 Months
Up to 30
4 Months
Up to 44
3 Months
Over 44
2 Months
Shutters over 30m² should be serviced at intervals equivalent to 50% of above cycles.
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Service & Repair Record
Standard Service Check Sheet For Fire Resistant Roller Shutter
Doors on Planned Maintenance
This Work is to be Carried Out by Trained Personnel Only
Shutter Curtain
• Check general condition of the shutter curtain
• Check laths for signs of wear or damage
• Check that end locks fixed to the end of laths are secure
• Check curtain is securely fixed to barrel assembly
• Check bottom rail section for wear or damage
Side Guides
Do not grease the side guides.
• Check all fixings are secure and that fusible washers are intact
• Check condition of guide channel and straighten any slight deformations
• Check guide stops at high level
• Check any chain keeps fitted
• Check that the shutter curtain feeds into the guides smoothly and correctly
• Check drop bar guides (if installed)
• Check drop bar system works correctly (if installed)
End Plates and Barrel Assembly at High Level
• Check fixings are secure
• Check all gearing is fitted
• Check all grub screws and keys
• Check drive chain is fitted
• Check haul chain
• On push up shutters, check barrel for correct tension (Re-tension barrel assembly if required to
correctly balance the shutter curtain)
• Check that the controlled descent operator is securely fixed
• Check condition of safety brake if fitted
• Check that coil casing and supports are securely fixed
Simulate Fire Test
• Check condition of any fusible link or solenoid
• Test the self-closing of the shutter by simulating fire conditions
• Test operation of any battery back-up device and warning systems (if installed)
• Re-set shutter after test is complete
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Electrical Drive System
• Check motor drive is securely fixed
• Check drive gearing and lubricate
• Check operation of manual over-ride system
• Check shutter travel limits and adjust if required
• Check correct operation of control buttons
• Check correct operation of safety beams (if installed)
• Check all other control systems (if installed)
The control descent operator is not designed to operate the shutter on a regular basis and
should only be used sparingly.
Date work carried out:
Work carried out:
Work performed by:
Sign:
Print:
Company name:
Date work carried out:
Work carried out:
Work performed by:
Sign:
Print:
Company name:
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