wind rated roller doors installation instructions - Steel

wind rated roller doors installation instructions - Steel
WIND RATED ROLLER DOORS
INSTALLATION INSTRUCTIONS
THESE INSTRUCTIONS ARE PROVIDED FOR THE USE
BY EXPERIENCED INSTALLERS OF GARAGE DOORS
BY UNDERTAKING THE INSTALLATION OF THIS DOOR,
THE INSTALLER UNDERSTANDS THE DANGERS
ASSOCIATED WITH THE INSTALLATION.
Steel-Line Garage Doors IS NOT RESPONSIBLE FOR
ANY AND ALL LIABILITY RESULTING IN THE INJURY
AND OR DEATH DERIVED FROM AN IMPROPER
INSTALLATION.
Revised July 2015
GENERAL WARNING!
To install this door safely, a number of precautions must be taken. For safety of all concerned,
pay heed to the warnings and instructions given below.
SPECIAL SAFETY WARNINGS OR REMARKS IN THIS MANUAL ARE
INDICATED WITH THIS SYMBOL.
PLEASE READ WARNINGS
CAREFULLY.

Please read this installation manual completely prior to installation. It is very important to
install this door correctly in order to achieve proper and safe operation.

The Steel-Line Wind Rated Roller Door is designed as a roller door to exceed the wind load
requirements of cyclonic regions C & D in Australia, in sizes to suit a maximum daylight
opening of 5100mm High x 5400mm Wide. The door weight, depending on size, can be as
much as 295kg (649lbs) and the forces generated in the springs are generally equal to the
door weight. Proper care must be taken not to release those forces violently as it could result
in serious physical injury.

All the components which have been supplied are designed for this specific roller door.
Replacement or adding additional components may have an adverse effect on the
performance, safety and the guarantee of the door.

Shaft of door is under strong spring tension. Do not attempt to loosen U-bolts on shaft
while under tension, without ensuring a suitable pipe wrench is locked onto shaft and
wedged against wall, or held securely while loosening the U-bolt. Otherwise the sudden
release of the spring forces will result in severe risk of injury.

All instructions are given as if viewing the door from inside looking out.
July 2015
Flaring of track replaced by plastic guide lead-in & direct chain drive option removed. Security clip ‘N’
wind rated roller door drawing added. Wind Rated was Cyclonic in title & text.
July 2014
General revision with inclusion of C2 only rated doors
Wind Rated Roller Door Installation Instructions
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SECTION 1: Pre-Installation Checks
A Roller Door is designed to be fitted behind the opening so the following dimensions and
conditions need to be checked, before fully unpacking the door for installation.
1. Opening Width: Check that the curtain supplied overlaps the daylight opening width by a
minimum of 50mm.
2. Side Clearance: The minimum side clearances are (based on 50mm overlap):
Plain Side
Direct/Planetary Gear
Drive Side
150mm
235mm
Windlock
NB: If door is to be motorised you will need to check with motor installation instructions for side room
required for that motor.
3. Opening Height: Your door will fit any opening height up to that stated on the package.
4. Headroom: A minimum clearance between the underside of the lintel and the ceiling. This
varies with height of the opening. See Chart below:
Door Height
Minimum Headroom * (mm)
3300mm
510
3600 - 4200mm
540
4800 - 5100mm
570
* This clearance must extend for a minimum of 600mm back from the opening. The
headroom stated above is minimum required if whole door is to be hidden from view from
outside the garage. It is possible to use less headroom than stated, but there will be a
corresponding reduction in door daylight open height.
Wind Rated Roller Door Installation Instructions
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5. Structural Condition of Opening: ENSURE THE AREA AROUND THE OPENING IS
STRONG ENOUGH TO SUPPORT THE DOOR AND THE WIND LOADS THE DOOR CAN
IMPOSE ON THE OPENING DURING CYCLONIC CONDITIONS, AS SPECIFIED AS
NATIONAL BUILDING CODE (NCC) 2013.
The surface where the door is to be fitted must be flush and reasonably smooth. Small
irregularities in brickwork are acceptable. The lintel must not protrude backwards or forwards
of the inside face of door opening side brickwork, otherwise this requires special instructions
(please consult your Steel-Line dealer).
For Wind Classification C2 (for other wind rating specifications refer drawings at end of
this guide):
Ultimate Wind Pressure
Doors under 4000mm wide
Doors 4000 & Wider
Inward
Outward
Inward
Outward
2.92kPa
-3.37kPa
2.92kPa
-3.04kPa
Ultimate Reactions (kN/m of Height)
Note:
Door Width 3500 – 4000mm
Door width 5000 – 5300mm
X = 42.7; Y = 6.0
X = 72.2; Y = 9.4
1. Wind classification information from AS4505 – 2012 table 5.2.
2. Ultimate Wind pressure includes appropriate local pressure factors.
3. Ultimate Reaction - X = Horizontal reaction in plane door. Y = Horizontal reaction perpendicular to plane door.
6. Fitting Notes:
a) For doors over 2.5m wide it is recommended that 2 people are available for fitting.
b) THE DOOR MUST BE FITTED SQUARE AND LEVEL, IRRESPECTIVE OF THE
SHAPE OF THE OPENING. ON NO ACCOUNT SHOULD ANY COMPENSATION BE
MADE TO DOOR TO SUIT AN IRREGULAR OPENING.
c) Ensure all necessary tools are at hand before starting.
d) The door package and its contents should be checked for obvious damage before
removal of wrapping. The package should contain:
i). The curtain rolled up and wrapped.
ii). One pair of tracks. These come in standard lengths of 2645mm (2200H up to
2600H doors), 3045mm (2700H up to 3000H), 4245 (3300H up to 4200H) and
5145mm (4800H up to 5100H) to suit the specified door opening height. These
may need to be cut to suit specified opening height.
iii). Accessories box which includes: a pair of brackets, two saddles, two ‘U’ bolts with washers
and nuts and fixing for steel or masonry. Series B Cyclonic roller doors will also include
planetary gear chain wheel, chain guide and chain lock.
iv). IF THERE IS ANY OBVIOUS DAMAGE YOUR SUPPLIER SHOULD BE CONTACTED
IMMEDIATELY.
Wind Rated Roller Door Installation Instructions
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SECTION 2: Installation
DO NOT CUT PACKAGING AROUND ROLLED CURTAIN UNTIL INSTRUCTED IN
STEP 7.
1. Fit Brackets: For manual doors refer to figure B only. For Chain operation fit main support
brackets to the wall in position as per figures below. For motorised operation check the manual
supplied with operator for side room requirements. It is imperative to get the brackets level with
each other and using a water level is recommended. The ‘B’ dimension from the ceiling is a
minimum and may be increased, but the ‘C’ dimension should be maintained wherever
possible. Fix support brackets by welding, masonry anchors or hex head bolts as suitable for
the building material. A good, solid fix is required.
For motorised doors refer please refer to the sideroom clearances noted in the information
provided with the operator and mount the bracket accordingly.
Door Height
Minimum Headroom
DIM ‘A’ (mm)
DIM ‘B’
DIM ‘C’
1200 – 2100mm
430
235
195
2200 – 2600mm
480
260
220
2700 – 3000mm
510
275
235
3300mm
510
275
235
3600 - 4200mm
540
290
250
4800 - 5100mm
570
305
265
2. Fit Planetary Chain Wheel (for manual chain operation only): On door heights 3.0m &
higher, planetary gearing is supplied for manual operation. The unit comes in 2 parts – an
internal ring gear with 3 bolts and locknuts and the fully assembly planetary gears already fitted
to the chain wheel. Fit the internal ring gear onto the required side using bolts and locknuts
provided. Line up with holes in the drum wheel (drilling is not required). Make sure the
locknuts are inside the drum.
Wind Rated Roller Door Installation Instructions
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Give the axle a ¼ turn and let go. This is important as it will make the shaft centre itself. Slip
chain wheel assembly over the shaft so the 4 planetary gears are fully inside the ring gear.
Mark the position of the hole on the little piece of metal tubing coming out of the chain wheel
and drill an appropriate hole through the axle. Slip bolt through and secure with lock nut. Fit
chain guide on shaft under chain wheel. Fit shaft collar to opposite end of axle leaving about
1mm gap between it and drum wheel.
3. Mount Door Curtain To Brackets: Lift the door curtain onto the brackets. On large doors you
will need chain blocks and tackle. (Note: Do not use brackets as lifting device) Slip the
pressed saddle (Series A), or metal cast saddle with ‘U’ bolt (Series AA doors), or heavy duty
metal cast saddle (Series B Doors) under the axle, locate between the 2 oblong holes in the
bracket and fit with the ‘U’ bolts (or bolts in case of heavy duty cast block saddle), washers and
nuts ensuring they are finger-tight only at this stage. Make sure door is central on the axle and
gap between rolled curtain and head wall is approximately 25mm - 35mm. Move axle sideways
if necessary. Rotate the curtain in the direction shown for
initial tension until the bottom rail is level with the axle at
the back of the door from the inside of building. Tighten the
U-bolts securely. Pre-tension the door rotating forward in
the direction shown in figure by 1½ to 1¾ turns. Large
doors may have 4 springs and you may not be able to
achieve 1¾ turns. If this is the case put as much pretension as physically possible and follow Step 7 after fitting
tracks and chain to complete final tensioning. Hold door in
position and cut wrapping/strapping (this might require
another person) and pull the door down about 500mm. Fit a softwood chock (about 300 –
400mm long) between door roll and door curtain to prevent door from winding back up. Take
care to ensure chock will not to damage door surface.
4. Cut And Fit Tracks: Cut the tracks (cut surplus from bottom of track only) to door opening
height + 45mm (+0; -10mm). Please note this rule assumes headroom complies with table
under Step 1. If headroom is less than value in table track length needs to be adjusted
accordingly.
Fit plastic lead-in to top of track ensuring it is
fully home and secure with Tek screw provided
into pilot hole located in front of track (shown
by red circle in photograph)
Slide track up and over the windlocks of the
curtain. Slide the track lugs/cleats from bottom
of track ensuring number of brackets match
number of windlock bars, or windlocks (in case
of C2 only doors to 3760mm wide) across
door.
Once both tracks fitted pull curtain down to closed position and mark the position of each
windlock on both tracks. The lugs/cleats need to be fixed adjacent the windlock to ensure
the wind rated performance of the door can be achieved. Refer photograph below. Push
track against jamb and ensure it is vertical and adjust sideways so that the windlock itself is
as close as possible centrally located within its ‘locking’ area of the track. Make sure the
bottom rail return is below the stops welded to the top of the tracks.
Wind Rated Roller Door Installation Instructions
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NB: Tracks & Lugs/Cleats - To ensure the rated door performance can be
achieved, it is IMPORTANT that the track cleats MUST equal the same number
of the windlocks on each side and where practicably possible aligns with the
windlocks when the door is in the closed position.
5. Fit Chain (for chain operation only): Fit the chain over the chain wheel and through the
chain guide. Join at cut link and hammer or bend closed. Fit chain lock onto the wall
approximately 1500mm up from floor and directly in line with the chain wheel. This provides
your locking mechanism. With the chain in the lock, the drum cannot be turned.
6. Adjust Tracks: Remove the wooden chock and carefully pull the door down ensuring it runs
freely. If it does not, reposition the tracks as necessary.
7. Adjust Door Tension: The initial tension already put in the springs may either be too great or
too little, making the door feel either light or heavy. The ideal tension will be where the door is
just a little heavy in the down position ensuring that it stays down and just a little light in the up
position ensuring that it stays up. You will probably need an assistant to adjust the tension.
First roll the door up and tie a rope around the whole door in the centre. This will prevent the
door from running down if you accidentally lose
tension. Slacken off the nuts of the “U” bolt on
one end. One ‘U’ bolt will retain the tension so
long as the door is fully open. Fit a set of
large self locking grips or ‘Stilsons’ to the axle
on this end, remembering that the axle will try to
turn in the decrease tension direction. While
holding the grips tightly, have your assistant
slacken off the “U” bolt nuts on the other end.
Increase or decrease the tension as required by
rotating the axle no more than 1/4 of a turn at a time. Your assistant can now tighten the “U”
bolt at the other end. Tighten the “U” bolt at your end as well and carefully try the door again. It
may be necessary to repeat this operation several times until the tension is just right.
NEVER ALTER DOOR TENSION UNLESS DOOR IS IN UP POSITION AND ROPED.
WHEN TENSIONING, NEVER STAND WITH FACE IN LINE WITH STILSONS, OR
SELF LOCKING GRIPS.
8. Confirm Door Operates Correctly: The installation is now complete. Operate the door
several times and confirm that it runs smoothly. See next section if problems occur.
Wind Rated Roller Door Installation Instructions
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SECTION 3: Problem Check
1. Difficult To Operate In Either Direction:
a) Check curtain not jamming in the tracks.
b) Check running clearance in the tracks (≈ 2mm per side).
c) Check tracks are upright and clean. Lubricate with silicon spray only.
2. Difficult To Close OR Open: Decrease OR increase spring tension (see Step 7 above).
3. Track/Shaft Relationship: If the door is very difficult to close the last 600mm, check the tracks
are fitted in correct relationship to the brackets and that the axle is correct distance from wall
(210mm – 250mm) i.e. repeat Step 4.
4. Coning: If the curtain rolls up un-evenly (cones out at one end) and the bottom rail appears
out of parallel with door roll and tracks, confirm the following:
a) Brackets are level with each other.
b) Axle is correctly centralised in roll (refer Step 3). If brackets are level, removing coning by
moving axle through the roll in opposite direction to coning and distance roughly equal to
length of coning.
Wind Rated Roller Door Installation Instructions
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