Wayne-Dalton 451 User Manual

Model 451/452 Aluminum FullView

COMMERCIAL GARAGE DOOR INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL

Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a trained door systems technician do the installation or repairs.

IMPORTANT

SAFETY NOTICES

An overhead door is a large heavy object that moves with the help of springs under high tension. Moving objects and springs under tension can cause injuries. For your safety and the safety of others, follow these instructions:

1. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

2. It is always recommended to wear eye protection when using tools, other wise serious eye injury could result.

3. Operate door ONLY when properly adjusted and free of obstructions.

4. Keep door in full view while operating it. Watch the door open or close completely before leaving the area.

5. Should the door become hard to operate or completely inoperative, a qualiﬁ ed door agency should correct the problem to prevent damage to the door or serious personal injury.

6. DO NOT PERMIT children to play with the garage door or the electrical controls. Fatal injury could result, should the child become entrapped between the door and the ﬂ oor.

7. To prevent serious injury or death, avoid standing in the open doorway or walking through the doorway while the door is moving.

8. Use lift handles/step plate when manually operating the door. DO NOT place ﬁ ngers into section joints when operating the door.

9. Remove pull rope if door is operated by an electric opener.

10. Door is constantly under EXTREME SPRING TENSION. To prevent possible serious injury or death, adjustments, repairs, removal, or installation, ESPECIALLY of SPRING ASSEMBLIES, CABLES, or BOTTOM BRACKETS, should be performed ONLY by qualiﬁ ed door service people.

11. Check door and its hardware monthly for loose, worn, or broken parts. Have any repairs or adjustments made by a qualiﬁ ed door agency.

12. Have the door professionally inspected once a year.

13. Lubricate hinges, springs and rollers once a year.

This manual MUST be attached to the wall in close proximity to the door.

OPERATING ZONE

You Can Save Time And Effort If You First Establish All The Facts About The “Operating Zone”. The “ Operating Zone” is the area surrounding the door opening, extending upward and backward as far as the door will travel. We call it the Operating Zone because it is the area that the door will have to operate within and the dimensions are critical and must be known in advance of a door and operator installation.

1. Daylight Opening: Exact size of ﬁ nished opening.

2. Sideroom: required distance from the door opening to a wall or any obstruction. Refer To Sideroom Requirements.

3. Headroom: required distance from top of door opening to the ceiling or underside of joists. Refer To Headroom Chart.

4. Backroom: required distance from door opening header to the furthest back point to which the door track or operator unit, and their

brackets, will extend. Refer to Backroom Chart.

Verify the operating zone dimensions.

1 - Exact size of ﬁ nished daylight opening. Do you have the correct door size? 2 - Sideroom requirements for track and spring shaft. (Refer to sideroom chart) 3 - Headroom requirements. (Refer to headroom chart for standard lift track) 4 - Backroom (depth into room) Manual lift = Door height plus 18” ; Operators = Door height plus 48” (Standard Lift) 5 - Jambs must be plumb and solidly attached to the building. Floor must be level or exact gradeline established before you start.

Shipping tags show important information, door size, track size and type, spring size and hardware type. Verify that all material is present and correct before attempting installation.

EXTEND JAMBS TO OPENING HEIGHT PLUS DIM Y PLUS 1-1/2” (MINIMUM LENGTH)

MINIMUM HEADROOM

REQUIRED (REFER TO

HEADROOM CHART)

DIM “Y” HEADER TO SHAFT CENTERLINE

8” FOR 2” TRACK 12” FOR 3” TRACK

HEADROOM CHART For Standard Lift Track (Minimum Distance Required)

DRUMS DIMS

400-8,

400-12

5250-18

800-32

Dim. Y INDICATES THE DISTANCE FROM THE HEADER TO THE CENTER LINE OF TORSION SHAFT. NOTE: 2 1/2” OF ADDITIONAL HEADROOM IS REQUIRED FOR SINGLE TROLLEY

OPERATOR INSTALLATIONS. NOTE: HEADROOM CAN BE REDUCED 2-1/2” BY USING THE QUICK CLOSING TOP FIXTURE OR BY SHORTENING THE VERTICAL TRACKS BY 3” MAX.

HEADROOM

DIM Y

HEADROOM

DIM Y

HEADROOM

DIM Y

3” TRACK, 15”

RADIUS

15-1/2”

13”

19”

14-1/2”

21”

16-1/2”

WALL ANGLES CUT 3” OFF FOR 12” RADIUS APPLICATIONS

TORSION SHAFTS REQUIRE 10” OF

SIDEROOM FOR SOLID SHAFTS AND 5” OF

SIDEROOM FOR TUBULAR SHAFTS

2” TRACK, 15”

RADIUS

14-1/2”

12”

18”

13-1/2”

20” 15”

2” TRACK,

12” RADIUS

12-1/2”

9”

15”

10-1/2”

17”

12-1/2”

SIDE ROOM “B”

HEADROOM “Y”

DAYLIGHT

OPENING HEIGHT

SIDE ROOM “A”

BACKROOM CHART (Minimum Distance Required)

TRACK

SIZE

MANUAL DEPTH

2”

MOTOR PLUS 66”

3”

MOTOR PLUS 66”

INTO ROOM

DOOR HEIGHT

PLUS 18”

DOOR HEIGHT

PLUS 24”

BACKROOM

DAYLIGHT

OPENING WIDTH

DIM. A

SIDEROOM TRACK

STEEL

3-1/2” 4” 10” 5”

4” 5” 10” 5”

MASONRY

AND WOOD

DIM. B

SIDEROOM

TORSION SHAFT

SOLID TUBE

SIDEROOM REQUIREMENTS

5/16 X 1” DRILLING/

TAPPING SCREW

1” OVERLAP

SIDE ROOM

3-1/2” MIN.

4-3/4”

3/8 X 3” MIN.

SLEEVE ANCHOR

PRECAST WALL WITH CORNER ANGLE

FLUSH

1-1/2”

2” TRACK

4-3/16”

OPTIONAL

MOUNTING

BRACKET

1/2”- 5/8”

3/8 X 3” MIN.

SLEEVE ANCHOR

1” OVERLAP

SIDE ROOM

3-1/2” MIN.

4-3/4”

PRECAST WALL WITHOUT CORNER ANGLE

5/16 X 1” DRILLING/

TAPPING SCREW

1” OVERLAP

1-1/2”

2” TRACK

4-3/16”

OPTIONAL

MOUNTING

BRACKET

1/2”- 5/8”

5/16 X 1” DRILLING/

TAPPING SCREW

1” OVERLAP

SIDE ROOM

3-1/2” MIN.

3/8 X 3” MIN.

SLEEVE ANCHOR

1” OVERLAP

1/2”- 5/8”

4-1/2

MIN.

1-1/2”

4-3/16”

STEEL JAMBS

2” TRACK

1/2”- 5/8”

5/16 X 1-5/8”

LAG SCREW

4” MIN.

SIDE ROOM

2” X 6” JAMB IS RECOMMENDED

1” OVERLAP

4” MIN.

SIDE ROOM

1-1/2”

WOOD JAMBS

2” TRACK

5/16 X 1” DRILLING/

TAPPING SCREW

4-3/16”

STEEL JAMBS

3” TRACK

1”

4-15/16”

4” MIN.

SIDE ROOM

5-1/2”

3/8 X 3” MIN.

SLEEVE ANCHOR

PRECAST WALL WITH CORNER ANGLE

1/2”- 5/8”

5-1/2”

MIN.

MOUNTING BRACKET

3” TRACK

1-1/2”

4-15/16”

OPTIONAL

5/16 X 1-5/8”

LAG SCREW

SIDE ROOM

5-1/2” MIN.

2” X 6” JAMB

IS RECOMMENDED

FLUSH

4” MIN.

SIDE ROOM

5-1/2”

PRECAST WALL WITHOUT CORNER ANGLE

1”

4-15/16”

WOOD JAMBS

3” TRACK

1/2”- 5/8”

1-1/2”

4-15/16”

OPTIONAL

MOUNTING

BRACKET

COUNTERBALANCE CABLES/ BOTTOM BRACKETS

For doors using the broken cable safety device, see page 19.

For Model 451 doors with the bottom bracket shown in FIG A, locate the bottom section and the left and right hand bottom brackets. Secure the counterbalance cables to the brackets using clevis pin, washer and cotter key as shown in FIG A. Secure bottom brackets to bottom section using (5) 1/4” x 7/8” self-drilling screws as shown in FIG B. Insert a roller into the bottom brackets as shown in FIG C.

For Model 451 doors with the bottom bracket shown in FIG D, Secure the counterbalance cables in the same manner as described above. Attach the bracket to the section with (5) 1/4” X 7/8” self drilling screws. Attach the roller carrier to the bottom bracket with (4) 1/4” X 7/8” self drilling screws. Insert a roller and 3/16” roller spacer into the roller carrier; the inner holes of the roller carrier are for 2” track; the outer holes of the roller carrier are for 3” track.

COUNTERBALANCE CABLE

BOTTOM BRACKET

CLEVIS PIN

COTTER KEY

WASHER

FIG A

BOTTOM BRACKET ASSEMBLY

BOTTOM SECTION

(5) 1/4” X 7/8” SELF

DRILLING SCREWS

BOTTOM SECTION

ATTACHED BOTTOM BRACKET ASSEMBLY

FIG B

(4) 1/4” X 7/8” SELF

DRILLING SCREWS

ROLLER

(5) 1/4” X 7/8” SELF

DRILLING SCREWS

ROLLER CARRIER

FIG C

3/16” ROLLER SPACER

ROLLER

OUTER HOLES FOR 3” TRACK

INNER HOLES FOR 2” TRACK

FIG D

HINGES

NOTE: Top sections do not require hinges.

Use the ENDHINGE CHART to determine the proper endhinges for the proper section. Install only the left hand end hinge, as the right hand end hinge will need to be installed when the sections are stacked. Align the proper left hand end hinges to the proper sections using the center line of the endstile as a guide and the 2 punch marks in the endstile to locate the placement of the end hinge. Secure using (2) 1/4” x 7/8” self drilling screws as shown in FIG E. Sections with double end stiles require 2 end hinges per side on each section, as shown in FIG F.

The end hinge sequence is dependent on track size (2” or 3”). 2” track applications begin with #1 hinges attached to the top corners of the bottom section. 3” track applications begin with #3 hinges attached to the top corners of the bottom section.

To install center hinges on doors without integral ribs, place the center hinge over the center stile(s), using the center line of the stile(s) as a guide, and secure to the section using (2) 1/4” x 7/8” self drilling screws, as shown in FIG G.

To install center hinges on doors with integral ribs, seat the bottom half of the half hinge(s) onto the integral rib above the center stile(s) and over the punch marks of each section, and secure to the rib with (2) 1/4”-20 x 5/8”carriage bolts and (2) 1/4” x 20 ﬂ ange hex nuts, as shown in FIG G. Repeat for all remaining sections, except top section.

END STILE

CENTER LINE

PUNCH MARKS

ATTACHED HINGE

DOUBLE END STILE

ATTACHED HINGE

1/4” 7/8” SELF-

DRILLING SCREWS

FIG E FIG F

SECTIONS WITHOUT INTEGRAL RIBS

CENTER LINE

ENDHINGE CHART

Section 2 inch track 3 inch track

Bottom #1 hinge #3 hinge

Second #2 hinge #4 hinge

Third #3 hinge #5 hinge

Fourth #4 hinge #6 hinge

Fifth #5 hinge #7 hinge

Sixth #6 hinge #8 hinge

Seventh #7 hinge #9 hinge

Hinges are stamped with their identiﬁ cation.

1/4” X 7/8” SELF-

DRILLING SCREWS

1/4” X 7/8” SELF-

DRILLING SCREWS

SECTIONS WITH INTEGRAL RIBS

INTEGRAL RIB

(2)1/4”- 20 X 5/8”

CARRIAGE BOLTS

HALF HINGE

PUNCH MARKS

CENTER

STILE

HINGE

(2) 1/4” X 20 FLANGE HEX

NUTS

CENTER STILE

FIG G

BOTTOM SECTION/ VERTICAL TRACK

Center and level (or support to a known grade level) the bottom section in the opening, using shims if necessary, as seen in FIG H. Temporarily attach the wall angles to the jambs with the appropriate lag screws, as shown in FIG H-1, FIG H-2 and FIG H-3. Allow 1/2” clearance between the section and the vertical tracks as illustrated in the sidereoom requirements illustrations on page 3. It is important that the top of each track is on the same plane.

NOTE: Products being installed to precast or block must use a 3/8” x 3” sleeve anchor to attach the wall angle to the building, as shown in FIG H-3. Use the slots in the wall angle as a drill template and drill a 3/8” hole (3-1/2” deep) and secure to anchor.

Stack the bottom section into position by hooking the left hand roller into the left hand vertical track, as shown in FIG H-4. Insert a roller into the proper, uninstalled right hand end hinge, and place the roller into the right hand vertical track. Lower the roller and hinge into the proper position over the section, and attach to the section in the same manner the left hand end hinge was attached, as described on page 5.

WALL ANGLE

5/16” X 1 5/8” LAG

FIG H-2

SCREW FOR USE ON

WOOD JAMBS.

FIG H-1

FIG H-3

5/16” X 1” SELF

WALL ANGLE

13”

DRILLING &

TAPPING SCREW

FOR USE ON STEEL

JAMBS.

30” OR

18”

24” O.C.

MAX

24” O.C.

MAX

24”

10”

NOTE: TYPICAL FASTENER SPACING.

FIG H-1

VERTICAL TRACK

FIG H-4

FIG H-2

3/8” X 3” SLEEVE ANCHOR (BY OTHERS) FOR USE ON PRE-CAST CONCRETE. ( DRILL A 3/8” X 3-1/2” DEEP HOLE)

FIG H-3

STACK THE SECTION INTO POSITION, BY HOOKING THE LEFT HAND ROLLER INTO THE VERTICAL TRACK AND REPEATING FOR THE RIGHT HAND SIDE.

FIG H-4

FIG H

STACKING SECTIONS

Locate the Lock Section (the second section) and insert a roller into the left end hinge. Stack this section into the opening by hooking the roller into the left hand vertical track and lowering the section onto the bottom section, as shown in FIG I. Insert a roller into the proper, uninstalled right hand end hinge, and place the roller into the right hand vertical track. Lower the roller and hinge into the proper position over the section, and attach to the section in the same manner the left hand end hinge was attached, as described on page 5. Verify section alignment, and ﬂ ip up the upper hinge leaf(s) from the bottom section and secure to the lock section using 1/4”-20 x 7/8” self-drilling screws. Continue to stack the remaining sections in the proper sequence, except for the top section.

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