B&D The Designer Series Bedienungsanleitung

www.bnd.com.au

& P7 Industrial™

installation instructions PART NO: 0T2429

The Designer Series

These instructions are intended for professional garage door

installers.All references are taken from inside looking out.

DOC# 165005_01

PART NO# 0T2429

RELEASED: 29/05/19

Standard Designer Series

Installation

New ush mount

Installation

contents

1.0 before you begin 3

1.1 installation safety warnings 3

1.2 fastener recommendations for tting garage doors 4

1.3 parts checklist 5

1.4 requirements before installation 6

1.4.1 measurements 6

1.4.2 initial calculations 6

1.5 tools 6

2.0 assembly 7

2.1 vertical tracks 7

2.2 door panels 7

3.0 installation 8

3.1 installing vertical tracks 8

3.2 installing bottom panel 8

3.3 adding panels 9

3.4 installing horizontal tracks 10

3.5 install top panel 11

3.5 standard spring counterbalance system 12

3.6 install torsion bar 13

3.7 adding tension to spring 14

3.8 nal checks 15

4.0 troubleshooting 16

5.0 appendix 18

5.1 ush mount installation 18

5.1.1 Assemble the frame 18

5.1.2 Assemble the tracks 19

5.1.3 door panels 20

5.1.4 Install the tracks 20

5.1.5 install seal carrier 21

5.1.6 installing bottom panel 21

5.1.7 Assemble Horizontal track 21

5.1.8 installing top panel 22

5.1.9 spring counterbalance system 22

5.2 rear torsion systems 23

5.3 hinged tapers 25

5.4 two piece shafts for large doors 26

6.0 after installation care 27

The Designer Series & P7 Industrial™installation instructions

1.1 installation safety warnings

WARNING!

Crush injury from

unsecured door

• Place a 2 metre exclusion zone around area under the garage opening

while installing door. If sufcient area is not available DO NOT install door.

• Follow the installation instructions.

Tension Springs • Ensure correctly tting winding bar is used.

• Ensure the correct length winding bar is utilised.

• Ensure winding bar is placed appropriately in the torsion socket plug.

• Ensure correct bolts are tightened or loosened (or clamp pliers) to ensure

there is no release or controlled release of energy from the spring either

through the torsion bar or the winding bar.

• Keep hands clear of the torsion plug at all times.

• Keep head clear of the tensioning bar at all times.

ELECTROCUTION! • Check risk assessment for any highlighted electrical power concerns.

• Ensure power source is isolated prior to commencement of job.

• Turn off electricity to site when necessary.

• Ensure you check the substrate for electrical wiring prior to penetration.

• Wear rubber soled footwear.

LACERATION: • Wear appropriate PPE (Dyneema cut off gloves) and keep hands well clear

of pinch points.

• Follow instructions explicitly, particularly for the installation of some parts

of the panel doors, as the unrolled cut out edges presents a very sharp

edge.

CAUTION:

Muscular strain • Practice correct lifting techniques when required.

• Use mechanical aids such as lifting devices, forklift and cranes where

possible.

• Avoid twisting.

Fall from ladder • Ensure ladder is the correct type for job.

• Ensure ladder is on at rm ground that will take the weight without the legs

sinking.

• Ensure user has 3 points of contact while on ladder.

Hand Tools • Wear appropriate PPE and utilise operators manual of all tools.

• Use appropriate noise/hearing protection in the form of ear plugs or ear

muffs.

• Ensure appropriate re protection available and housekeeping to ensure

that ammable liquids or materials are removed from the area of work.

Entanglement • Keep hands and loose clothing clear of moving door and guides at all

times.

TWO PERSON LIFT: • Depending on the size of the door, this product may requires a two person

lift. Use proper techniques and equipment to lift the door from the trailer

and into position.

This B&D Door is designed and tested to provide security, attractive appearance and smooth , low

effort operation provided it is installed and operated in strict accordance with the following safety

warnings. Failure to comply with the following instructions may result in death, serious personal injury

or property damage.

NOTE: No guarantee will be given or responsibility accepted by the manufacturers if the door is not

installed as instructed.

1.0 before you begin

The Designer Series & P7 Industrial™installation instructions

WARNING!

The installer must select and use fasteners appropriate to the material into which they are being fixed.

1.2 fastener recommendations for tting garage doors

substrate type fastener required washer

required

plug

required

drilled

hole ø

(mm)

min hole depth

(mm)

B&D fastner

pack

Unlined Plaster

Lined 100pk 500pk

solid brick

(>10 MPa)

screw, coach

5/16 - 9tpi x 50 washer at M8 plug, nylon

5/16 x 50 10 60 90 FK0 011 FK0012

three hole brick

(> 30 MPa)

screw anka M8 x 75

ange hex head washer 3/8”n/a 875 75 FK0024 FK0023

(50PK)

ten hole brick

(>15 MPa)

screw anka M8 x 75

ange hex head washer 3/8”n/a 875 75 FK0024 FK0023

(50PK)

concrete block

(> 8 MPa)

screw anka M8 x 75

ange hex head washer 3/8”n/a 875 75 FK0024 FK0023

(50PK)

concrete

(> 15 MPa)

screw, coach

5/16 - 9tpi x 80 washer at M8 plug, nylon

5/16 x 80 10 60 90 FK0013 FK0014

timber screw, coach

5/16 - 9tpi x 50 washer at M8 n/a 560 90 F K0 011 FK0012

steel section

(0.9-2mm thick)

screw tek

14g - 20tpi x 25

ange hex head ZP

washer at M8 n/a n/a n/a n/a FK0019 FK0020

important notes

1. For installation to substrate materials not covered in the above chart, the installer should seek expert advice.

2. Substitute fasteners are not recommend unless approved.

3. The above chart species the fasteners for new substrate materials only. Seek specialist advice regarding

pre-existing substrate materials.

4. It is important that correct washer and plug is used and the correct pilot hole drilled where specied.

The Designer Series & P7 Industrial™installation instructions

1.3 parts checklist

ITEM DESCRIPTION QTY

A DOOR PANELS PACKAGE 1

B TORSION BAR 1

CHORIZONTAL TRACKS 2

DVERTICAL TRACKS 2

ESHORT TOP TRACK ANGLE 2

F HORIZONTAL BRACKETS 2

G SMALL ANGLE JAMB BRACKETS 2+

H WASHERS 6+

I TENSION SPRING 1-4

J CABLE DRUMS 2

KSPRING ANCHOR BRACKET 2

1.3.1 pack contents

ITEM DESCRIPTION QTY

L SIDE BEARING BRACKETS 2

MWHEEL AXLES 8+

N LIFTING CABLE 2

O TEK SCREWS 20+

P HANGERS 9+

Q HINGED HANGERS 8+

R BOTTOM PANEL BRACKET 2

S AXLE PLATE HANGER 2

T BOTTOM HANGERS 2

U SNAP PINS 2+

V SHAFT COLLAR 1

The Designer Series & P7 Industrial™installation instructions

mounting - The door is designed to be mounted behind the opening, however for ush mount doors, refer to the

Appendix for mounting instructions.

obstructions - Ensure that the surface where the door will be tted is smooth, and the area behind the opening is

free from any protrusions.

structural suitability - Ensure the opening is strong enough to support the door. If unsure, consult a builder.

level and plumb - The door must be installed in an absolutely level position, if opening is not level and square,

appearance and/or sideroom requirements will be affected. The oor should be level or recessed across the

opening to avoid gaps.

1.4 requirements before installation

HEIGHT

WIDTH

SIDEROOM

BACKROOM

HEADROOM

LEVEL DATUM

1.4.1 measurements

(refer to appendix for rear torsion allowances)

opening width - As the door overlaps each side by

30mm or more, the door should be 60mm wider than the

opening. A wider door can be tted as long as additional

sideroom and xing is available. See Fig 1.4.1.

opening height - The door will t any opening height

up to the marked door size.

sideroom - A minimum of 120mm of sideroom is required

over and above door width and should extend above the

head to allow for bracket xing.

headroom - depending on the cable drums used

a minimum of 340mm (390mm for larger doors) of

headroom is required.

backroom - as the door extends into the garage when

opening a minimum of the door height + 300mm for tracks

is required (+ 1000mm if opener tted).

level datum - use a water or lazer level to mark a datum

line on both sides approx. 1.5m from the oor. Use this line

to compare the distance on each side to the opening

height to determine if the opening is level.

vertical track height - the track height should be the

door height minus the short top track angle measurement.

1.4.2 initial calculations

a) Open the package of door panels and locate the label on the end of the door panel.

b) The label lists the Sales No: XXXXXX, then underneath DH: X,XXXmm (door height).

c) Calculate the vertical track length:

tip

door height

Fig: 1.4.1

(standard 127mm,

low headroom 275mm)

short top track angle

-=vertical track length

It is recommended that this door is installed by a professional door installer using a professional and specialised

tool kit.

1.5 tools

d) Calculate the track width:

tip

door height 3/4

x=horizontal track

brace postion

e) Calculate the horizontal track brace position:

tip

panel width 20mm

+=track width

(from the inside edge)

The Designer Series & P7 Industrial™installation instructions

2.0 assembly

2.1 vertical tracks

a) Cut the Vertical Straight tracks Dto the calculated

length as listed in section 1.4.2.

b) Afx the small angle jamb brackets Gand short top

track angle Eto the straight track Dusing 6 x 5/16 at

head bolts and wiz nuts, noting the distance required

from the wall to the track as shown in Fig 2.1.1.

c) Connect the horizontal bracket Fto the short top track

angle Eusing a 1/4 domed head bolts and wiz nut in

top corner of the “V”.

Fig: 2.1.1

left hand track shown

2.2 door panels

a) Open up the pack of door panels, making sure the

bottom panel (weather strip seal on the bottom of the

panel and bottom hinge hole) is on top of the pack.

Start with the bottom panel.

b) Place the axles plate hanger Sonto the bottom

hanger Tand secure onto the bottom panel as

shown in Fig 2.2.1 using tek screws. Ensure to line up

the holes with the bottom panel bracket R.

NOTE: Refer to appendix if installing a taper or rear torsion system as this requires a different hanger.

tip

Do not unwind lifting cable until specified

to do so.

c) Secure the bottom panel bracket Rwith 2 tek

screws, then slide in wheel axle Mthrough the axle

plate hanger to the bottom panel bracket.

d) Push the end of each lifting cable N, onto the

bottom hanger, followed by a washer Hand secure

with a snap pin UFig 2.2.1.

Fig: 2.2.1

70mm

40mm

NOTE: Refer to appendix for

ush mounting installations

tip

Apply general purpose grease to all axles

before fitting them.

e) Attach the hanger Pto the top of the panel at every

door stile, using 2 tek screws, then place 2 hinged

hangers Qat either end of the panel and secure

with tek screws.

NOTE: The small angle jamb brackets and the short top track angle, provide adjustable slots to move the

track out from the wall. For larger doors one bracket is placed at the bottom and the second backet placed

approximately midway.

f) Insert the wheel axle M. NOTE: Once the panel is in place the hinged hangers

Qcan be adjusted if needed to ensure the panels are parallel to the opening.

g) Repeat steps e) and f) to assemble other middle panels.

The Designer Series & P7 Industrial™installation instructions

3.0 installation

3.1 installing vertical tracks

10 mm

“V” section

a) Set the vertical tracks parallel on both sides of the door

at the vertical track width calculated in Section 1.4.2.

b) The tracks should be panel width + 20mm apart. Use

the level/datum marks to ensure the tracks are level with

each other and the same distance to the top of the track

or the door will not function correctly. Fig 3.1.1

c) Ensure to follow the measurements as shown in Fig 3.1.2

to set out the placement of the track and brackets.

d) Once satised temporarily x in position with at least

two (2) xings to the top bracket and one to each of the

lower track brackets. These will hold the tracks in position

and allow for minor adjustments. Fig: 3.1.1

Fig: 3.1.2

NOTE: Refer to appendix to install ush mount track system.

WARNING! All fixings must be fitted after the door

is fully adjusted and operating satisfactorily.

Equal Equal

3.2 installing bottom panel

10 mm

“V” section

TWO PERSON LIFT: depending on the size of the door, this process may

require two persons to lift into place.

a) Carefully lower the wheels of the bottom

panel into the tracks and lower so the panel

is sitting level in the door opening Fig 3.2.1.

b) Check that the wheels are stiting in the “V”

groove of the vertical track on each side

and there is sufcient clearance between

the panel and the track as per Fig 3.1.2.

CAUTION: After installation is complete all

plastic protective lm must be removed

from all panels.

Fig: 3.2.1

The Designer Series & P7 Industrial™installation instructions

3.3 adding panels

TWO PERSON LIFT: depending on the size of

the door, this process may require two persons

to lift into place.

a) Before adding the next panel into the tracks t a

temporary spacer, 1-2mm thick, at each panel joint

to give clearance between each panel in order to

decrease paint rub.

b) Insert the next panel into the guides and lower to

rest on top of the bottom panel. Fig 3.3.1 and 3.3.2.

c) Screw the hangers and hinged hangers to the

lowered panel.

NOTE: The hinged hangers are adjustable to ensure the

panels are parallel to the opening.

d) Repeat this procedure for all other panels with the

exception of the top panel which is positioned after

the horizontal track is installed Fig 3.3.3.

e) Once satised with the door placement, secure all

xing points on the vertical tracks.

Fig: 3.3.1

CAUTION: Ensure the warning label is placed on

the door in a clearly visible position.

Fig: 3.3.2

Fig: 3.3.3

The Designer Series & P7 Industrial™installation instructions

EQUAL

Assemble the track as shown in Figure 3.4.1. The

curve must align and butt up against the vertical

track snugly.

3.4 installing horizontal tracks

track

stop

¾ track length

equal equal

¾ track length

Fig: 3.4.1

Before bracing the horizontal tracks, ensure that

they are square to the opening and level. To

check whether your diagonals are equal:

a) Measure from the top of the vertical track to

the end of the horizontal track.

b) Check both sides.

c) Adjust if necessary.

The track support must be located along the

horizontal track approximately at 3/4door height.

For doors higher than 2280mm and/or wider

than 4700mm two supports will be required.

d) Calculate the horizontal track brace position as per

section 1.4.2.

e) Measure along the horizontal track to the desired

position and nd a structurally sound location to x

your support to the ceiling or side wall. Fig 3.4.2 or

Fig 3.4.3.

f) Each installation must be assessed individually for

ceiling xing requirements.

WARNING! Failure to position supports

approximately 3/4door height along the

track can result in the tracks twisting out.

Fig: 3.4.2

WARNING! For all doors higher than 2280mm

and wider than 4700mm two (2) ceiling

supports must be fitted per horizontal track.

single support

double support

The safety stop must always be tted to prevent the

panels from accidently exiting the track

g) Install the safety stop at the end of the horizontal

track as shown in Fig 3.4.4.

Fig: 3.4.4

WARNING! The safety stop must be installed.

Failure to do so may cause serious personal

injury or damage to property.

tip

Check that the clearance in the vertical

tracks as per Fig 3.1.2 is also in the

horizontal tracks.

Fig: 3.4.3

NOTE: Refer to appendix to install ush mount track system.

The Designer Series & P7 Industrial™installation instructions

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