GDS DuraRoll, DuraRoll Mini Installation Instructions Manual

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DuraRoll Roller Garage Door

Installation Instructions

For residential single and double size doors

DuraRoll

Steel Roller Garage Door

HEAVY -

LIFT WITH

CAUTION!

YOUR SAFETY

FIRST!

Read this booklet

carefully before

installing your door

DuraRoll & DuraRoll Mini

2016 V1

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Both one and two-car doors are installed in the same manner.

Be sure all warning labels and tags are properly afﬁxed to the door and that the home owner information is left with the purchaser.

GENERAL NOTES

WHO SHOULD

INSTALL THIS DOOR?

A minimum of two people must be available for ﬁtting. However due to the weight and spring tension of larger doors, we insist that three people or suitable lifting gear be available for installation on

doors over 10ft wide or 9ft high.

PRE-INSTALLATION CARE AND HANDLING

• The door curtain must be handled with care at all times

• The doors length must be supported in its entirety during transport and handling

• The door must be stored on a ﬂat DRY surface

• Packaging must not be removed until instructed (at the correct step in the installation)

Ensure that the area around the opening is strong enough to support the door.

WARNING!

FRAGILE!

WARNING!

KEYPOINTS: ELECTRICALLY

OPERATED DOORS

Please read the instructions relating to the installation of an electric motor prior to commencing. Key guidance is summarised here and repeated at the relevant step in the installation.

• The installed door must operate efﬁciently when used manually. Ensure sufﬁcient clearance between door and bracket to facilitate ﬁtting of motor (See Side Clearance, page 4).

• Turn off the power before making any adjustments.

• Make sure the anti-coning collar is adjusted and secure on the drum shaft to eliminate sideways movement on the opposite side to which motor is to be ﬁtted.

• When installing the door, ensure the motor is disengaged and the drum turns freely.

• Never engage the manual release with motor running.

• The upper limit on the operator should be set to stop the roller door, 30-40mm below the guide stop, to avoid damaging the drive gears.

• Weight bar must be attached to bottom bar with rivets/bolts.

This new GDS door has been designed for ease of operation, security and attractive

appearance with minimal maintenance. Performance of the door will be impaired if it

is installed incorrectly. Read these instructions carefully before commencing the

installation. Warranty is void if the door is not installed correctly according to

these instructions.

Goggles Safety Shoes Gloves

SAFETY EQUIPMENT

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Tape measure

Stanley knife

Pencil

Spirit level

8,13 & 17mm sockets

8mm spanner

Masonry drill

Electric drill

‘A’ rated steps x2

Drill bit 10mm masonry 13mm steel bit

Square ﬁle

Two 18” pipe wrenches

Hammer

Screw drivers

Hacksaw

TOOLS REQUIRED FOR INSTALLATION

THE PACKED DOOR

DO NOT REMOVE ANY WRAPPING UNTIL INSTRUCTED*

CHECK FOR OBVIOUS SIGNS OF DAMAGE AND REFER TO WARNING LABEL

Curtain

Guides

Brackets

Fixings

*STEEL OUTER WRAPPING CAN BE REMOVED IF PRESENT

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BEFORE YOU START: OPENING SIZE

BEFORE YOU START: SIDE CLEARANCE

Opening

height

Opening width + overlap

Opening width

Garage opening

viewed from the inside

Door curtain roll

Curtain overlap

Door curtain size

Up to 2896mm (9’6”) wide &

2438mm (8’0”) high

Over 2896mm (9’6”) wide &

2438mm (8’0”) high

Guide size

30mmª

50mm

Overlap

each side

25mmª

50mm

OPENING WIDTH:

DuraRoll garage doors ﬁt behind the garage opening. Check that the door curtain supplied overlaps the opening width at each side by the minimum requirements:

ªIn Ireland all door sizes are supplied with 50mm guides

OPENING HEIGHT:

The door will ﬁt any opening height up to that stated on the packaging, e.g. a 2134mm high door can be ﬁtted to a 2000mm high opening

Lintel

Opening

Width

Opening

Height

Side

Clearance

Side

Clearance

Headroom

Backroom

Side clearance

Garage opening

viewed from the inside

Door curtain size

Up to 2896mm (9’6”) wide &

2438mm (8’0”) high

Up to 2896mm (9’6”) wide

Over 2896mm (9’6”) wide &

2438mm (8’0”) high

Over 2896mm (9’6”) wide

Guide

size

30mmª

50mm

Side clearance

for manual doors

95mmª

each side

95mmª

each side

120mm

each side

120mm

each side

Side clearance for doors with a motor

135mmª motor side

95mm non-motor side

165mmª motor side

95mm non-motor side

160mm motor side

120mm non-motor side

190mm motor side

120mm non-motor side

How much room do I need at the side of the garage opening? The door is mounted onto brackets and the brackets must be set

in from the side of the garage opening by the minimum distance to the outside edge of the bracket as shown in the table below.

Doors with a motor require extra clearance on the side the motor is ﬁtted - see table below.

To achieve the minimum side clearance you will need to cut the ends of the door axle.

STANDARD DOORS

MINI DOORS

STRUCTURAL CONDITIONS OF OPENING:

The surface where the door is to be ﬁtted must be ﬂush and reasonably smooth. Small irregularities in brick work will be acceptable. The lintel must not protrude backwards or forwards from the brick piers.

ªIn Ireland all door sizes are supplied with 50mm guides

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BEFORE YOU START: BACKROOM

BEFORE YOU START: HEADROOM

BEFORE YOU START: FITTING NOTES

How much room do I need behind the garage opening? The door curtain is mounted on brackets above the garage opening and projects back

into the garage. The door will require the minimum backroom as shown:

Door curtain size Door curtain size

All door sizes All door sizes

Guide size Guide size

30mm or

50mm

30mm or

50mm

Minimum backroom Minimum backroom

495mm 390mm

STANDARD DOORS MINI DOORS

How much room do I need above the garage opening? The door curtain is mounted on brackets above the garage opening and to

allow maximum drive through height, the minimum headroom required is shown in the table below.

If insufﬁcient headroom is available to allow the door roll to be ﬁtted fully above the opening, the door may be ﬁtted projecting down into the opening up to a maximum of 100mm without the need for a fascia. If the door projects down by more than 100mm a fascia (not supplied) will be required see ﬁgure 1.

Note: 10mm more headroom is required to install the door than is needed to operate the door once installed. If the available headroom is right at the minimum, the bracket can be ﬁxed 10mm lower whilst the door roll is ﬁtted and tensioned and then tapped up by 10mm once the door is installed to give full clearance with no hangdown.

*The minimum headroom but will require bracket position adjustment

during installation to achieve full opening height. (see page 9)

**The minimum headroom that requires no bracket position adjustment

during installation to achieve full opening height. (see page 9)

Garage opening

viewed from the inside

Door curtain size

Up to

2438mm (8’0”) high

Up to

2134mm (7’0”) high

Over 2438mm (8’0”) high &

up to 3048mm (10’0”) high

Minimum headroom

431mm* / 441mm**

343mm* / 353mm**

483mm / 493mm**

Up to 100mm hangdown without the need for a fascia

Hangdown

No Hangdown

100mm

FIGURE 1

STANDARD DOORS

MINI DOORS

Do not remove any wrapping, or steel protective outer wrapping if ﬁtted to your door, until instructed.

(a) Door package and its contents should be checked for obvious damage before removal of protective outer wrapping (If on your door).

(b) The door should only be ﬁtted after any plastering of the area has been completed. Plaster splashes will damage the pre-ﬁnish on the curtain and cause premature wear of the nyloﬂex within the guides.

(

c) The door must be ﬁtted square and level irrespective

of the shape of the opening. On no account should any compensation be made to suit an irregular opening

EVEN IF THE OPENING IS NOT SQUARE OR LEVEL THE DOOR MUST ALWAYS BE FITTED SQUARE & LEVEL

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COMPONENTS

C 1x

Left Guide

Curtain Stop, Nut & Bolt

Axle Saddle

Axle U-Bolt & 2x Flange Nuts

G 1x

Lock Hole Protective Cover

D 4x

Guide Lug

1xB

Bracket

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C 1x

Universal (unhanded)

Right Guide

Guide Lug

Lock Hole Protective Cover

Axle Saddle

Axle U-Bolt & 2x Flange Nuts

Handed - marked with L (left) or R (Right)

Parts are handed (to ﬁt on the left or right side of the door) or unhanded (ﬁtting to either left or right side of the door). Any reference to handing - left or right assumes you are viewing the door from the inside. Items are not shown to scale for clarity.

KEY

1xB

Bracket

1xA

Curtain

H 1x

Curtain Stop, Nut & Bolt

FIXINGS LIST

M10 x 65mm Sleeve anchor Hex nut with washer

M8 x 45mm coach screws

22mm washer

M10 x 50

Blue wall

plugs

x14 x14

x14

Your door will be supplied either with sleeve anchors or coach screws and plugs (both types are suitable for ﬁtting DuraRoll doors)

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Mark door position and ﬁx brackets

LINTEL

HEADROOM - DISTANCE ABOVE BRACKET TO CEILING

BRACKET DISTANCE ABOVE LINTEL

DISTANCE THE CURTAIN OVERLAPS THE OPENING

BRACKET INSET DISTANCE FROM OPENING EDGE

LINTEL

Mark the door curtain overlaps on the wall - ‘C’

Check that the door curtain supplied overlaps the opening width at each side by the minimum requirements:

C=25mm each side for 30mm guides C=50mm each side for 50mm guides

TOOLS REQUIRED

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Mark the ﬁxing position of the bracket

STANDARD DOOR

Distance from the bottom of the lintel to the top of the bracket:

A=200mm

Minimum headroom above the bracket

B=231mm* (doors up to 8’0”/2438mm high) B=283mm* (doors over 8’0”/2438mm high)

For the full height of the opening to be available

A+B=431mm* (doors up to 8’0”/2438mm high) A+B=483mm* (doors over 8’0”/2438mm high)

If the full headroom is not available (A+B=431mm/483mm), the bracket can be ﬁxed 241mm*/293mm* below the ceiling with the door curtain projecting down into the opening by up to a maximum of 100mm when fully open without the need for a fascia - see page 5 for detail drawings.

The minimum distance from the edge of the opening to the bracket is:

D= Curtain overlap (C) + 10mm min D= Curtain overlap (C) + 185mm max

MINI DOOR

A=140mm from the bottom of the lintel to the top of the

bracket

B=203mm* minimum headroom above the bracket A+B=343mm* for the full height of the opening to be available

with the door fully open If the full headroom is not available (A+B=343mm), the bracket

can be ﬁxed 213mm below the ceiling with the door curtain projecting down into the opening by up to a maximum of 100mm when fully open without the need for a fascia. The minimum distance from the edge of the opening to the bracket is:

D=Curtain overlap (C) + 10mm min D=Curtain overlap (C) + 185mm max

*Note: 10mm more headroom is required to install the door than is needed to operate the door once installed. If the available headroom is right at the minimum, the bracket can be ﬁxed 10mm lower whilst the door roll is ﬁtted and tensioned and then tapped up by 10mm once the door is installed to give full clearance with no hangdown. If this is the case, ﬁx the brackets through the slotted holes (step 1) to allow for tapping up once the door roll is installed.

PARTS REQUIRED

2xB

E 2x

1xA

C 2x

F 2x

FIXINGS REQUIRED

2 x6

CHECK LEVELS

Fix the brackets in place at each side of the opening.

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Prepare the guides

For automatic installations the measurement from the top of the horizontal leg of the support bracket to the bottom edge of the stop bar is critical. It must never be less than:

F=200mm Standard doors F=140mm Mini doors

D=35mm Minimum on doors with 30mm guides D=60mm Minimum on doors with 50mm guides

STANDARD DOOR FULL HEADROOM AVAILABLE

MINI DOOR FULL HEADROOM AVAILABLE

STANDARD DOOR RESTRICTED HEADROOM AVAILABLE

MINI DOOR RESTRICTED HEADROOM AVAILABLE

Cutting the guides to length: Measure down from the top of the wall

bracket by:

F=200mm for Standard Doors F=140mm for Mini Doors

Mark the wall. Measure from this point to the ﬁnished ﬂoor level.

Transfer measurement (G) to the guide measuring from the bottom of the stop bar.

Shorten the guide to the required length.

The distance shown from the top of the bracket to the ceiling is the minimum required for the door to operate once installed - 10mm additional space is required to install the door - see the note at the foot of page 9.

FOR THE CORRECT OPERATION OF THE DOOR, THE GUIDES MUST BE FITTED IN THE POSITIONS ILLUSTRATED BELOW.

FLOOR LEVEL

200mm140mm

D D

100mm

Max

100mm

Max

231mm

Min**

203mm

Min

231mm

Min**

**283mm on

doors over

8’0/2438mm

high

**283mm on

doors over

8’0/2438mm

high

203mm

Min

STOP BAR

STANDARD DOORS F= 200mm

Mark the wall here

MINI DOORS F= 140mm

* *

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Splay the guides creating a 3 sided funnel effect, it is critical to (if not already done so) to hammer ﬂat the top 6” section that is exposed by the top notch.

See step 1, page 17

Position the ﬁxing lugs: Hammer the second from top (2) and bottom ﬁxing (4) lugs into place (ﬁgure 2) allowing a gap for the Lock bar lug (see step 1 page 17).

(2)

(3)

(1)

(4)

Figure 2

1 2

PARTS REQUIRED

D 4x

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= =

Whilst the door is on the ﬂoor,

rotate the axle back and forwards

through the roll to centre it

Position the

door ready

for ﬁtting with

the bottom

rail facing the

opening

The Axel will protrude 11” (280mm)

beyond the drum wheel at each side

Position and mount the door

Check axle length does not foul any obstructions. Cut down if necessary ensuring the axle is even and centred.

Lift the complete door curtain and axle onto the brackets ensuring that the roll is the correct way round with the bottom rail as shown below.

Fit saddle and ‘U’ bolt, nut and washers loosely at each support bracket. See ﬁgure 1 for the location of Standard (main slot) and ﬁgure 2 for Mini doors (small and main slot)

Bottom rail start position

A minimum of two people must be available for ﬁtting. However due to the weight and spring tension of larger doors, we insist that three people be available for installation on doors over 10ft wide

or 9ft high.

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MINI DOORS

STANDARD DOORS

Centre the door roll in the opening by lifting the curtain and axle together and moving either way using the Curtain overlap marks on the wall as a guide. Make sure the axle protrudes evenly on both sides 11” (280mm) from the drum wheel

Tighten the ‘U’ bolts with the bottom rail at the start position as shown in point 2.

IF AUTOMATION IS TO BE FITTED SEE SEPARATE INSTRUCTIONS AT

THIS POINT (SUPPLIED WITH YOUR

AUTOMATION).

IF AUTOMATION IS REQUIRED –

TIGHTEN ONE END ONLY.

Figure 1 Figure 2

= =

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Up to 2 turns standard doors Up to 3 turns mini doors

WARNING DANGER! HIGH SPRING TENSION CAN CAUSE SEVERE INJURY OR DEATH. REPAIRS OR ADJUSTMENTS MUST BE MADE BY 2 PEOPLE.

IMPORTANT NOTE: Pre-tension should now be applied to the springs by turning the curtain roll approx 2 turns forward for standard door and 3 turns for mini doors

The amount of pre-tension required may vary with individual doors and applications - See adjustments section on page 16 and 17.

PRE-TENSION:- Do not cut the

CARDBOARD bands that hold the door curtain in a roll. However, , if the door has a protective steel wrapping, cut the bands and remove this before you pre-tension.

Carefully cut the wrapping to expose a small portion of the bottom rail. Hold the door by the bottom rail before removing all wrapping. DO NOT RELEASE THE BOTTOM RAIL. The door will have a strong tendency to rise, WHICH IF UNCONTROLLED COULD CAUSE SERIOUS DAMAGE OR INJURY DUE TO SPRING TENSION. The door

must be held until both guides are securely ﬁxed in place.

NOTE: Knife marks or cutting of the bottom seal or the nyloﬂex webbing voids the door warranty

ENSURE THE DOOR CURTAIN IS CENTRED. IF ADJUSTMENT IS REQUIRED, CENTRE THE DOOR ROLL BY LIFTING THE CURTAIN AND AXLE TOGETHER

A person must hold and control the door curtain at all times

Overlap Mark

Curtain edge

CENTRE CURTAIN!

FIXINGS REQUIRED

2 x8

Tension the door & ﬁx the guides

PARTS REQUIRED

G 2x

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Slide

Top Lug

Slide each guide onto the door curtain allowing approx 3-5mm clearance between edges of curtain and inside edge of guide to ensure door travels smoothly.

Drill wall and ﬁx the top lug of each guide with a 10mm x 65mm sleeve anchor or coach screw.

4 5

CHECK GUIDES ARE VERTICAL AND PARALLEL!

Fix the remaining lugs.

Fitting the stop bar catchers

THE BOTTOM EDGE OF THE GUIDE STOP BARS MUST NOT BE CLOSER TO THE HORIZONTAL PART OF THE SUPPORT BRACKETS THAN DISTANCE ‘F’. F=220MM STANDARD DOORS F=140MM MINI DOORS IF THIS IS NOT OBSERVED THE DOOR WILL BE DIFFICULT TO CLOSE

IF THE BRACKETS WERE FIXED 10MM LOWER TO ALLOW FOR FITTING ON THE LIMIT OF HEADROOM CLEARANCE, THESE CAN NOW BE TAPPED UP TO ACHIEVE THE FINAL POSITION. BRACKET LEVEL MUST BE CHECKED ON COMPLETION OF TAPPING UP.

Stop bar

pre-drilled

hole

STOP BAR

To access the pre-drilled hole for the stop bar, pull away the bottom rubber seal, ﬁt and reposition the seal

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IF THE DOOR IS NOT SET PROPERLY COMPLETE THE FINAL ADJUSTMENT SECTION (P18) BEFORE CUTTING THE LOCK BAR HOLES.

Check door settings

GUIDES: Now that you have both guides

ﬁrmly ﬁxed, pull the curtain down slowly. Continue to pull the curtain down to the ﬂoor ensuring that it runs freely. If it does not, reposition guides for clearance 3-5mm as necessary (ﬁxing lugs are slotted for adjustment - ﬁgure 3).

CONING: Check that the door rolls up

evenly and squarely with the ends of the roll, if it rolls out unevenly (cones out at one end) repeat FINAL adjustment section on page 16.

DOOR TENSION: The door is now

installed. Lower the door curtain to the half open position to check that the spring tension is in balance. From this position the door curtain does not rise or lower of its own accord when released.

The door should be slightly over tensioned during this running in period. i.e. when put to the ground it should want to rise 25mm 40mm unless locked down.

Coning

effect on

curtain

Figure 3

PARTS REQUIRED

DG2x

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TO MARK THE GUIDES FOR THE LOCK BAR HOLES, THE DOOR MUST BE FULLY CLOSED

WARNING: DO NOT RAISE DOOR WITH THE KEY IN LOCK!

Position the ﬁnal guide lug aligned with the lock bar slots, ﬁt the ﬁnger protection lock bar covers and ﬁx in place.

Cut lock bar holes & ﬁt ﬁnger protection

Engage the lock bar to mark the point of entry

within the guides. Mark position of lock bar on

the back of the guide.

Floor level

Note: To ensure maximum efﬁciency of the weather seal it will be necessary to ensure a very neat ﬁt between the locking bar and the slot in the guide. When the lock bars are engaged the weather seal should be

compressed against the ﬂoor.

SECURITY NOTE FOR AUTOMATIC DOORS

To stop attempts to prise the bottom of the door up, the curtain can be secured to the drum wheel.

Fully close the door, mark the corrugation just before the curtain leaves the top roll. Open the door partially, approximately 400mm, so you are able to see the mark.

Drill through the curtain and drum wheel rim and ﬁx with a self tapping screw.

18mm high x

13mm wide

MARK

DRILL

Then drill a series of holes and ﬁle out a guide slot, just large enough to accept each lock bar.

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Final adjustments & troubleshooting

DIFFICULT TO OPERATE IN EITHER DIRECTION

(a) Check that the curtain is not jamming in the

guides.

(b) Check running clearance in the guides (3-

5mm per side).

DIFFICULT TO CLOSE

Decrease the spring tension (See spring tension adjustments page 19).

GUIDE/AXLE RELATIONSHIP (SEE FIGURE 3)

If the door is very difﬁcult to close during the last 600mm of travel, check that the guides are ﬁtted in the correct relationship to the brackets and that the axle is the correct distance from the wall. (see step 3, page 10, 11). One or both will be incorrect, thereby increasing lead angle into the mouth of the guides, making the door difﬁcult to close.

CONING (SEE FIGURE 4)

If the curtain rolls up unevenly (cones out at one end) and the bottom rail appears out of parallel with the door roll and guides, check for the following:

(a) Brackets not level.

(b) The axle is not the same distance back from the wall at each side.

If the brackets are level and the axle distance from the wall is equal at both sides, remove the coning by moving the axle through the roll in the opposite direction to the coning.

This operation should be done by minimum of two people and ensure the door is fully rolled up to minimise spring tension before starting.

CONING ADJUSTMENTS

Follow the steps in ﬁnal spring tension adjustments, (see next section) up to (e) where it states “to increase tension”. Do not rotate the axle unless spring tension is to be changed. While still retaining a ﬁrm hold on the axle to prevent axle rotation using a pipe wrench, the axle should be lightly tapped in the direction of the coning (See ﬁgure 4). Move no more than 20mm at a time. Then follow the steps and secure axle. After adjustment the door needs to be opened and closed 2-3 times to settle the new alignment. You may need to repeat this step a number of times.

If coning persists, ﬁtting of an anti coning collar/exhaust clamp (1 3/8”/35mm) may be necessary. Note the side to which the door is coned and, with the door closed, ﬁt an anti coning collar onto the axle tight against the boss of the drum wheel to prevent movement to the left or right as the door opens or closes. (Figure 5)

Figure 4:

Coning

Figure 5:

Coning Clamp

220-

250mm

Figure 3

LIGHT

TAPS!

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MAINTENANCE

The following suggestions will keep the door working efﬁciently.

1. Do not grease or oil the guides.

2. Periodically clean the inside of the

guides with white methylated spirits or similar and spray with silicone spray or car/furniture polish.

3. It may be necessary to lubricate the

locking mechanism via the key hole using graphite dust lubricant if operation becomes difﬁcult.

4. Your door should be washed with a

quality car shampoo at least every 2 months to prevent the build up of dirt, salt and other corrosive substances. If your door is installed within 2 miles of the sea, your door should be cleaned in this way at least monthly.

WARNING! DANGER! HIGH

SPRING TENSION CAN CAUSE SEVERE INJURY OR DEATH. REPAIRS OR ADJUSTMENTS MUST BE MADE BY TWO PEOPLE USING PROPER TOOLS AND INSTRUCTIONS.

FINAL SPRING TENSION ADJUSTMENTS (SEE FIGURE 6)

AS A PRECAUTION, ATTACH A PIPE

WRENCH AT THE OPPOSITE END TO BE WORKED ON AND ENSURE IT IS HELD TIGHTLY BY ANOTHER PERSON.

(a) One ‘U’ bolt clamp should be selected to loosen ﬁrst and the other side should remain fully tightened. The remaining tight ‘U’ bolt clamp will retain the existing tension when the door is fully open (rolled up). However, as a precaution a pipe wrench must be also be attached to the axle at the opposite side to be worked on and held tightly by one of the installers.

THIS OPERATION SHOULD NOT BE

ATTEMPTED WITH THE DOOR IN THE CLOSED POSITION AS THE TENSION IS VERY MUCH GREATER AND COULD LEAD TO DAMAGE OR SERIOUS INJURY.

(b) Loosen but do not fully remove the selected ‘U’ bolt clamp.

(d) The other person should then move to the other end of the door roll and with an 18” pipe wrench, grip the axle ﬁrmly. Loosen but do not fully remove the other ‘U’ bolt clamp until the axle is free.

(e) To increase tension pull down on the pipe wrench and to decrease tension allow the pipe wrench to move up (see ﬁgure 6).

(f) Fully tighten adjacent ‘U’ bolt clamp while holding tension with a pipe wrench. Do not release pipe wrench until ‘U’ bolts are tight. (Ensure that it never slips as this would cause loss of tension and possible injury or damage to door).

Decrease

tension

Loosen U-bolt

Increase

tension

Figure 6:

Tensioning

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Garage Door

Call: Northern Ireland: 028 2565 5555

HEAVY -

LIFT WITH

CAUTION!

YOUR SAFETY

FIRST!

Read this booklet

carefully before

installing your door

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GDS DuraRoll, DuraRoll Mini Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual