Roll-A-Door
Series 2 Industrial Doors
INSTALLATION INSTRUCTIONS
DISCLAIMER
THESE INSTRUCTIONS ARE INTENDED FOR
PROFESSIONAL GARAGE DOOR INSTALLERS
Note: All references are taken from inside looking out
Revision 2 July 2009
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2
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Roll-A-Door Series 2 Installation Instructions
1.0 BEFORE YOU START
1.1 SAFETY CHECKLIST
The following hazards and hazard controls have been identified for installers during the installation of this door.
Hazard
Control
•
•
•
Housekeeping - risk of slip trip or fall
Housekeeping - risk of injury to other people or animals
in the installers work area
•
•
•
Tidy up site prior to start work as a minimum area should
be at least the area of the installation back into the garage
and 2 metres in front
If the Site housekeeping is deemed to be unsafe do not
install the door
Keep all people well clear of installers work area with
appropriate signage and discussion with owner
Manual handling when moving the door from the Trailer
or Ute to the installation area - risk of musculoskeletal
injury
Manual handling when installing Doors & Openers
particularly above head height - risk of musculoskeletal
injury or twisting
Manual handling when installing tracks and torsion bars risk of musculoskeletal injury
Manual Handling when installing the door opener - risk of
musculoskeletal injury or twisting
•
•
•
•
•
•
Correct lifting technique for Roller Door
Use of 2 person lifts
Use of mechanical aids such as lifting stands
Avoid twisting (Practice correct lifting techniques)
Correct use of ladders while installing tracks
Use of correct technique of knotted rope installation aids
•
Working at heights and working with ladders - risk of fall
from height
•
•
•
Ladder check
Ladder placement
Do not work off the top rung
•
Sharp edges on Door, tracks or related jewellery - risk of
laceration
•
•
Wear appropriate PPE (Dyneema cut off Gloves)
Follow instruction explicitly particularly for the installation
of some parts of the doors as the unrolled cut out edges
presents a very sharp edge
•
Pinch points - risk of cut, puncture or crush injury
•
Wear appropriate PPE and keep hands well clear of pinch
points
Ensure hands well clear of the panels
•
•
•
•
•
•
•
•
Use of hand tools - risk of eye injury, laceration cut stab
or puncture injuries (Tools checklist)
Use of Electric/ Battery or pneumatic tools - noise hazard
Use of cutting tools creating sparks - risk of fire
•
•
Tension spring - risk of release of stored energy (various
door parts, tools, jewellery striking installer on the head
or body)
•
•
•
•
•
•
•
Wear appropriate PPE and utilise operators manual
Use appropriate noise/hearing protection in the form of
ear plugs or ear muffs
Ensure appropriate fire protection available and
housekeeping to ensure that flammable liquids or
materials are removed from the area of work
Ensure door is correctly secured
Ensure that pipe wrench is fitted correctly to the axle and
if it is gripped onto the axle do not underestimate the
tension in the spring when undoing the clamps
Ensure the correct length pipe wrench is utilised
Ensure correct bolts are tightened or loosened to ensure
there is no release or controlled release of energy from the
spring through the pipe wrench
Keep hands clear of the pipe wrench at all times
Keep head clear of the pipe wrench at all times
1.2 PREPARATION
DO NOT CUT THE PACKAGING THAT HOLDS THE DOOR IN A ROLL
At a later stage during the installation you will be told just when to cut the packaging.
Remove brackets, guides and bag of small parts from each end of the door roll.
Because B&D Roll-A-Doors overlap the opening on each side, the door and opening widths should be
measured to determine the amount of door overlap to enable correct positioning of the brackets.
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Roll-A-Door Series 2 Installation Instructions
1.3 REQUIREMENTS BEFORE INSTALLATION
B&D Roll-A-Doors are normally installed to operate behind the
opening, overlapping as described in the dimension sketch,
opposite. Openings should therefore have sufficient return on
both sides to accommodate the support brackets and door
guides, with necessary working clearances.
A1
D
Curtain
PLAN
B
A1
The door is supported on brackets above the opening at each
end and requires headroom for the door to roll up in (see
Dimension Panel). Consequently, piers or door posts must
continue up past the top of the opening to provide fixing for the
support brackets.
A2
CHAIN WHEEL
DOORS
B
It is preferable that lintels (or ‘heads’) be built flush with, or
slightly forward, to the back of the door posts if possible. This
avoids an excessive gap between the door and the lintel,
while allowing sufficient working clearance to prevent the door
rubbing against the back of the lintel.
DOOR SIZE – Width: The door curtain should be 100mm (see
Dimension Panel) wider than the opening. However, a wider
than normal door can be fitted by allowing the door to overlap
further on each side, providing the additional sideroom is
available.
A2
Chain wheel pulley
NORMAL HEADROOM
RESTRICTED HEADROOM
F
F
C1
Lintel
C2
Lintel
E2
E1
END VIEW
END VIEW
Ceiling Line
Height: A door can not be installed higher than its maximum
size; however, it can be installed in a lower position (providing
the door guides are cut to suit – as shown later).
C
Lintel Line
If the opening is too high, the door should be installed at the
maximum door height position and the opening reduced or
treated as shown in Step 2.2 under the heading “Bracket
Fixing”.
guides
ELEVATION
Daylight opening
WARNING! No guarantee will be given or responsibility
accepted by the manufacturers if the door is not installed as
instructed. For satisfactory door operation please follow the
instructions carefully.
NOTE: Hand operated doors up to 2400mm high, the bottom rail
will hang 65mm below lintel. For doors over 2400mm high bottom
rail will be level with lintel.
DIMENSION PANEL
HEIGHT
Up to 2400
Up to 2400
2401-3000
3001-3300
3001-3300
3601-4200
4201-5100
WIDTH
Up to 5500
Over 5500
Up to 5500
Up to 5500
Over 5500
Up to 5100
Up to 5100
A1
135
135
175
210
210
210
210
A2
135
135
135
135
135
135
135
B
35-70
35-70
35-70
35-70
35-60
35-70
35-70
C1
540
540
620
620
620
620
635
C2*
475
475
555
555
555
555
590
D
555
555
565
565
565
565
615
E1
245
245
310
310
310
310
310
E2*
180
180
245
245
245
245
265
F
295
295
310
310
310
310
325
G*
65
65
65
65
65
65
45
Operation
Hand Operated
Hand Operated
Direct Drive
Planetary Gearing
Planetary Gearing
Planetary Gearing
Planetary Gearing
*C2, E2, G Dimensions are for Restricted Headroom Installations Only, (G = Height of guide top above bracket arm see Step 4).
Dimensions are recommended and suit Normal Headroom Installations, top of guide will be level with top of bracket arm (i.e. G).
All measurements are in millimeters and are minimum unless otherwise shown.
NOTE: It is not recommended that doors fitted in restricted headroom be fitted with openers.
2.0 INSTALLATION
2.1 FIXING REQUIREMENTS
For attachments to good timber work, coach screws are the standard fixings supplied with B&D Roll-A-Doors. When installing onto
brickwork special fittings will be required. The following items are recommended and can be obtained from most hardware stores.
It is the installers’ responsibility to ensure that the fixing method is sound.
When deciding the fixing method, dynamic loads on door brackets as well as the door weight must be considered.
Revision 2 July 2009
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Roll-A-Door Series 2 Installation Instructions
ALTERNATE METHODS OF ATTACHING BRACKETS AND GUIDES
Right
Hand
Bracket
For Guides:
Use the 40mm x 8mm (1V x 5/16”)
coach screws supplied, with a good
quality plastic masonry plug or suitable
masonry anchors.
Masonry
Anchors
(minimum
bolt size
10mm 3/8”)
NOTE TO BUILDERS:
Masonry blockwork should be properly
filled and reinforced if brackets are to
be mounted directly to blockwork with
masonry anchors. Where the blockwork
is not solidly filled but structurally sound,
long bolts should be passed through the
blockwork using suitable steel plates
under bolt heads.
Special consideration should be given
to brick type and construction of wall,
to ensure satisfactory fixing e.g. welding
detail if fixed to steel.
STEEL
CONSTRUCTION
BRICK
CONSTRUCTION
For Brackets:
Use six 10mm (3/8”) bolt size masonry
anchors; (dynabolts or similar).
Weld
Bolt Guides
to steel
work
Left Hand
Bracket
MASONRY BLOCK
CONSTRUCTION
SECURE GUIDE
Long Bolts
Coach
Screws
into
masonry
plugs
Steel Plate
Right Hand
Bracket
2.2 BRACKET FIXING
Check the opening dimensions to ensure you have the correct
door size. Check floor and lintel levels and work from the lowest
side or from the side with the least headroom. Mark out first
bracket after checking dimension panel for height of brackets
above lintel, E1 for normal headroom installation and E2 if
headroom is restricted. (If insufficient headroom, measure down
from ceiling or obstruction using dimension C1 or C2 and mark a
new line and treat as the lintel). Mark out one bracket, drill and
fix after allowing sufficient side clearance for door curtain Using
a water level or a straight edge and spirit level, transfer position
of top of first bracket arm to opposite side of opening, then
mark, drill and fix second bracket. (NOTE: the brackets must be
perfectly level for correct door operation). Also ensure that the
brackets are secure.
Ceiling line or lowest obstruction
Top of Bracket Arm Line
F
C1 C2
E1 E2
Lintel Line
Allow for width of
door curtain plus
Dimension ‘B’ clearance
NOTE:
1. Where possible, and for best performance, doors should be installed in the normal headroom position. The restricted headroom
installation should only be used where headroom is restricted and is not recommended for electrically driven doors.
2. The bottom rail of doors below 2400mm high will hang below lintel and reduce walk in height by 65mm. For doors above 2400mm
high, the bottom rail will be flush with the lintel.
3. Where insufficient headroom exists and brackets are placed above a marked lintel line it may be necessary to fit a false head or
lintel to improve appearance of the installation and to improve cover.
2.3 POSITION DOOR ON BRACKETS
With the door the correct way round (the curtain
rolls down the rear of the opening) carefully lift door
onto the brackets using block and tackles attached
to the door axles, or other suitable lifting equipment
– avoid curtain damage.
A.
Position Bottom Rail here
“U” bolt Axle Clamp
For Doors up to 3000mm High with
Single Saddle and “U” Bolt Fixing
Saddle
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Roll-A-Door Series 2 Installation Instructions
For doors up to 3000mm high, rest axle on cast iron saddle and loosely secure with “U” bolts, nuts and washers, through slots in
bracket arm. (See sketch).
Position Bottom Rail here
Keeper Plate
B.
For Doors up to 3000mm High with Double
Saddles through Bolts and Keeper Plates
Double Saddle
For doors over 3000mm high, rest axle between two cast iron saddles and loosely secure to bracket arm with bolts, plate nuts
and washers provided. (See sketch below) If chain gear is fitted, ensure that the chain is placed around the chain wheel and hangs
down freely.
C.
10mm Bolts
25mm x 5mm Plate
Axle
Cast Iron Saddles
Bracket Arm
Washers
25mm x 5mm Plate
Before tightening “U” bolts or saddle bolts, position the door
1. So that it overlaps the opening evenly both sides.
2. So that the axle is positioned on the bracket arm slots as far forward as possible, while still allowing the bottom rail to pass the lintel
when the door roll is rotated. (See sketch B)
3. Rotate both the door and the axle so that the bottom rail is level with the bracket arm. (See sketch B) Now tighten the “U” bolts or
saddle bolts very tightly, using washers under nuts, to a torque of 40 newton metres or 30 ft.lb.
WARNING: Axle must be securely clamped otherwise door will lose spring tension.
2.4 INSTALL GUIDES
Guides must be the correct length. The guide top is to be level with the top of bracket arm for preferred “normal headroom” fixing or
above the bracket arm by dimension G for “restricted headroom” fixing. If guides need to be shortened cut from bottom of guide.
GUIDE LENGTH – PREFERRED HEADROOM
G
Bracket Arm
Top of guides should be level with top of bracket arm for all door heights.
This is the recommended position for electrically driven doors.
GUIDE LENGTH – RESTRICTED HEADROOM
Cushion Head Stop
Guide Lug
DOOR HEIGHT
DIMENSION G
Up to 4200mm
4200mm to 5100mm
Max 65mm
Max 45mm
Chain Wheel
Position guides true and plumb at each side of the opening.
Allowing 3-4mm of working clearance between the door and
the inside of each guide, mark, drill and fix both guides. Use
the 10mm (5/16”) coach screws and washers supplied (with
suitable plastic plugs for masonry application or other fixings
to ensure satisfactory attachment. (Note: Welding of guides to
steelwork is usually not recommended).
Spirit
Level
Chain Clip
Revision 2 July 2009
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Roll-A-Door Series 2 Installation Instructions
2.5 SPRING TENSIONING BOTTOM RAIL STOPS
Check top of guide lead in to ensure that the door does not make contact when rotated. Damage to Nylofelt could result. The curtain
must feed in smoothly without bumping – adjust lead in as required.
Apply, tension to the springs by rotating door approximately two (2) complete turns in a forward direction (see arrow on sketch A)
after ensuring axle is securely clamped. The amount of tension required for satisfactory operation may vary with individual doors,
depending on size. Final adjustment should be made later.
A.
RO
T
WARNING
Once the packaging containing the door roll is cut, the door will have
a strong tendency to rise and revolve. If uncontrolled, the rapidly
unrolling door could cause damage or injury. Therefore, it must be
securely held until bottom rail stops are fitted. Chain wheel doors can
be held in position by locking the chain in the chain clip attached to
the left hand guide.
E TO APPL
AT SIO Y
TEN N
Hold door firmly and cut the packaging. Feed door down into guides
below head stop.
Fit bottom rail stops using self locking nuts provided. Allow door to
rise and to rest against head stops. (See sketch B.)
FINAL ADJUSTMENT
Operate door up and down a number of times to check operation.
If operation is uneven or not smooth, rectify as below: –
Self locking
Nuts
B.
Faults
1. Door hard to operate in one direction.
2. Door hard to operate in both directions.
3. Door is stiff to work and rattles over lead in on top of guides.
4. Door is scraping in the guides.
WARNING
Do not grease the guides. Grease will damage the Nylofelt running strips and make doors heavier to operate.
Remedies
1. Adjust spring tension.
2. Check guide clearances (see that door is not jamming). Also check that the inside surfaces of the guides
are clean and free of any oil film. Use a spirit cleaner if necessary. Polishing the inside surfaces of the
guides improves operation.
3. i) Check that guides are not too long. Move the door closer to the lintel.
ii) With the door up and chain secured, loosen one “U” bolt/saddle bolt and push that side of the door
towards opening as far as possible without scraping lintel. Tighten the “U” bolt and repeat operation
with the other side, ensuring that the axle is still parallel with opening.
iii) Pack out top lug of guide.
4. Check that the guides are plumb, the clearances are correct and the door is correctly centred with the
opening. Also check that the brackets are level.
2.6 LOCKING
INTERNAL WAIST HIGH SLIDE BOLT
(Left hand side shown – viewed from inside.)
With door fully closed
check that bolt slides
through guide. Adjust
hole if necessary.
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Roll-A-Door Series 2 Installation Instructions
ADJUSTING SPRING TENSION IF NECESSARY
METHOD OF FITTING OPTIONAL
PADBOLT TYPE LOCKING
Wave Washer
Flat Washer
Outside Locking Bar
Bottom Rail
Inside Locking Bar
LOCKING BAR ASSEMBLY
Head Stop
IMPORTANT
– See Note
IMPORTANT
Head-stop must
be secured to slide
bolt as shown in
drawing before door
is operated. Failure
to do so will result
in unrolling of door
causing damage.
Hand Operated and Direct Drive Doors Only
With door in open position (rolled up), tie two ropes right
around door approximately 12” from each end. With a person
at each end secure a firm hold on axle with stilson or pipe
wrench and loosen axle clamp with socket spanner. Axle can
then be rotated in required direction (see diagram below)
until approximate tension is gained. It is recommended that
alteration to spring adjustment be only by small degrees till the
best position Is found. Axle clamps must then be re-tightened
to a tension of 40 Newton metres or 30 ft.lbs. Before releasing
hold on pipe wrench (stilson). Repeat process if spring still
requires further tension.
Pipe wrench at
least 450mm
(18”) long
Hold axle before
loosening
“U” bolt
To loosen
spring tension
PULL
To tighten
spring tension
“U” bolts
to be loosened
at both ends
CENTRE LIFT LOCK
a. Undo screws to separate lock from faceplate.
b. Fit faceplate to outside of door. Fit hooks onto curtain edge,
then slide faceplate as far to the right as possible. Use
adhesive tape to hold in position.
c. Attach the lock body to the faceplate from the inside, using the
mounting screws and washers. Do not over-tighten the screws.
d. With the door in the closed position slide the end of the
locking bars through the locking bar retainers, and while
holding the bars level mark the side of the guides.
e. Tap and bend the cut-outs as shown. If locking slots do not
line up, re-drlll new holes in the correct position ensuring
that the slot is no wider than the existing slot.
f. Slide bars through guide slot, then back, onto lock arms.
Screw on securely using 4mm x 6mm screws supplied.
Attach self
adhesive lock
bar retainers
Doors with Planetary Geared Chain Wheel Only
If the door tension needs adjusting and the door is fitted with
Planetary Gearing then follow the steps below:
1. Ensure that the door is in the OPEN position
2. Secure a rope around the centre of the door roll and use
vice grips to clamp the guides just under the bottom rail of
the door to prevent the door from closing suddenly during
the re-tensioning process.
3. Secure both chains in the chain clip.
This end first
HOOKS
4. Carefully loosen the axle clamps
5. Adjusting Tension
(a) Faceplate
(b) Lock Body
(e) Lock Arm
(d) Cutouts
WARNING: Hold Axle before loosening “U” bolts.
IMPORTANT: Do not attempt to loosen “U” bolts before
securing firm hold on Axle with Pipe Wrench (stillsons). Do not
use filters or similar brittle steel tools such as Tommy Bars.
(c) Locking Bar
SELF ADHESIVE LOCK BAR RETAINERS
Position as indicated and clean the surface before proceeding.
1. Peel back and stick in position.
2. For additional strength drill 2 x 1/8 holes from inside using
retainer as a template.
3. Fit 2 x 1/8 pop rivits to each retainer from the face of the door.
a. To increase spring tension, carefully pull down on the rear
chain, Lock the chain in the chain clip.
b. To reduce spring tension, hold the rear chain firmly,
carefully release chain from the chain clips and allow
the rear chain to move upwards, take care that the full
tension is not removed from the springs. Lock the chain
in the chain clip.
NOTE: As a safety precaution to protect both the door and the
installer, lock a section of the chain in the chain clip so that the
chain is restricted to short movements.
6. When the tension is correct, secure the chain in the chain
clip and re-tighten the axle clamps to the correct tension.
7. The correct adjustment will only be found by trial and error,
adjustments should be restricted to approximately one
revolution of the chain wheel.
Revision 2 July 2009
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Roll-A-Door Series 2 Installation Instructions
3.0 AFTER INSTALLATION CARE
REGULAR MAINTENANCE REQUIRED
GENERAL CARE OF YOUR
SERIES 2 INDUSTRIAL DOOR
CLEANING
COLORBOND® & COLOURED STEEL FINISH Your B&D
Series 2 Industrial Door has been pre-painted with a silicone
modified polyester formulation, which is one of the best paint
films commercially available today. However, all exposed
surfaces require some attention to guard against the premature
onset of corrosion and any other harmful atmospheric effects.
In our atmosphere there are harmful deposits that gather on
the door surface and if not removed regularly, will seriously
affect the appearance and life of the door.
B&D recommends that you check the operation of your Series
2 Industrial Door at least every six months (more regularly in
extreme environments or frequent use). The effort required to
manually open and to manually close the door should be about
the same (if door has an automatic opener, put into manual
mode before testing door).
NOTE: do not grease or oil the guides on doors fitted with
Nylofelt.
If the door is difficult to operate in either direction (up or down)
then check that the inside surfaces of the guides are clean and
free of obstructions.
Washing of the door with clean water and a cloth every 14 days
is recommended – particular care should be taken to clean
areas of the door not normally washed by rain.
If the door is still difficult to operate, then your door will need
a service to adjust the spring tension and possibly other
operational parts of the door.
LOCK
This service should only be carried out by an experienced door
technician, using the correct tools.
Your lock does not require special maintenance, however, if the
keyway becomes stiff, the application of powdered graphite is
recommended – do not grease or oil the lock.
WARNING! Do not disassemble the lock mechanism and do
not allow paint to enter the lock keyway.
If you have an automatic opener fitted to your door, it is
particularly important that you ensure the optimum operation of
the door, otherwise you may reduce the effective life of the opener.
To keep your door running well, it is recommended that your
door be serviced, by an experienced door technician, every 12
months (more regularly in extreme environments or frequent
use), or earlier if required.
SPRING TENSION
It is natural for springs to lose tension over time. When spring
tension is adjusted or when your door is first installed it is usual
to apply a little more tension than is required for balanced
operation, to allow for the normal “settling in” of the springs.
WARRANTY
The B&D Series 2 Industrial Door in residential use is covered
by a 12 month warranty for complete door and parts, surface
(excludes salt corrosion).
Warranty conditional on proper care as recommended above.
Full details of the warranty are available from www.bnd.com.au
B&D Doors Office Locations:
Brisbane:
17 Oasis Court, Clontarf 4019.
Phone: (07) 3883 0200
Melbourne:
147-153 Caterbury Rd, Kilsyth 3137.
Phone: (03) 9237 7766
Sydney:
34 Marigold St, Revesby 2212.
Phone: (02) 9722 5555
Adelaide:
23 Frederick Rd, Royal Park 5014.
Phone: (08) 8440 4747
Wollongong:
13-14, Drummond St, Coniston NSW 2500.
Phone: (02) 4226 2288
Perth:
96 Mulgul Rd, Malaga 6090.
Phone: (08) 9247 8777
Newcastle:
Unit 1/108 Mitchell Rd, Cardiff NSW 2285.
Phone: (02) 4956 8533
International/Export:
34 Marigold St, Revesby 2212.
Phone: +61 (0)2 9722 5555
YOUR REPRESENTATIVE IS
Prefixed trademarks are the property of B&D Australia Pty Ltd
B&D Doors & Openers is a division of B&D Australia Pty Ltd, an Alesco company
ABN 25 010 473 971
Copyright 2009 B&D Australia Pty Ltd.
Website: www.bnd.com.au