INSTALLATION MANUAL - FindTheNeedle.co.uk
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1. Fig 23 4 8 2 PREPARATION BEFORE MOUNTING It s necessary to conduct shaft assembly before mounting Below is given the order of divided torsion shaft with two springs of reverse spiraling direction assembly fig 24 By assembling the following requirements should be met Left spring fitting and cable drum code LH with red marks should be installed on the left side of the shaft when looking from the inside of the premises Right spring fitting and cable drum code RH with black marks should be placed on the right side of the shaft Left spring should be marked by a red line right by any other color Cable drums are set on the shaft in such a way that the slot for the cable on butt end of the drum was placed from the outer side 30 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS bracket Left spring fitting i Square key Additional Spring break device w alf coupler Shaft Cable drum Left spring Additional bracket Spring break device Right spring fitting Intermediate bracket Half coupler Square key Mounting is done in the following order Mount the right shaft part 1 Dismantle the flange coupler 2 Set half coupler on the shaft connecting shaft butt end and bearing surface of half coupler flange Set water stop2. e 00 Fig 40 4 15 2 LOCK INSTALLATION Installation of the lock is performed in the following order Unpack the device Unscrew the fixing screw and take off the cap of the lock fig 37 1 fig 37 1 INSTALLATIONMMANVAL INDUSTRIAL DOORS HIGHMOUNTING WITHBOTTOMSHAFT POSITIONING 59 60 ALUTECH DOOR SYSTEMS Fix on the door curtain the locking device together with the remote plate fig 37 2 with the help of 6 self tapping screws Screws must be placed into the apertures done by the manufacturer Fig 37 2 Turning the handle pull out the wicket locking mechanism as far as it would go in the sup port of the doors Make the marking and do an aperture with the diameter 16 mm in the support for the input of the wicket locking mechanism fig 37 3 Fig 37 3 Turning the handle button pull out the wicket locking mechanism entirely Open the aperture for the installation of one fixing screw of outer cover plate Place the outer cover plate into the ready aperture in the door curtain putting the sealing on it in advance The cover plate must be fixed with 2 tightening screws fig 37 4 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSIT
3. Fig 43 1 Microswitch that turns off the electric drive when the rope loosens or breaks down in as sembly with mounting bracket see fig 43 2 is fixed to bottom bracket movable part For installation it is necessary to weaken nut from bottom bracket motionless straight A lug side install mounting bracket in assembly with microswitch under the nut Tighten the nut see fig 43 3 Make switch positioning in such a way that it is activated in contact with A lug when the bottom bracket movable part is turned in case rope loosens or breaks Microswitch connection is done to junction box fixed on door leaf according to the scheme with normally closed contact Mounting Microswitch Alug bracket Fig 43 2 Fig 43 3 Wicket sensor security is installed in plant conditions Microswitch connection is done to junction box according to the scheme with normally closed contact INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH DOOR SYSTEMS Optosensor securities are installed on doors completed with Dynamic electric drive Optosensor security consists of two infrared sensor security emitter and receiver installed in bottom sealing profile When the profile is deformed door leaf tripping over obstacle optical ray is disconnected and a signal for door stopping and leaf lift is generated by control unit FINISHING WORKS By sealing of joints and ga
4. 3 5 ALUTECH DOOR SYSTEMS APERTURE PERFORMING FOR FIXING The following drilling regimes for fixing element installation are recommended depending on wall construction material Pure drilling regime without punches This regime is recommended for aperture per forming in hollow brick light and cellular concretes lime gas blocks shell limestone and also in metal constructions Drilling regime with light punches is recommended for aperture drilling in whole brick Punching regime is recommended for walls of concrete with density more than 700 kg m and constructions of natural stone The depth of aperture drilling should be one screw diameter more than the anchoring part of dowel The aperture diameter should not exceed the dowel diameter the aperture should be clean of drilling waste Minimal dowel anchoring depth is given in the table below Wall material Minimal depth mm Concrete 40 Whole brick 40 Brick with vertical hollows 60 Bkey locks of cellular natural stone 50 Light concrete 60 REQUIREMENTS TO THE PASSAGES OF THE PREMISES We draw the attention of our partners that the essential precondition for the door mounting with the least expenses is the quality preparation of passage frame for door installation It s very important for the first step to carefully measure the passage mentioning the material of walls and their thickness Prepared passages should meet the followi
5. 52 DOOR SYSTEMS For wicket closing DECELERATION turn the closing speed screw CKEY LOCKWISE For wicket closing ACCELERATION turn the closing speed screw ANTICKEY LOCKWISE Wicket compressing speed adjustment is done with a closing speed screw analogically Slowing down intensity adjustment when closing the wicket The closer is factory adjusted in such a way that when the wicket headroom angle is more than 70 degrees wicket slow down happens For wicket slow down intensity increase turn the back check control screw CKEY LOCKWISE For wicket slow down intensity decrease turn the back check control screw ANTICKEY LOCKWISE WARNING 1 It is prohibited to turn wicket closing speed screw compressing speed screw back check control screw more than 2 turns ANTICKEY LOCKWISE from factory adjustments Larger turn may lead to hydraulic liquid leaking out 2 It is prohibited to cut off slow down adjustment valve Wicket closing effort adjustment Wicket closing effort factory adjustment is made in such a way that for normal exploitation you do not need to change it If for some reason it is necessary for you to adjust wicket closing effort it is done in the follow ing way For wicket closing effort INCREASE turn the spring power adjusting nut CKEY LOCKWISE For wicket closing effort DECREASE turn the spring power adjusting nut ANTICKEY LOCKWISE Wicket closing effort adjustment range is 9 turns relatively factory adjustment I
6. 0 en 0 0 sh el Fig 34 3 Place hinges on wicket passage framing and wicket leaf fix them with 6 3 16 self tapping screws Hinge positioning is shown in Fig 34 4 0001 um 0009 600 Fig 34 4 INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MOUNTING WITH BOTTONISHAFT POSITIONING 47 ALUTECH DOOR SYSTEMS Open the wicket and remove remote intermediate plates Fig 34 5 4 10 2 CYLINDER KEY LOCK MECHANISM AND PUSH HANDLE INSTALLATION Installation of cylinder mechanism of the lock is shown in fig 34 6 0 J J gi fl SN lis 710 4 e Fig 34 6 Installation of wicket handles is shown in fig 34 7 48 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH DOOR SYSTEMS Fig 34 7 4 10 3 SAFETY GEAR ADJUSTMENT Two safety gears are used to prevent the sagging of the wicket when it is closed Safety gears are fixed on the end of door curtain wi
7. DOOR MOUNT DOOR SYSTEMS Fig 31 1 4 install intermediate hinges fix each with four 6 3x16 self tapping screws fig 31 2 Fig 31 2 5 install the following section and so on 4 9 3 TOP BRACKET INSTALLATION Top bracket installation onto the panel is done in the following way fig 32 fix top bracket with three 6 3x16 self tapping screws set distance rings on rollers to prevent door leaf from side shift Distance rings are chosen in such a way to prevent leaf motion 4 6 mm Put Litol 24 lubricant on rollers Place runners into roller plate ears NSTALLATION MANUALNDUSTRI LCDOORS HIGH MOUNTING WITH BODTOM SHAFT PdsrtioN NG 4 9 4 ALUTECH DOOR SYSTEMS Place roller into vertical tracks and fix roller plate to the bracket with two M6x16 round head bolts and nuts Fig 32 After side and intermediate hinge mounting check and if necessary adjust runner installation The roller should lean to vertical track rolling paths and rotate freely by hand The rope should be placed behind side hinge rollers DOOR TOP SECTION CLOSE CONFORMITY TO PASSAGE HEADROOM Close fitting of door top section to passage headroom is provided by top roller proper position adjustment The adjustment is done i
8. 3 We Spring with tips 28 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING e Intermediate bracket Cable drum Coupler adjustable Fig 20 _ ALUTECH DOOR SYSTEMS Spring break devices art SBD 1 are used with the shaft with diameter 1 25 4 mm Spring break devices art SBD 5 4 are used with the shaft with diameter 1 4 31 75 mm Ifthe shaft axis is placed from the wall at a distance more than 86 mm spring break de vices art SBD 1 are used with the bracket art B 86 fig 21 Bolts M8x25 and nuts are used for fixing Bracket art B 86 On springs with high level of turning spring break device art SBD 5 4 is used together with bracket art B 152 and reinforcing side bracket art B 152A fig 22 Bracket art B 152 INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MQUNTING WITH BOTTONISHAFT POSITIONING 29 ALUTECH DOOR SYSTEMS Mind spring extension when it stretches when determining bracket position Minimal distance A fig 23 between spring fitting spring is not winded and intermediate bracket is counted considering spring length extension when it is winded by formula A d n 5 where A distance between spring tip to intermediate bracket mm d spring wire diameter mm number of spring winding turns ANTH
9. Fig 29 Attention Between spring tip and spring break device bracket and also between bracket and clutch joint plate there should be a 1 2 mm gap that is provided by space washer installation Place and fix tooth chain hoist on shaft with set screws Chain hoist rim should be placed symmetrically relatively latch long axis INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 37 ALUTECH DOOR SYSTEMS 4 9 DOORLEAF INSTALLATION DOORS WITHOUT A WICKET 4 9 1 BOTTOM SECTION INSTALLATION Assembly and installation of door leaf bottom section is shown in fig 30 21 9 oic 19 Fig 30 Assembly and installation of door leaf bottom section is held in the following order 1 Fix the panel on the mounting place Use when needed supports level the panel in the horizontal position with the help of carpenter s bar level Support height should be no more than 10 mm maximum 2 Install and fix side brackets together with hinges to the section Place side bracket over bot tom part of the hinge Fixing is done with three 6 3x16 self tapping screws fig 30 1 Fig 30 1 38 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH DOOR SYSTEMS 3 Put Litol 24 lubricant on rollers 4 Set rollers into roll
10. SDS magnetic heads set 1 Bank of drills 1 2 INSTALLATION MANUALJINDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS Tool title Number item Drill machine for concrete 6 mm L 160 200 mm 2 Drill machine for concrete 8 mm L 200 260 mm 2 Drill machine for concrete 10 mm L 550 mm 2 Drill machine for concrete 12 mm L 550 mm 2 Drill machine for concrete 14 mm L 750 mm 2 Taps set 1 Multipurpose tap holder 1 Chisel set 1 Silicon gun 1 Tester equipment 1 Electric soldering iron 60 W 1 Strip 30 m minimum 1 Multi purpose 4 fold step ladder 1 Multi purpose step ladder of three section more than 6 m 2 Trammel 125 mm 1 Tape measure 5 m 1 Tape measure 10 m 1 Safety spectacles 2 Respirator 2 Headpiece 3 Protective gloves set 3 Multi purpose first aid set 1 2 SAFETY MEASURES Only qualified personnel familiar with door design and its mounting process trained and in structed on safety measures is admitted to door mounting Safety measures description is given in Appendix B INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 3 ALUTECH 3 3 1 3 2 DOOR SYSTEMS INSTALLATION AND FIXING RULES FOR DOOR BEARING CONSTRUCTION REQUIREMENTS FOR MOUNTING Doors should be placed symmetrically relatively to passage pintle On mounting door bearing bases should be level
11. cable drums are installed it is obligatory to have sup porting shaft element spring break device or intermediate bracket Forthe doors of more than 4100 mm in width installation of two intermediate brackets is necessary Possible variants of torsion shafts mounting schemes are presented on fig 20 C HAAAAAAAAAAARH Whole shaft One spring gt E ul Whole shaft Two springs of reverse spiraling i direction o jul Whole shaft Two springs of the same spiraling direction dem d 1 Divided shaft One spring EMT m Divided shaft Two springs of reverse spiraling E piv VVVTE direction Divided shaft Two springs of reverse spiraling S v VV 1 direction Door width more than 4100 mm _ PEE um Divided shaft Two springs of the same spiral HOARE SAA ing direction Divided shaft Three springs amp Divided shaft Three springs of the same spiral ing direction Door width more than 4100 mm 69 TAA Divided shaft Four springs BY V V VU V VET Graphics Bearing rod with bearing support 1 Er Spring break device with bearing support
12. on ladder steps SAFETY MEASURES BY WORK WITH ELECTRIC TOOL Work with electric tools is allowed for people specially trained and instructed on the working place and also have proper qualification group on electrical safety Electric instrument working at voltage not more than 380 220 V should be used by mounting works The choice of electric instrument class is done according to the category of premises on the degree of electrical shock hazard Metal electric tool body working on voltage more than 42 V of AC current and more than 110 V of direct current in the premises of heightened danger specially dangerous and in outside mounts should be grounded Shifter fork should be with ground contact Tool switching is made to grounded network Extenders used should have a plug and a socket with ground contact By work with such a tool it s necessary to use preservers rubber gloves galoshes Preservers should be tested according to established legitimate procedures INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 69 ALUTECH 70 DOOR SYSTEMS Before starting the work it is necessary to do the following check the set for completeness and for reliability of fixing parts external examination check for cable intact cord its protective pipe and plug integrity of isolating body parts handle and brush holder caps availability of protective covers and their servicing ground network servicing check
13. or oil covered surfaces to prevent electric shock injury by insulant damage It s necessary to check the places of wire points to the contacts of manual electrified tool they should not be any tension and wires should not have any fractures Crossing of electric wire cable with electrical welding wires supply hose of oxygen acetylene and other gas is prohibited SECURITY MEASURES BY CONDUCTING INSTALLATION AND WIRING WORKS Installation and wiring works should be done according to Procedure for electrical installation design PEID with meeting the requirements of Safety regulations by electrical installation operation SR by electrical installation operation INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING Distributed by JD UK Ltd www jdukltd co uk info jdukltd co uk 01924 472924 ALUTECH GROUP OF COMPANIES WWW ALUTECH COMPANY COM ALUTECH DOOR SYSTEMS Ingenernaya str 4 220075 Minsk Republic of Belarus Tel 375 17 299 62 22 Fax 375 17 299 60 77 e mail info alutech doors by Distributed by JD UK Ltd www jdukltd co uk info jdukltd co uk 01924 472924
14. to the panel with six 6 3x16 self tapping screws fig 30 4 Te Fig 30 4 A When the doors are completed with manual control elements such as pull rope 001 manual lift block with a rope installation of proper self tapping screws is done when fixing rope branches see fig 38 2 42 2 4 9 2 INSTALLATION OF THE FOLLOWING LEAF SECTIONS Door leaf sections are mounted according to marking that defines sequence number Carry sections vertically Fix sections with side and intermediate hinges fig 31 40 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS Fig 31 Leaf assembly is done in the following way 1 install second section on the bottom one Panel ends should be in one plane 2 install and fix side hinges to the second section according to fig 30 1 and 30 2 3 fix top side hinge half loop fig 31 1 installed on bottom panel to the panel with two 6 3x16 self tapping screws The panel should be strictly vertical INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 41 ALUTECH
15. 4 5 DOOR BEARING CARCASS MOUNTING in 4 6 HORIZONTAL TRACK FIXING TO CEILING CONSTRUCTIONS 7 4 8 INSTALLATION OF A SHAFT ASSEMBLED BY SPRINGS 4 9 DOOR LEAF INSTALLATION DOORS WITHOUT A WICKET 4 10 DOOR LEAF INSTALLATION DOORS WITH A WICKET 4 11 ROPE TENSION ADJUSTMENT 4 12 SPRING TENSION 4 13 DOOR LEAF CONTROLS INSTALLATION STANDARD KITTING 4 14 SPRING BUMPER INSTALLATION P ps 4 15 DOOR LEAF CONTROLS INSTALLATION ADDITIONAL KITTING PEE 5 FINISHING WORKS 6 ADJUSTMENT TESTING AND CHECKING OF THE PRODUCT 65 7 HANDLING OVER OF MOUNTED PRODUCTS 65 APPENDIX A SPRING BREAK DEVICE MECHANISM scsssssssssssssssesssesssscsssscetsscessscatsscstseenssscareceatssenses 67 APPENDIX B SAFETY MEASURES eere entente entro tosta tns tn tassa stata enata sas tn tassa sn ata 68 Proper sectional door mounting is an essential condition for ensuring high consumer quality of goods In this Manual the recommended procedure and description of the main typical technology process operations on door mounting are given and also the list of the necessary instruments and accessories The present Manual may be used as guidelines in training and working of the technical staff It is made basing on our knowledge and experience All the rules and regulations applying to door mou
16. ALUTECH DOOR SYSTEMS Sa INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING November 2011 Distributed by JD UK Ltd www jdukltd co uk info jdukltd co uk 01924 472924 Distributed by JD UK Ltd www jdukltd co uk info jdukltd co uk 01924 472924 ALUTECH DOOR SYSTEMS INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING Contents 1 GENERAL INSTRUCTIONS cssssssssssssssssssssssssssssssssssssusssssssssssssssssssssssssssssssssssesssssusssssssesssssussssssseesssssseessseees 1 1 OPTIMAL NUMBER OF MOUNTING CREW TUN 1 2 RECOMMENDED KIT OF TOOLS AND FIXINGS NEEDED FOR MOUNTING CREW 2 SAFETY MEASURES ues tUe E sepe 3 3 INSTALLATION AND FIXING RULES FOR DOOR BEARING CONSTRUCTION REQUIREMENTS FOR MOUNTING ud 3 2 FIXING RULES FOR BEARING STRUCTURES OF 33 FASTENING ELEMENTS FOR FIXING DOOR ELEMENTS TO BEARING CONSTRUCTIONS 34 APERTURE PERFORMING FOR FIXING passa Eta E 3 5 REQUIREMENTS TO THE PASSAGES OF THE PREMISES 3 6 FINISHED PASSAGE CHECK 4 DOOR MOUNTING 4 1 PREPARATION BEFORE MOUNTING 4 2 MEASURE PROFILE 55 43 SEALS INSTALLATION INTO BEARING RODS 4 4 DOOR BEARING CARCASS VERTICAL FRAME ASSEMBD
17. DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 5 ALUTECH 3 3 DOOR SYSTEMS Fig 3 2 FASTENING ELEMENTS FOR FIXING DOOR ELEMENTS TO BEARING CONSTRUCTIONS Different fastening elements may be used in door mounting the choice depends on passage material characteristics All fixing parts should be resistant to corrosion Metallic frame tie anchor dowels fig 4 1 nylon dowels with inturn screws fig 4 2 are used to fix doors to the wall made of concrete whole brick ceramsite concrete natural stone and other similar materials 1 H E Fig 4 1 Fig 4 2 Oblong plastic dowels with inturn screws 160 mm long are used to fix doors to the wall made of light and cellular concretes bricks with vertical hollows lime gas blocks shell limestone Anchor and dowel outer diameter 10 mm For fixing doors to metal constructions it is necessary to use self tapping screws with outer thread diameter 8 mm fig 4 3 Fig 4 3 To provide secure door construction element pressing to building constructions under screw heads and nuts it is necessary to install flat steel washer with outer diameter 24 30 mm thickness 1 6 2 0 mm Screws should be made of steel with corrosion resistant coating with thickness not less than 9 micron Screw strength grade not less than 5 6 INSTALLATION MANWALJINDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING 3 4
18. HORIZONTAL TRACK FIXING TO CEILING CONSTRUCTIONS 4 6 1 Hanger placement Hangers are placed along horizontal tracks fig 18 The front hanger should be placed at 900 1000 mm distance off of the premises passage The rear hanger should be placed 300 mm from horizontal track edge Fig 18 20 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING DOOR MOUNTING ALUTECH 4 6 2 HANGER CONSTRUCTION Horizontal track hanging to ceiling constructions should be carried out on hangers Hanger construction is shown in fig 18 1 Corner bracket C profile Top mounting bracket Horizontal track Bottom bearing bracket Fig 18 1 Hanger e Before hanger installation it is necessary to do its subassembly fig 18 2 for that do the following place side bracket into C profile that serves for hanger fixing to ceiling install M8x25 round head bolt slide bracket out of C profile firmly into bolt install and tighten nut with shoulder IiNstatiamondnANUALIINDUSTGlAU DOORS HIGHMOUNTING WITH BOTTOMSHAFT POsITIONNG 0 0 01924 472034 ALUTECH DOOR MOUNTING DOORSYSTEMS m i b ur i Lil Fig 18 2 4 6 3 Hanger mounting Place horizontal tracks using carpenter bar level with a slight inclination towards passage 0 5 Hanger mounting is done the following way 1 Check diagonal frames
19. IONING DOOR MOUNTING ALUTECH DOOR SYSTEMS Fig 37 4 Open the lock place the cylinder mechanism center of the lock and fix it with a screw fig 37 5 Fig 37 5 Place the cap of the lock and fix it with a screw 4 15 3 001 MANUAL LIFT BLOCK INSTALLATION Rope for manual lift pull down of door leaf can be supplied with HKU001bkey lock and a rope Fig 42 1 shows the scheme of block fixing Before block installation it is necessary to make 4 apertures in triangular plate with diameter 8 5mm The block is fixed with four bolts and nuts INSTALLATMIONMANVAL INDUSTRIAd DOORS HIGHMOUNTING WITH BOTTOMSHAFT POSITIONING 1761 ALUTECH DOOR MOUNTING DOOR SYSTEMS Fig 42 1 Fig 42 2 shows rope fixing scheme Rope branches are fixed with washer and 6 3x35 self tapping screw inturned in the panel through bottom bracket aperture Fig 42 2 Rope fixing 4 15 4 DOORS WITH ELECTRIC DRIVE Mounting connection and adjusting of electric drive and automation elements safety and security should be carried out according to proper mounting and adjusting instructions Type scheme of automatic mechanism elements is given in fig 43 When doors are completed with electric drive the following safety elements are installed Microswitches that turn off the electric drive when the springs break Microswitches that turn o
20. MANVAL INDUSTRIAL DOORS HIGHMOUNTING WITH BOTTOMSHAFT POSITIONING 224 47293 ALUTECH DOOR MOUNTING DOOR SYSTEMS Corner bracket Bolt M8x25 Mounting bracket Self tapping screw Fig 18 4 Installation of brace on the hanger After door bearing carcass fixing to building constructions of the garage premises it is necessary to check construction mounting and fixing element tightening 2a4tributed by JD INSTALLATION mANunt iNpUstel dboons icH MOUNTING WITH BODTOMSHAFT BOSITIONING4 ALUTECH 4 7 JOIST INSTALLATION Joist installation scheme is shown in fig 19 Fig 19 Joist installation 4 7 1 TRIANGULAR PLATE INSTALLATION Triangular plate installation is shown in fig 19 and is made in the following order 1 Fix two clamp plates to the triangular plate by the M8x25 round head bolts Wrench bolt nuts providing a 3 5 mm gap between clamp plate and bracket 2 Place bracket firmly into passage barrier entering clamp plates inside C cover plates on bearing rod 3 Fix bolted assembly 4 Fixtriangular plate to passage barrier Bracket fixing is done in three points INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 25 ALUTECH DOOR SYSTEMS ee 4 7 2 JOIST FIXING Joist is fixed on triangular plates in a way to provide c
21. STRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 57 ALUTECH DOOR SYSTEMS Fig 39 2 Fix spring bumper in such a way that when the doors are fully lifted spring bumper spring is approximately 2 3 length compressed in its free state fig 39 3 Fig 39 3 4 15 DOOR LEAF CONTROLS INSTALLATION ADDITIONAL KITTING 4 15 1 CHAIN HOIST INSTALLATION Manual control doors may also be actuated with a chain hoist with chain hoist ratio 1 4 Door lifting and lowering is carried out with steel round link chain which actuates chain hoist mechanism Chain fixing is carried out with key locking device chain link is entered into key locking device slot Key locking device is fixed to passage wall Chain hoist is installed directly on door shaft Chain hoist fixing is done to the wall of the premises or to door carcass triangular plates with mounting angle profile and two M6 round head bolts that come with chain hoist Install distance rings on the bolts that come with the chain hoist 58 INSTALLATION MANUALJINDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR MOUNTING DOOR SYSTEMS After fixing the chain hoist install fixing ring onto shaft Chain hoist installation scheme is given in fig 40 Distance rings Stop ring Mounting bracket Chain hoist 11 C CO CO 27 CO C C
22. able drum placing Joist is fixed with plates and M10x130 bolts with nuts fig 19 2 It is necessary to additionally drill apertures with 5 mm in diameter in bottom joist side and fix joist to triangular plates with 6 3x16 self tapping screws 26 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH DOOR SYSTEMS Fig 19 2 4 7 3 SIDE BRACKET INSTALLATION Side brackets are installed on the joist and are fixed with plates and M10x130 bolts with nuts fig 19 3 It is necessary to additionally drill apertures with 5 mm in diameter in top joist side and fix to it side brackets with 6 3x16 self tapping screws Fig 19 3 INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 27 ALUTECH DOOR SYSTEMS 4 8 INSTALLATION OF A SHAFT ASSEMBLED BY SPRINGS 4 8 1 TORSION SHAFT CONSTRUCTION VARIANTS AND ASSEMBLY RULES Torsion shafts can have different variants of configuration and assembly The variants of installation of one two three or four springs are possible The springs can have the same as well as reverse spiraling direction Moreover the installations of the whole continuous shaft and shaft consisting of two parts is possible The following conditions should be carried out in assembly and mounting of shaft Inarea where coupler adjustable and
23. between body and plug ground contact switcher definition functional check functional check of electric instrument out of chain hoist By work use only serviceable tool tested and sealed Prevent breaks bending of electricity cable and also laying it in the places of construction material piling traffic flow By work in rainy weather by snowfall the places of cable laying and the places where the works with electric tools are being conducted should be covered by tents By work with electric tools IT S PROHIBITED to hold a tool at the cable remove chips and sawdust from a cutting tool as well as to change cutting tool until it s fully stopped Fixing of a changeable working tool should be done by a proper instrument switch electric tool to network with characteristics that do not meet the requirements indicated in engineering manual move electric tool from one working place to another with the engine switched on leave unsupervised the instrument switched to network and a tool with working engine leave unsupervised electrified tool to prevent using it by strangers If electric tool body is getting hot it s necessary to make routine breaks If there is a smell or smoke loud noise or vibration immediately switch the instrument off of network till the fault is handled By conducting work it s necessary to prevent direct contact between cable or wire powering electrified tool and metallic items hot wet
24. de and intermediate hinges in the door curtain with the inbuilt wicket is performed in the same way as with the doors without wicket INSTALLATIONTMANUAL INDUSTRIAZ DOORS HIGH MOUNTING WITH BOTTOMSHAFT POSrti fuNG 45 ALUTECH DOOR SYSTEMS Door curtain mounting has its own peculiarities and is performed in the following way Install the bottom section on the place of mounting Fig 34 1 Using supports if necessary place the section horizontally The supports are installed under bottom section side stops Bottom stop end positioning plane should match zero mark plane wearing floor level Install an eaves lath under the end profile of the bottom section at the central axes of the wicket Check horizontality of mounted section with carpenter s level placed on panel head and wicket wings Fig 34 1 Fig 34 1 mounting of wicket door sections planes of intermediate sections must coincide Fig 34 2 Adjustment of sections in vertical position is carried out with the help of side hinges QO o o Fig 34 2 46 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS e After installing the wicket sections it is necessary to unwind self tapping screws and remove transport braces Fig 34 3 Way of removing the braces top down
25. e and fix to it side brackets with 6 3x16 self tapping screws Fig 26 3 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING DOOR SYSTEMS Fix spring break device to additional bracket fig 26 4 for that do the following Move spring in assembly with spring break device along shaft towards additional bracket Fixspring break device to additional bracket with two bolts and nuts Place shaft into side bracket bearing Join shafts with a coupler setting clutch coupler bolts fig 27 1 tighten slightly coupler bolt nuts Both square key grooves should be placed in one line Fig 27 1 Fixspring break device on joist fig 27 2 for that do the following Fig 27 2 3 Install stop rings close to side bracket inner bearing race fig 28 and fix them tightening set screws Fig 28 36 INSTALLATION MANWALJINDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH _ DOOR SYSTEMS 4 Spring break device preparation to work is done in the following way Temporarily block the latch installing fixing pin fig 29 Attention extract pin only after door final assembly
26. e door torsion spring tend untwist turning the joint plate 1 When the plate turns the latch 2 comes off the lug A and under action of spring break device spring comes into ratchet chain hoist 3 gash that turns together with shaft Shaft block ing from cranking occurs thereby leaf drop is prevented INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 67 ALUTECH 68 DOOR SYSTEMS APPENDIX B SAFETY MEASURES GENERAL REQUIREMENTS Door mounting should be done only by qualified specialists who know door design and door mounting technological process trained and instructed on security measures Mounting works are allowed to be done only in work wear not limiting movement and also in a skull guard On material drilling that have thrown chips by metal chopping or cutting it s necessary to use protective glasses A respirator should be used to protect respiratory apparatus from building dust Fitter s hammers and sledge hammers should have smooth a little bit convex surfaces of flats without dents slants handerings chips and splits The length of hammer handle should be no more than 250 mm and sledge hammer handle length no more than 700 mm hammers and sledge hammers should be firmly fit on handles and fixed by wedges All the tools that have sharpened ends for handles files screw drivers etc should have length of handles of not more than 150 mm Wooden handles should be ti
27. ed in vertical planes Bearing rods should be placed close to passage framing along the full length The gaps of 5 mm maximum are accepted The difference of diagonals measured between two end points of bear ing rods ends should not exceed 2 mm Product elements mounting and leveling on the wall before their fixing may be carried out with the help of metal washers mounted in area of fixing points Mounting accuracy of the product is controlled by the builder s level dimension type US6 1 US6 4 1 st group of accuracy State Standard 9416 83 and tape measure 8 m 2nd group of accuracy State Standard 7502 89 It is accepted to use builder s levels and tape measures of other types but not with less accuracy FIXING RULES FOR BEARING STRUCTURES OF DOORS The door should be properly fixed not to pose any potential hazard for the life or health of people Fixing points of the goods should ensure regular allocation of forces that effect the product and their secure transmission on building structure elements The choice of the fixing element depends on load distribution and durability of the building construction Building constructions should stand the expansion force that appears while tight ening fixing elements Wooden cork construction foam is prohibited to use as fixing elements When the passage is made of solid mass materials as concrete natural stone whole brick then the fixing of door bearing elements is made directly to the pas
28. er cover plate Place safety plastic insert on roller axes 5 Place roller into horizontal track profile and fix roller cover plate to side bracket with two M6x16 roundhead bolts and nuts with shoulder fig 30 2 Roller cover plate adjustment is done in such a way that roller adjoins vertical track path at mini mal gap between section and bearing rod side seal The roller should rotate freely by hand Fig 30 2 6 Turning shaft slowly unwind the ropes N It is forbidden to unwind ropes from the drums that are put off the shaft to avoid rope kink that can lead to rope lay splitting 7 Put on rope loops on bottom bracket thread chasers fig 30 3 Place rope loops between two washers To fix rope place nut on thread chaser While assembly pay attention that the rope is placed in special bottom bracket groove Install splint to prevent rope coming out of the groove splint INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQUNTING WITH BOTTOMISHAFT POSITIONING 39 ALUTECH DOOR SYSTEMS 8 install and fix bottom brackets on the section put Litol 24 lubrication on rollers set distance rings on rollers to prevent door leaf from side shift fig 30 4 Distance rings are chosen in such a way to prevent leaf motion 4 6 mm place runners into bottom bracket ears place rollers into vertical tracks fix each bracket
29. es do following Lift the panel loosening rope tension and fix the panel in this position with the help of support Unfasten the fixating screw of the in a drum Adjust rope working length as needed Fasten the fixating screw of the rope in a drum Pull down the panel in the initial position and check the evenness of rope tension SPRING TENSION Before spring tensioning it s necessary to take measures for door leaf lifting prevention Be careful by tensioning the springs use tensioning tool of proper size 4 12 2 Spring tensioning is done in the following order release spring spring fitting bolts Insert drive into spring fitting slot below fig 35 While turning the drive turn over tip for a quarter of turn Holding the first drive install the second drive into the next spring fitting slot INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MQOUNTING WITH BOTTONISHAFT POSITIONING 53 ALUTECH DOOR SYSTEMS Holding the second drive remove the first drive out of spring fitting slot Repeat steps 2 4 making the proper number of spring tensions The proper number of turns for tensioning of each spring is presented in the door table Check the number of spring tension turns by the number of turns made by marking line e After tensioning for the purpose of turn to turn friction reduction stretch the springs in the axis direction for 5 10 mm until there are gaps between the turns Insta
30. ews When locking bar is installed make an aperture with diameter 16 mm in bearing rod INSTALLATIONMMANUVAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMSHAFT PdsITIONING 55 ALUTECH DOOR SYSTEMS Fig 37 Pull rope fastening is shown in fig 38 1 and 38 2 The upper end of the rope is fixed to bearing rod with a brace to do that it is necessary to pre liminarily drill in bracket flange an aperture with 6 5 7 mm diameter The lower end is fixed with washer and 6 3x35 self tapping screw inturned in the panel through bottom bracket aperture Qoococooceoood Fig 38 1 Rope fixing 56 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING ALUTECH DOOR SYSTEMS Fig 38 2 Rope fixing to bottom bracket 4 14 SPRING BUMPER INSTALLATION Spring bumper installation is done in the following way Make door leaf full lift mark edge position of the upper section and pull down the leaf Fix spring bumper with 4 M6x16 roundhead bolts and nuts with shoulder to mounting bracket fig 39 1 Install spring bumper placing into C shape profile of the horizontal track insert plates with fastening M8x25 roundhead bolts bolts are placed from the insert plate side fig 39 2 INSTALLATION MANUAL INDU
31. ff the electric drive when the rope loosens or breaks down Wicket sensor security that turns off electric drive when the wicket is open Optical safety sensor security on door leaf bottom edge optosensor security Bztributed by INSTALLATION MANUALINOUSTRIALIDOORS HIGH MOUNTING WITH BODTOM SHAFT BdsITIONING ALUTECH DOOR SYSTEMS F A AAP PAAAA TU VV VG V NN I 5 6 5 D 7 8 1 electric drive 2 control unit 3 junction box 4 spring breakage microswitch 5 rope rupture microswitch 6 wicket sensor security 7 optosensor security emitter 8 optosensor security receiver Fig 43 Microswitch that turns off electric drive when the springs break is fixed on spring break device with two screws Make switch positioning in such a way that it is activated in contact with clutch A movable plate lug when the plate is turned in case spring breaks see fig 43 1 Microswitch connection is done to electric drive control unit according to the scheme with normally closed contact INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 63 ALUTECH 64 DOOR SYSTEMS
32. g order unscrew M6x16 bottom press bolt nuts that fix vertical track to bearing rod extract press bolts fig 9 1 Fig 9 1 install measure profile between bearing rods install press bolts placing them from outside of bearing rod fig 9 2 Install and tighten the nuts Press bolt Measure profile Nut Bearing rod Fig 9 2 Fixing of measure profile to bearing rod INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 11 ALUTECH DOOR SYSTEMS 4 5 DOOR BEARING CARCASS MOUNTING Door bearing carcass consists of two bearing rods 1 with vertical tracks and seals two radius profiles 2 two horizontal tracks 3 and rear headroom 4 The scheme of the bearing carcass is shown in fig 10 1 2 3 4 1 2 3 bearing rod with vertical track and seal radius profile horizontal track Begg Noe rear headroom Fig 10 Door bearing carcass scheme 12 INSTALLATION MANUALZINDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS 4 5 1 DOOR BEARING CARCASS VERTICAL FRAME FIXING 1 Fixing of the assembled vertical frame of door bearing carcass to the passage fig 11 is made in the following order Put the frame to the passage and symmetrize the frame to passage Level and fix the frame in the vertical plane match notchings i
33. ghtened by bandage rings Percussion devices chisels plugging chisels mandrels punches should not have oblique and battered shanks splits burs Length of chisel plugging chisel should be not more than 150 mm including tapered part of a chisel it should be not more than 60 70 mm cutting edge straight or a little bit convex Wrenches should not have splits or nicks and should match sizes of nuts and bolt heads wrench jaws should be parallel not worked out or rolled To move working tool to work place it s necessary to use special bag or box When working on the tool boxing it s necessary to use special belts It s prohibited to put tools in the pockets of work wear SECURITY MEASURES BY WORKING AT HEIGHT Works at heights of 1 5 m and more from the floor surface are considered works conducted at height Works at height of 5 m from ground surface overlaps or working platforms and stages are considered steeplejack works Health state of people doing steeplejack works should meet medical requirements set for workers doing this type of work Safety mounting belt should be used by working at heights In case it s impossible to fix safety belt to the elements of building construction it s necessary to use safety rope which has been set behind the construction elements in advance The works in this case are fulfilled by two mounting workers Devices and tools should be fixed tightened to prevent their falling when working o
34. ile to horizontal track joint plate it is necessary to install two M6x16 press bolts and nuts with shoulders fig 16 1 Place bolts from inside of the profile INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQUNTING WITH BOTTONISHAFT POSITIONING 17 ALUTECH DOOR SYSTEMS Fig 16 1 Vertical track and radius profile rolling path edges should be matched to provide punchless rolling of feed rollers x I O 2 Place horizontal track in assemblage with radius profile to bearing rod and fix it with two M8x25 roundhead bolts and nuts fig 16 2 Fig 16 2 18 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BODTOMSHAFT POSITIONING ALUTECH DOOR SYSTEMS 3 fix radius profile to bearing rod fixing plate with one M6x16 press bolt and nut with shoulder fig 16 3 Place bolt from inside of radius profile Fig 16 3 Vertical track and radius profile rolling path edges should be matched 4 fix another track to bearing rod analogically 4 5 3 REAR HEADROOM INSTALLATION Measure profile in assembly can be used as a rear headroom Its fixing to horizontal track is done with M8x25 roundhead bolts and nuts with shoulders fig 17 Fig 17 INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MOUNTING 5 POSITIONING 19 ALUTECH 4 6
35. in door operation totally eliminate the possibility of rope touching leaf and tracks Spring break device disposition should provide the possibility of cable drum groove installation SHAFT MOUNTING ON JOIST Shaft mounting on joist is shown in fig 25 Fig 25 INSTALLATION MANUAL INDUSTRIALC IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH Shaft mounting is done in the following way 1 Mount part of shaft installed from the right side of doors fig 26 Fig 26 Place shaft into side bracket bearing fig 26 1 Fix side bracket on joist fig 26 2 with plates and M10x130 bolts It is necessary to additionally drill aperture with 5 mm in diameter in top joist side and fix to it side brackets with 6 3x16 self tapping screws Fig 26 1 INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 33 ALUTECH 34 DOOR SYSTEMS Fig 26 2 Fix spring break device on for that do the following Unscrew additional bracket fixing nuts to the clutch Move spring in assembly with spring break device along shaft towards intermediate bracket to provide the possibility of spring break device additional bracket installation Fixadditional bracket on joist fig 26 3 with plates and M10x130 bolts It is recommended to drill aperture with 5 mm in diameter in top joist sid
36. into half coupler and shaft grooving Tighten the set screw firmly into shaft 3 Wrench the screw remove half coupler from shaft By the given screw mark drills the shaft 0 5 1 0 mm deep 4 Set half coupler onto shaft 5 Fix half coupler on shaft tightening fastening screws with a wrench 6 Set intermediate bracket on shaft 7 Set ready fitted spring with tips 8 Set spring break device on shaft and fix it to spring tip with the help of 2 bolts out of coupler set fig 24 1 9 Put spring break device tooth chain hoist on shaft 10 Set dowel and fix it with clutch tooth chain hoist screw 11 Fix additional brackets to spring break device 12 Set cable drum Cable drum is installed on shaft in such a way that groove for rope placing made on drum end is withoutside INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 31 ALUTECH 4 8 3 32 DOOR SYSTEMS Fig 24 1 Spring fixing to sparing break device Mount left shaft part analogically setting half coupler spring spring break device and cable drum For doors more than 4100 mm wide intermediate bracket is also mounted onto the left shaft e After shaft assembly it is recommended to eliminate errors while mounting to place shafts on the floor of the premises and determine cable drum spring break device and intermediate bracket mutual disposition Cable drum should be placed in such a way that
37. ll square key into shaft and spring fitting slots fixin this position fastening tips bolts Extract the drive from the tip slot Fig 35 4 12 3 Check door balancing For this purpose lift door leaf for about half of the passage height Door leaf should be held in this position If the leaf is taken down or up it s necessary to conduct additional adjustment of spring tension Increase or decrease of spring tension is allowed within the limits of 1 2 turns 54 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING assidu ALUTECH DOOR SYSTEMS 4 13 DOORLEAF CONTROLS INSTALLATION STANDARD KITTING Ondoors in standard kitting the following control elements are installed Double sided handle Locking bar Pull rope Handle 07 is installed into the aperture made in the door curtain Handle set includes a pull 1 with a bearing plate 2 an overlay 3 a pan shape handle 4 insulation seal ing 5 fig 36 While the mounting pulls are tied with screws and nuts Screws are installed at the inner side of the doors fig 36 2 After the handle is fixed it is required to install caps that close the nuts Fig 36 1 Handle installation Outside view Fig 36 2 Handle installation Inside view Locking bar fig 37 is installed into four apertures made in door leaf section Locking bar is fixed with four 6 3x16 self tapping scr
38. n the constructions under which there are current carrying parts alive IT S PROHIBITED to use safety belts with metal chain slings by work with constructions under which there are current carrying parts alive INSTALLATION MANUALZINDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS Endless cable should be used for upward supply of door elements tools and mounting devices The worker standing below should hold the cable to prevent load swinging and coming it close to current carrying parts IT S PROHIBITED TO stand under the ladder which the works are held throw up anything for the worker above The supply should be done with the help of a strong rope SECURITY MEASURES BY WORK WITH THE USE OF LADDERS AND STEPS Ladders and steps should be supplied with a device preventing possibility of shear and turn over by working Bottom ends of ladders and steps should have binding with sharp ends for installation on soil and for using ladders on smooth surfaces metal tile concrete shoes from rubber or other material are used IT S PROHIBITED TO work with a ladder when standing on steps which are less than 1 m away from its upper end work with power tool from ladders work on two last steps of ladders that do not have railings and stops stand on steps ladder or step ladder for more than one person stand under the ladder where the work is held puta tool
39. n the bearing rods with meter marks on the passage Fig 11 onthe rods fix reinforcing side brackets with M6x16 round head bolts and nuts with shoulders Reinforcing side bracket installation variant outside bearing rods is shown in fig 12 1 inside bearing rods in fig 12 2 INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 13 ALUTECH DOOR SYSTEMS D ei Ne Fig 12 1 14 INSTALLATION MOUNTING WITH POSHIONING ALUTECH DOOR SYSTEMS Fig 12 2 INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH 5 POSITIONING 15 ALUTECH DOOR SYSTEMS onthe wall mark the places where apertures for fixing elements will be dowels screws etc Scheme of door bearing carcass vertical frame fixing elements placing is presented on fig 13 1 and 13 2 When reinforcing cor
40. n the following order 1 Press on the top panel from the inside of the premises providing maximum possible elastic edge crumpling of the upper seal 2 adjust top roller placement by means of moving roller plate with following screw tightening The runner should bear against profile part of the track In fig 33 rope placement scheme is shown To prevent rope abrasion of side hinge roller axes of bottom and in some cases second section from bottom it s necessary to install plastic safety inserts INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING 43 ALUTECH DOOR SYSTEMS g 0 8 ED ds ge g EOR 3 0 e o Plastic safety insert 1 Fig 33 44 INSTALLATION MANUAL INDUSTRIACDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSITIONING _ ALUTECH 4 10 DOOR LEAF INSTALLATION DOORS WITH A WICKET 4 10 1 LEAF WITH A WICKET ASSEMBLY Door leaf with the inbuilt wicket is shown in fig 34 f Fig 34 The mounting of bottom and top brackets si
41. ner brackets are installed on the outer side of bearing rods fig 13 1 rod and brackets fixing elements are staggered When reinforcing corner brackets are installed on the inside of bearing rods fig 13 2 fixing elements are placed in each perforating hole drilled in the rod shelf Fixing elements installation places L la 34 la a B d Fig 13 1 Fig 13 2 according to the marking executed drill in the wall the apertures of the necessary size for fixing elements place the fixing elements tighten them controlling the fixed bearing rods verticality 2 Remove measure profile for this purpose unfasten and extract the nuts of press bolts fig 14 Fig 14 16 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS 3 Place press bolts from the inside of bearing rod fig 15 Place and fasten the nuts with a wrench Fig 15 4 5 2 HORIZONTAL TRACKS FIXING TO BEARING RODS Assembly and fixing of tracks to bearing rods is shown in fig 16 16 2 99 Oo 16 1 16 3 onoj 9 Fig 16 Horizontal tracks assembly and fixing is made in the following way 1 Assemble horizontal track with radius profile To fix radius prof
42. ng requirements the passages should be of a rectangular shape or other shape agreed by the Customer and the Producer the surface of frame planes should be straight and smooth without burls of plaster or cracks the deviation of work surfaces from vertical and horizontal lines should not exceed 1 5 mm m but not more than 5mm thearea needed for door mounting should be free from building heating piping and ventilation etc If the passages are prepared by the Customer with deviations from the presented norms the Customer is to eliminate them before door mounting start INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MQOUNTING POSITIONING 7 ALUTECH DOOR SYSTEMS 3 6 FINISHED PASSAGE CHECK Before starting door mounting it is necessary to make sure the quality of the prepared passage is satisfactory see part 3 5 It is necessary to check if the existing space dimensions necessary for door mounting corre spond the demands pointed out in the document Design description and technical guide for industrial door mounting 4 DOOR MOUNTING 4 1 PREPARATION BEFORE MOUNTING Before mounting it is necessary to make installation marks from both sides of passage fig 5 The marks are made at 1 m distance from zero mark the level of the clean floor using flexible liquid level or squared level used with measure profile headroom from the door set Fig 5 Ins
43. nting should be strictly observed The content of this document cannot be a basis for claims ALUTECH Company reserves the right to change and make additions to the door configuration and this manual O 2011 by Alutech Door Systems INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MQOUNTING POSITIONING 1 ALUTECH DOOR SYSTEMS 1 GENERAL INSTRUCTIONS 1 1 OPTIMAL NUMBER OF MOUNTING CREW Optimal number of mounting crew is 3 people There should be a fitter in a crew while mounting an automated door The number of the crew may be increased when mounting big size doors An average norm for mounting crew is mounting of 1 door in 4 hours 1 2 RECOMMENDED KIT OF TOOLS AND FIXINGS NEEDED FOR MOUNTING CREW Tool title Number item Electric punch 2 Electric drill 1 Battery screwdriver 1 Electric corner cutoff machine 1 SDS adapter with quick key lock vice 2 Riveting gun 1 Carpenter s bar levels 1 5 and 0 5m 1of each Tool box 2 Fitter s hammer 400 9 2 Impactor tools set chisel plugging chisel punch piercer 1 Multi purpose hack saw with changeable blades 1 Scissors for metal 1 Side nippers of middle size 1 Big combination pliers 1 Files set 1 Hard metal screwdriver set 1 Magnet screwdriver with nozzles 1 Electro indicated screwdriver 1 Hex key wrench assembly set 2 Straight bits and cap keys set 1 Open end and ring spanner set 1
44. of horizontal tracks Acceptable difference in sizes is no more than 2 mm Fix the frame in the leveled position 2 Install hanger subassembling fig 18 2 up to the ceiling make hole marks for dowel installation 3 Drill a hole in the ceiling hammer a dowel in a hole and fix the hanger to the ceiling 22tributed by JD NsTALLATION ManuaLsiNDUsTRiALDOORS HIGH MOUNTING WiTH BOTTOM SHAFT BOSHIONING4 DOOR MOUNTING ALUTECH DOOR SYSTEMS 4 Install bottom support bracket into hanger C profile and fix it with M8x16 bolt with hexagon head fig 18 3 5 Install top mounting bracket and fix it with M8x16 bolt with hexagon head 6 Check diagonals of horizontal track frame Diagonals should be equal 7 Check nut fixing 8 If necessary cut off excess hanger C profile part from below Hanger subassembling Top mounting bracket Horizontal track Bottom bearing bracket Fig 18 3 hanger mounting 4 6 4 INSTALLATION OF BRACE ON THE HANGER Horizontal track rear hanger should be additionally enforced with brace fig 18 4 Brace consists of mounting profile and corner bracket connected together by M8x25 roundhead bolt with a shoulder nut Brace is fixed to hanger C profile with 8x25 self tapping screw For screw installation in the profile sidewall make an aperture 7 mm in diameter The brace is fixed to the ceiling covering or garage premises wall by a dowel INSTALLATIONM
45. ps it s necessary to use compressors in tubes silicon polyurethane acryl based Filling foams should not pop up By using polyurethane foam it s important to check on door elements not to change their form After consolidation of sealing material that comes out of bearing rods plane they are erased and if necessary the decorative sealing of joints can be done By sealing of separate joints and gaps that are more than 3 mm in size there should be used plasters compatible with passage material and allowed to use by the Customer Before conducting of plastering works it s necessary to protect doors from ingress of splashes mortar mix concrete gypsum After finishing mounting works remove protective film from panels Clean dirty spots on doors Door cleaning is done with clean water and mild washing liquids with a sponge or soft cloth For window cleaning if necessary use liquids for cleaning plastic Washing liquids used must be neutral to acryl and polycarbonate Don t use abrasive washing liquids or window washing liquids containing alcohol ADJUSTMENT TESTING AND CHECKING OF THE PRODUCT After door mounting carrying out check key locking devices and electric drive programming Door operability should be checked by five times leaf lifting lowering cycle For doors with electric drive check additionally automation on every mode programmed HANDLING OVER OF MOUNTED PRODUCTS Installed product handling over to Customer is ca
46. rried out in the following order Full door operational demonstration is carried out by the representative of the Organiza tion that carried out door mounting Fulfillment of part Mounting Certificate in the Passport is carried out Product implementation date is recorded Signature of a person with clarification responsible for mounting is set Data of the organization name address tel number that carried out door mounting is fixed Stamp the Organization that carried out door mounting is put Mounting Certificate is signed by the Customer with stamping if there is one with the Customer INSTALLATION MANUAL INDUSTRIAL DQORS3HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 65 ALUTECH HANDLING OVER OF MOUNTED PRODUCTS Deetributed by JD 4574 mANunt NpUstal cipoons HreH MOUNTING Witd BoDTOM SHAFT BdsITIONING4 ALUTECH DOOR SYSTEMS APPENDIX A SPRING BREAK DEVICE MECHANISM Spring break device safety function is realized when torsion spring breaks Mechanism 15 based on door shaft mechanical block Inregular exploitation conditions owing to door torsion spring torque moment joint plate 1 is turned in such a way that the latch 2 under the influence of spring break device spring is pressed to joint plate lug A Ratchet chain hoist 3 installed on shaft 4 can turn freely together with shaft on square key when headroom and closing the door Incase of breakag
47. sage fig 1 Fig 1 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS When the passage is made of hollow materials as economy brick cavitated ceramic and lime sand brick ceramic slot and silicate stones and also of light and cellular concrete gas silicate blocks and other building materials with low compressive resistance it is recommended to frame the construction passage with steel moulded profile fig 2 It is allowed to fix door bearing elements directly to the passage using fixing elements with increased enchoring length 7 Fig 2 When the door mounting is made onto metal constructions it is necessary to use self tapping screws or bolts with nuts If it is impossible to fix metal framing on the passage it is recommended to fix the doors with the help of tie rods Bearing rod strengthening is made with the use of corner brackets that are fixed to the pas sage and the rod Fixing to the rod is made by two bolts M6x16 with round head and nuts with a shoulder The bolts are entered from the bracket side through ready aperture pairs in the rod fig 3 1 With the distance less than 125 mm from the end of the passage to the side wall corner brackets may be installed only inside the bearing rod fig 3 2 Fig 3 1 INSTALLATION MANUAL INDUSTRIAL
48. t is prohibited to make adjustments more than established range ROPE TENSION ADJUSTMENT Drums should be leveled on shaft in such a way that the ropes do not touch door elements on their lifting Drum position adjustment in relation to shaft in axial position is made in the following way Turn fixing screw in the drum hub on the value needed for free axial movement of cable drum relatively shaft Level the drum in proper axial position Set dowel and fix drum position tightening fastening screw INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING 4 12 4 12 1 ALUTECH DOOR SYSTEMS For regular door exploitation ropes should be tightened No rope sagging is admitted Rope tightening regulation after bottom bracket fixing on the door leaf section it is necessary to turn shaft till rope sagging is adjusted For rope tightening make spring winding 1 5 2 turns and fix it in this position tightening tip bolts In case one of the ropes is still sagging the sag can be eliminated by simultaneous shaft turn which is provided by a coupler construction it has slot holes for tightening screws For that unfasten coupler tightening bolts turn the shaft on which side there is sagging hold ing another shaft in initial position After eliminating rope sagging fix tightening bolts of the coupler When the doors are completed with continuous shaft for sag elimination of one of the rop
49. tallation marks making 8 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS 4 2 MEASURE PROFILE ASSEMBLY Measure profile assembly fig 6 is done in the following way place measure profile brackets from headroom butts fix brackets with two 8 25 round head bolts and nuts with shoulders Fig 6 Measure profile assembly 4 3 SEALS INSTALLATION INTO BEARING RODS Before mounting it is necessary unpack bearing rods and place seals into them Seal installation into bearing rod is shown in fig 7 Seal Bearing rod Fig 7 Seal installation INSTALLATION MANUAL INDUSTRIAL DQORSAHIGH MQOUNTING WITH BOTTOMISHAFT POSITIONING ALUTECH DOOR SYSTEMS 4 4 DOOR BEARING CARCASS VERTICAL FRAME ASSEMBLY In industrial doors with high mounting with bottom shaft positioning bearing rods are pro duced in two variants whole rods and compound rods In the present manual whole bearing rod variant is considered Vertical frame consists of three main elements two bearing rods and measure profile fig 8 Fig 8 Vertical frame of bearing rod in assembly 10 INSTALLATION MANUALJINDUSTRIAC DOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING OOR MOUNTIN _ ALUTECH DOOR SYSTEMS Vertical frame assembly is done in the followin
50. th screws Fixing devices are installed on the end of the wicket When the wicket is closed fixing device enters in the gear groove Groove apertures in the gears allow to regulate the gear positioning at height fig 34 8 Fig 34 8 4 10 4 WICKET DOOR CLOSER INSTALLATION Pusher is installed on the door curtain from inside Pusher should be positioned in such a way that wicket closing effort regulation nut spring tension is placed from the side opposite to ledge from the side of wicket opening hinges INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 49 ALUTECH DOOR SYSTEMS Pusher installation is performed in the following way remove the protective cap of the pusher install a pull bar on the mounting shank end of the shaft and fix it with a screw The pull bar should be placed at an angle to the pusher s plane fig 34 9 I 5 Fig 34 9 Place pusher rod roller into guiding groove of the wicket passage framing profile Fig 34 10 Fix pusher box the wicket with four self tapping screws supplied with the pusher Screws are wound into apertures preliminarily prepared by the manufacturer Make door closer adjustment if necessary Install door closer protective cover and fix it with two screws Fig 34 10 ADJUSTMENT OF PUSHER Construction of pusher allows to perform the follo
51. wing settings Speed of closing the wicket Speed of pressing the wicket Intensity of braking at the wicket opening Efforts at closing the wicket 50 INSTALLATION MANUAL INDUSTRIAL IDOORS HIGH MOUNTING WITH BOTTOM SHAFT POSHIONING ALUTECH DOOR SYSTEMS Wicket leaf Door leaf Spring power adjusting nut Door closer O i O Back check control nut Closing speed nut Fig 34 11 When all adjustments are been made fulfill the requirements below and also the requirements of the Manual enclosed to door closer by the Manufacturer Wicket closing and pressing speed adjustment Closing cycle consists of two consecutive stages wicket preliminary closing and compressing fixing Door closer has the following factory setting Wicket closing cycle starts when headroom angle is approximately 70 degrees Wicket compressing starts when the headroom angle is approximately 10 degrees Leaf speed on the compressing stage is established much lower than on preliminary closing stage A Wicket closing and compressing speed change is done by turning two definite screws valves placed in the closer body First adjust wicket closing speed and then wicket compressing speed INSTALLATION MANUAL INDUSTRIAL DOORS HIGH MOUNTING WITH BOTTOMISHAFT POSITIONING 51 ALUTECH 4 11
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