PFT Sectional Panelift Icon Panelift and Insul Shield

Product Information: PFT, PFI & Insul-ShieldTM Installation

Instructions

Models:

• PFT
• PFI
• Insul-ShieldTM

Contents:

• 1.0 Before You Begin
• 1.1 Installation Safety Warnings
• 1.3 Parts Checklist
• 1.4 Requirements Before Installation
• 1.5 Tools
• 2.0 Assembly
• 2.1 Vertical Tracks
• 2.2 Door Panels
• 2.3 Assembling Bottom & Middle Panels
• 3.0 Installation
• 3.1 Installing Vertical Tracks
• 3.2 Adding Panels
• 3.3 Fitting Reinforcing
• 3.4 Installing Horizontal Tracks
• 3.5 Standard Spring Counterbalance System
• 3.6 Install Torsion Bar
• 3.7 Adding Tension to Spring
• 3.8 Final Checks
• 4.0 Troubleshooting
• 5.0 Appendix
• 5.1 Two Piece Shafts for Large Doors
• 5.2 Rear Torsion Systems
• 5.3 Hinged Tapers
• 5.4 Single & Double End Stile Quick Closer
• 5.5 Lock Installation
• 5.6 After Installation Care

1.0 Before You Begin

1.1 Installation Safety Warnings

This B&D Door is designed and tested to provide security,
attractive appearance, and smooth, low-effort operation provided it
is installed and operated in strict accordance with the following
safety warnings. Failure to comply with the following instructions
may result in death, serious personal injury, or property
damage.

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

WARNING!

• Crush injury from unsecured door
• Tension Springs LACERATION:
• Muscular strain
• Fall from ladder
• Hand Tools Entanglement

Place a 2-meter exclusion zone around the area under the garage
opening while installing the door. If sufficient area is not
available, DO NOT install the door. Follow the
installation instructions.

Ensure correctly fitting winding bar is used. Ensure the correct
length winding bar is utilized. Ensure winding bar is placed
appropriately in the torsion socket plug. Ensure correct bolts are
tightened or loosened (or clamp pliers) to ensure there is no
release or controlled release of energy from the spring either
through the torsion bar or the winding bar. Keep hands clear of the
torsion plug at all times. Keep head clear of the tensioning bar at
all times.

Keep hands and loose clothing clear of moving door and guides at
all times.

Depending on the size of the door, this product may require a
two-person lift. Use proper techniques and equipment to lift the
door from the trailer and into position.

1.3 Parts Checklist

1.3.1 Pack Contents

The pack contains various parts required for installation,
including:

• Screws
• Washers
• Plugs

1.4 Requirements Before Installation

Before installation, make sure you have completed initial
calculations and have the required substrate type fasteners,
washers, and plugs based on the material of the garage
structure.

1.5 Tools

You will need the following tools for installation:

• Screwdriver
• Wrench
• Drill
• Socket Set

Product Usage Instructions:

2.0 Assembly

Follow the steps below to assemble the garage door:

1. Install the vertical tracks (2.1).
2. Attach the door panels (2.2).
3. Assemble the bottom and middle panels (2.3).

3.0 Installation

Follow the steps below to install the garage door:

1. Install the vertical tracks (3.1).
2. Add panels to the door (3.2).
3. Fit reinforcing (3.3).
4. Install horizontal tracks (3.4).
5. Set up the standard spring counterbalance system (3.5).
6. Install the torsion bar (3.6).
7. Add tension to the spring (3.7).
8. Perform final checks (3.8).

4.0 Troubleshooting

Refer to the troubleshooting section for common spring problems
and their solutions.

5.0 Appendix

The appendix provides additional information on specific topics
related to the installation and usage of the garage door, including
two-piece shafts for large doors, rear torsion systems, hinged
tapers, single & double end stile quick closer, lock
installation, and after installation care.

Models: PFT, PFI & Insul-ShieldTM installation instructions

These instructions are intended for professional garage door installers. All references are taken from inside looking out.

DOC# PART NO# RELEASED:

165001_10 OT2515 04/07/23

www.bnd.com.au

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

2

contents

1.0 before you begin

3

1.1 installation safety warnings

3

1.2 fasteners recommendations for fitting Panelift®

4

1.3 parts checklist

5

1.3.1 pack contents

1.4 requirements before installation

6

1.4.2 initial calculations

1.5 tools

7

2.0 assembly

8

2.1 vertical tracks

8

2.2 door panels

8

2.3 assembling bottom & middle panels

10

3.0 installation

12

3.1 installing vertical tracks

12

3.2 adding panels

13

3.3 fitting reinforcing

14

3.4 installing horizontal tracks

15

3.5 standard spring counterbalance system

16

3.6 install torsion bar

17

3.7 adding tension to spring

18

3.8 final checks

19

4.0 troubleshooting

20

common spring problems

21

5.0 appendix

22

5.1 two piece shafts for large doors

22

5.2 rear torsion systems

23

5.3 hinged tapers

25

5.4 Single & Double End Stile Quick Closer

26

5.5 lock installation

28

5.6 after installation care

29

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

3

1.0 before you begin
1.1 installation safety warnings
This B&D Door is designed and tested to provide security, attractive appearance and smooth , low effort operation provided it is installed and operated in strict accordance with the following safety warnings. Failure to comply with the following instructions may result in death, serious personal injury or property damage.
NOTE: No guarantee will be given or responsibility accepted by the manufacturers if the door is not installed as instructed.

WARNING!

Crush injury from

·

unsecured door

·

Tension Springs

·

·

·

·

· ·

ELECTROCUTION! ·
·

·

·

·

LACERATION:

·

·

CAUTION:

Muscular strain

·

·

·

Fall from ladder

·

·

·

Hand Tools

·

·

·

Entanglement

·

TWO PERSON LIFT: ·

Place a 2 metre exclusion zone around area under the garage opening while installing door. If sufficient area is not available DO NOT install door. Follow the installation instructions.
Ensure correctly fitting winding bar is used. Ensure the correct length winding bar is utilised. Ensure winding bar is placed appropriately in the torsion socket plug. Ensure correct bolts are tightened or loosened (or clamp pliers) to ensure there is no release or controlled release of energy from the spring either through the torsion bar or the winding bar. Keep hands clear of the torsion plug at all times. Keep head clear of the tensioning bar at all times.
Check risk assessment for any highlighted electrical power concerns. Ensure power source is isolated prior to commencement of job. Turn off electricity to site when necessary. Ensure you check the substrate for electrical wiring prior to penetration. Wear rubber soled footwear. Wear appropriate PPE (Dyneema cut off gloves) and keep hands well clear of pinch points. Follow instructions explicitly, particularly for the installation of some parts of the panel doors, as the unrolled cut out edges presents a very sharp edge.
Practice correct lifting techniques when required. Use mechanical aids such as lifting devices, forklift and cranes where possible. Avoid twisting. Ensure ladder is the correct type for job. Ensure ladder is on flat firm ground that will take the weight without the legs sinking. Ensure user has 3 points of contact while on ladder. Wear appropriate PPE and utilise operators manual of all tools. Use appropriate noise/hearing protection in the form of ear plugs or ear muffs. Ensure appropriate fire protection available and housekeeping to ensure that flammable liquids or materials are removed from the area of work.
Keep hands and loose clothing clear of moving door and guides at all times.
Depending on the size of the door, this product may requires a two person lift. Use proper techniques and equipment to lift the door from the trailer and into position.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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1.2 fasteners recommendations for fitting Panelift®

substrate type fastener required

washer required

plug required

solid brick (>10 MPa) three hole brick (> 30 MPa) ten hole brick (>15 MPa) concrete block (> 8 MPa) concrete (> 15 MPa)
timber
steel section (0.9-2mm thick)

screw, coach 5/16 – 9tpi x 50
screw anka M8 x 75 flange hex head
screw anka M8 x 75 flange hex head
screw anka M8 x 75 flange hex head
screw, coach 5/16 – 9tpi x 80
screw, coach 5/16 – 9tpi x 50
screw tek 14g – 20tpi x 25 flange hex head ZP

washer flat M8 washer 3/8″ washer 3/8″ washer 3/8″
washer flat M8 washer flat M8
washer flat M8

plug, nylon 5/16 x 50 n/a
n/a
n/a plug, nylon
5/16 x 80 n/a
n/a

drilled hole ø (mm)
10 8 8 8 10 5
n/a

min hole depth (mm)

B&D fastner pack

Unlined

Plaster Lined

100pk

500pk

60

90 FK0011 FK0012

75

75

FK0024

FK0023
(50PK)

75

75

FK0024

FK0023
(50PK)

75

75

FK0024

FK0023
(50PK)

60

90 FK0013 FK0014

60

90 FK0011 FK0012

n/a

n/a FK0019 FK0020

important notes 1. For installation to substrate materials not covered in the above chart, the installer should seek expert advice 2. Substitute fasteners are not recommend unless approved. 3. The above chart specifies the fasteners for new substrate materials only. Seek specialist advice regarding
pre-existing substrate materials. 4. It is important that correct washer and plug is used and the correct pilot hole drilled where specified.
WARNING!
The installer must select and use fasteners appropriate to the material into which they are being fixed.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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1.3 parts checklist
1.3.1 pack contents

K V

A B

C D E

J

U

T

I

R

S

F H

Q

P

W

M

G

N X

O

L PANELIFT SECTIONAL DOOR

ITEM DESCRIPTION

QTY

A DOOR PANELS PACKAGE

1

B TORSION BAR (TUBE OR SOLID)

1

C PANEL REINFORCING

1+

D HORIZONTAL TRACKS

2

E VERTICAL STRAIGHT TRACKS

2

F POLYPROPYLENE CURVES

2

G SMALL ANGLE JAMB BRACKETS

4+

H WASHERS

6+

I TENSION SPRING

1-4

J REINFORCING END CAPS

2+

K CABLE DRUMS

2

L WHEEL AXLES

10+

M LIFTING CABLE

2

N BOTTOM HANGERS

2

O HINGE PINS

18+

P HINGE LINKS

9+

Q SPRING ANCHOR BRACKET

1

R TOP HANGER

2

S SIDE BEARING BRACKETS

2+

T SHORT TOP TRACK ANGLE

2

U HORIZONTAL BRACKETS

2

V SHAFT COLLAR

1

W QUICK CLOSER BRACING PLATE

2+

X QUICK CLOSER HANGER

2+

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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1.4 requirements before installation
mounting – The door is designed to be mounted
behind the opening.
obstructions – Ensure that the surface where the door
will be fitted is flush and smooth, and the area behind the opening is free from any protrusions.

structural suitability – Ensure the opening is strong
enough to support the door. If unsure, consult a builder.
level and plumb – The door must be installed in
an absolutely level position, if opening is not level and square, appearance and/or sideroom requirements will be affected. The floor should be level or recessed across the opening to avoid gaps.

1.4.1 measurements

opening width – As the door overlaps each side by
30mm or more, the door should be 60mm wider than the opening. A wider door can be fitted as long as additional sideroom and fixing is available. (Fig 1.4.1)
opening height – The door will fit any opening height
up to the marked door size.
sideroom – A minimum of 120mm (140mm for
SmoothTrack double wheels and axles) of sideroom is required over and above door width and should extend above the head to allow for bracket fixing. (Fig 1.4.2 for rear torsion & Auto-lock).
CAUTION: 6 panel high doors over 6000mm wide and 7 panel high doors over 5000mm wide require 5-18 cable drums.

headroom – A minumum of 250mm is required.
Refer to Fig 1.4.2 for extra measurements.
backroom – as the door extends into the garage
when opening refer to Fig 1.4.2 for measurements.
level datum – use a water or laser level to mark a
datum line on both sides approx. 1.5m from the floor. Use this line to compare the distance on each side to the opening height to determine if the opening is plumb.

LEVEL DATUM

SIDEROOM

HEADROOM

BACKROOM

WIDTH HEIGHT

Fig: 1.4.1

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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1.4.2 initial calculations
Measurement headroom FTS = front torsion small curve FTL = front torsion large curve Quick closer kit = front torsion RTS = rear torsion small curve sideroom rear torsion sideroom PFT door PFI door backroom Panel height + Automated doors rail + opener backroom headroom (min)
Fig: 1.4.2

Cable drums

4-8 & 4-13

5-18

end bearing brackets combo brackets

end bearing brackets

250mm

270mm

290mm

290mm

310mm

330mm

180mm

190mm

230mm

190mm

190mm

155mm

195mm

without Auto-lock

with Auto-lock

120 mm

175 mm

140 mm

195 mm

recommend

minimum

350mm

100mm

doors up to 2400 high doors up to 3000 high doors up to 3990 high

3374mm

4164mm

4954mm

57mm

57mm

57mm

tip

NOTE: for automated rear torsion setups, please contact your B&D representative or technical support on 13 62 63.

a) Open the package of door panels and locate the label on the end of the door panel. b) The label lists the Sales No: XXXXXX, then underneath DH: X,XXXmm (door height). c) Calculate the vertical track length:

tip

door height

–

track curve

=

FTL (large curve) 190mm

vertical track length

FTS (small curve) 170mm

d) Calculate the horizontal track brace position:

tip

door height

x

3/4

=

horizontal track brace postion

e) For Quick Close option: door height
tip

–

track curve

=

FTL (large curve) 255mm

FTS (small curve) 235mm

vertical track length

1.5 tools
t is recommended that this door is installed by a professional door installer using a professional and specialised It is recommended that this door is installed by a professional door installer using a professional and specialised tool kit.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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2.0 assembly
2.1 vertical tracks
F U
T

a) Cut the Vertical Straight tracks E to the calculated length as listed in section 1.4.2.
b) Assemble vertical straight track E , polypropylene curve F using 4 x 1/4 domed head bolts and wiz nuts as shown in Fig 2.1.1.
c) Affix the small angle jamb brackets G and short top track angle T to the straight track using 6 x 5/16 flat head bolts and wiz nuts, noting the distance required from the wall to the track.
d) Connect the horizontal bracket U to the short top track angle T using a 1/4 domed head bolts and wiz nut in top corner of the “V”. The remaining bolts will be used when connecting the horizontal track.
NOTE: The small angle jamb brackets and the short top track angle, provide adjustable slots to move the track out from the wall. Take note of Fig 3.1.2 for measurements.
2.2 door panels
NOTE: Refer to appendix if installing a taper.
a) Open up the pack of door panels, making sure the bottom panel (weather strip seal on the bottom of the panel and bottom hinge hole) is on top of the pack. Start with the bottom panel.
b) Insert each lifting cable M , through the holes of the left and right bottom hangers N Fig 2.2.1.

G E
Fig: 2.1.1
left hand track shown
c) Remove existing 2 or 4 screws in the bottom corner of the bottom panel near the weather strip and discard. For larger doors: use Bottom hanger plates SD0018 and SD0019 fitted under bottom hanger first (parts are supplied in BOXPF-A8). Affix with tekscrews.

N
M
Fig: 2.2.1
CAUTION: DO NOT hold cable in place by squeezing the bracket around it as this will cause the cable to fracture and break. Should you need to temporarily hold the tip cable in place during installation, before spring tension is applied, only secure with stick tape.

use TEK screw for edge

Fig: 2.2.2

weatherseal

50mm

remove 4 stile screws

d) Cut the weatherseal for a 50mm overhang and tuck

back in on itself to hold in position.

e) Attach the left and right bottom hangers to the lower end of the door using 6 x TEK screws in each.
f) Repeat step a – e for Fig: 2.2.3
other end of panel.

secure hanger using 6 TEK
screws to each

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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g) Insert the polypropylene hinge links P or

P

Insul-ShieldTM (refer to appendix) into the recesses

of the top of the panel and fix into place using the

white hinge pins O . Fig 2.2.4.

There is a link for every point where there O tip is a stile.

h) Insert 4 x the appropriate wheel axle L (standard, extended or smooth track) into the top and bottom of the panel.
i) Repeat the process for fitting links, pins and wheel axles to the top of each middle panel.
NOTE: The top panel can be easily identified by always having a centre stile for use with an opener and no hinge link cut outs in the curved top edge.
j) Once you have finished assembling the middle panels, fit the PFI Seal (if included) to the top panel as shown in Fig 2.2.5 or alternatively fit the seal to the lintel. The fixing points should be spaced at 300 – 400 mm centres.

single enstile door L
Fig: 2.2.4

O P

O P

O double enstile door

Fig: 2.2.5
k) Insert the appropriate wheel axle L (standard, extended or smooth track) into the top hanger R Fig 2.2.6.
l) Attach the top hangers to the top corners of the panel, using the vertical slots only.
NOTE: The additional two fixings will be fitted to the left and right side after the panel is lowered into the tracks and adjusted to vertical.
Refer to BAL-Maze instructions to fit tip optional panel seals if purchased.
WARNING! Ensure all tek screws indicated are fitted after adjusting.

L R
Fig: 2.2.6

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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2.3 assembling bottom & middle panels

INSULATED INSUL-SHIELDTM: Hinge links are in two pieces and clip together when inserted. After the next panel has been lowered in place a special screw is inserted to hold in place as shown in Figure 2.3.3.

MIDDLE PANELS: Repeat the process for fitting links, pins and wheels and axles to the top of each middle panel.

Parts Used

hinge pin

hinge linwksheel axles

Figure 2.3.1
other panels

Insul-ShieldTM

Smooth-TrackTM

bottom hangers (left hand- right
hand)

2 lifting cable (variable)

Figure 2.3.2

standard bottom black hinge

bottom panels

bottom grey hinge
with offset

weather strip

secure hanger using 6 TEK
screws to each

A

B

C

NOTE: DO NOT hold cable in place by squeezing the bracket around it as this will cause the cable to fracture and break. Should you need to temporally hold the cable in place during installation before spring tension is applied only secure with sticky tape.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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Figure 2.3.3
Fitting the insulated door split link from inside
1. Click the male section of the link marked TOP in first. Ensure TOP is facing you from inside looking out.
2. Insert the female part to the male and click together.
3. The screw is fitted after the next panel has been placed onto the link via the hole provided.

Figure 2.3.4 assemble links & pins onto the panel
Insert the polypropylene hinge links into the recesses at the top of the panel and fix into place using the white pins, insert appropriate wheels and axles,

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

3.0 installation
3.1 installing vertical tracks
CAUTION: If jamb seals are being fitted they should be cut 100mm taller than the door height and fitted prior to fitting the vertical tracks.
a) Set the vertical tracks parallel on both sides of the door. Use the level/datum marks to ensure the tracks are level with each other or the door will not function correctly. Fig 3.1.1
b) Ensure to follow the measurements as shown in Fig 3.1.2 to set out the placement of the track and brackets.
Refer to BAL-Maze instructions for tip measurements on track placement.
c) Once satisfied temporarily fix in position with at least three (3) fixings to the top bracket and one to each of the lower track brackets. These will hold the tracks in position and allow for minor adjustments.
WARNING! All fixings with washers must be fitted after the door is fully adjusted and operating satisfactorily.

*tracks shown are indicative only.
Fig: 3.1.1

10mm

jamb lintel seal 20mm

12
nylon bristle brush 20mm

50mm

90mm 145 mm

Recommended 30mm

PANELIFT® (PFT) with optional Auto-lock measurements for vertical track
Fig: 3.1.2

70mm 110mm 165 mm

Recommended 30mm

PANELIFT® ICON (PFI) with Auto-lock and jamb lintel seal
measurements for vertical track

70mm 110mm
165 mm

Recommended 30mm

PANELIFT® ICON (PFI) with Auto-lock and nylon Bristle Brush
measurements for vertical track

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

13

3.2 adding panels
TWO PERSON LIFT: depending on the size of the door, this process may require two persons to lift into place.
a) Carefully lower the wheels of the bottom panel into the tracks and lower so the panel is sitting level in the door opening.
b) Check that the wheels are stiting in the “V” groove of the vertical track on each side and there is sufficient clearance between the panel and the track as per Fig 3.1.2.
c) Insert the next panel into the tracks and rest on top of the bottom panel. Fig 3.2.2.

Fig: 3.2.1

Fig: 3.2.2
WARNING! Use caution when adjusting and securing hinge links between panels as pinching may occur.
d) Starting in the centre, lift the panel enough to ensure each link is in its respective recess and held into place by a hinge pin.
e) Repeat this procedure for all other panels with the exception of the top panel which has externally mounted adjustable metal hangers.
f) Once the top panel is in place and adjusted to vertical the additional locking fixings must be added. Fig 3.2.4.
CAUTION: Ensure the warning label is placed on the door in a clearly visible position.

Fig: 3.2.3 Fig: 3.2.4

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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3.3 fitting reinforcing

WARNING! Doors wider than 3545mm require panel reinforcing. Failure to do so can cause damage to the panels.

The number of reinforcing required for each door is listed in Fig 3.3.3.

Reinforcing always starts on the top panel. depending on the number of panels, there may be some panels without reinforcing.

1 reo = top panel

tip

2 reo = top + bottom panel 3 reo = top + bottom panel + middle panel

4 reo = top + bottom panel + middle panels

The reinforcement is generally fixed across the centre of the panel, however there are three situations that require alternative placement.

Senario

Placement

top panel with automatic opener

fit reinforcing as high as possible

top panel with windows fit reinforcing as high as possible

locking panel, when lock lock is generally centred

is installed

so offset the reinforcing

a) Review the tables in Fig 3.3.3 to determine how many reinforcing bars are required.
b) Secure the reinforcing bar to the top panel with 2 screws per stile as per Fig 3.3.1.
c) Other panels can be placed in the centre of the panel as per Fig 3.3.2

Fig: 3.3.1 Fig: 3.3.2

B&D Panelift® (PFT) doors

no. of panels
3 4 5 6

1750 3050
0 0 0 0

door width break points (mm)

3055 3500 3505 4500 4505 4705 4710 5000 5005 5400 5405 5600

0

1

2

2

2

2

0

1

2

2

2

3

0

1

2

2

3

3

0

1

2

2

3

5

5605 5740
2 3 3 6

5745 5800
2 3 3 6

5805 6000
2 3 4 6

B&D Panelift® IconTM (PFI) doors

no. of

door width break points (mm)

panels 1750 3050 3055 3500 3505 4500 4505 4705 4710 5000 5005 5400 5405 5600 5605 5740 5745 5800 5805 6000

3

0

0

2

3

3

3

3

3

3

3

4

0

0

2

3

3

3

4

4

4

4

5

0

0

2

3

3

4

4

4

4

5

6

0

0

2

3

4

4

6

6

6

6

7

0

0

2

3

3

4

7

7

7

7

Fig: 3.3.3

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

15

3.4 installing horizontal tracks
Assemble the track as shown in Figure 3.4.1, ensuring that a washer is used under the wiz nut. The plastic curve must align and butt up against the vertical track and horizontal track snugly.
Before bracing the horizontal tracks, ensure that they are square to the opening and level. To check whether your diagonals are equal: a) Measure from the top of the vertical track to the
end of the horizontal track. b) Check both sides. c) Adjust if necessary.
The track support must be located along the horizontal track approximately at 3/4 door height. For doors higher than 2280mm and/or wider than 5000mm two supports will be required.
WARNING! Failure to position supports approximately 3/4 door height along the track can result in the tracks twisting out.
d) Calculate the horizontal track brace position as per section 1.4.2.
e) Measure along the horizontal track to the desired position and find a structurally sound location to fix your support to the ceiling or side wall. Fig 3.4.2.
f) Each installation must be assessed individually for ceiling fixing requirements.
WARNING! For all insulated panels two (2) ceiling supports must be fitted per horizontal track for all doors over 2400mm x 3000mm.
The safety stop must always be fitted to prevent the panels from accidently exiting the track g) Install the safety stop at the end of the horizontal
track as shown in Fig 3.4.3.
WARNING! The safety stop must be installed. Failure to do so may cause serious personal injury or damage to property.

EQUAL

EQUAL
ensure a washer is used under the wiz nut

Fig: 3.4.1

¾ door height
single support Check that the clearance in the vertical tip tracks as per Fig 3.1.2 is also in the horizontal tracks

Fig: 3.4.2

¾ door heeiqguhat l equal
double support

Fig: 3.4.3

track stop

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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LEFT HAND SIDE

RIGHT HAND SIDE

red cable drum black plug

red plug

black cable drum

INSIDE GARAGE LOOKING OUT

Springs & drums are now colour coded based on winding direction to match
international standards.

Refer to appendix for large doors containing two piece shafts.

Fig: 3.5.1

3.5 standard spring counterbalance system

The springs and drums for the counterbalance system are now colour coded to easily identify which side of the centre bracket the spring is placed. Fig. 3.5.1.
a) Determine whether the spring anchor bracket Q is going to be mounted to the wall or ceiling as per Fig 3.5.2 and ensure the cut corner of the bracket is facing down.
b) Place the torsion bar B on the floor and slide the spring anchor bracket Q onto the torsion bar, positioning it approximately half way along.
the bearing flange in the spring anchor tip bracket must face the spring in single spring
mountings.

fixed to wall
cut corner facing down

fixed to ceiling Q
Fig: 3.5.2
K

c) Locate the cable drum/s K , spring/s I , shaft collar V , washers H and side bearing brackets S and assemble them as shown in Fig. 3.5.3.
NOTE: 6 panel high doors over 6000mm wide and 7 panel high doors over 5000mm wide require 5-18 cable drums.

bolt 3/8″ washer 3/8″

red plug

B
cable drum marked with black paint

d) Ensure the shaft collar is butted up against the anchor

Q

bracket and fixed to axle on spring side of anchor bracket.

NOTE: Shaft Collar not required in double spring mountings.

shaft collar

V

CAUTION: DO NOT tighten

bolts in cable drums yet

I

Only for single spring installations

black plug

K

nut 3/8″

H S

cable drum marked with red paint

Fig: 3.5.3 double spring shown

Refer to appendix for large
tip doors containing two piece shafts.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

17

3.6 install torsion bar

Before lifting the torsion bar into position, check there

is a solid foundation of either brickwork, timber studs,

head or ceiling that will support the lifting system

Q

correctly.

K S

Fig: 3.6.2
Fig: 3.6.1
a) Lift the torsion bar assembly into position, resting both ends over the top of the horizontal tracks. Fig. 3.6.1.
b) Ensure that the side bearing brackets S and cable drums K are situated on the inside of the horizontal tracks.
c) Line up the spring anchor bracket Q with the middle of the door, so that the cut corner is facing down.
d) Slide the torsion bar assembly towards the wall so the spring anchor bracket can touch the wall (the axle must be parallel with the opening).
e) Secure the spring anchor bracket to the wall/ ceiling and the side bearing brackets to the tracks as shown in Fig 3.6.1.
f) Attach the lifting cable to the cable drum by slipping the cable into the slot on the outside groove. (the ferrule will prevent the cable from coming out) Fig 3.6.2.
g) Wind the cable by hand by turning the cable drum away from the door.
h) Once the cable is taut, slide the cable drum against the side bearing bracket and tighten the screws to the torsion bar. Fig 3.6.3.

Refer to appendix for rear torsion installations
Fig: 3.6.3
CAUTION: Be careful not to over tighten the set-screws

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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3.7 adding tension to spring
WARNING! Torsion springs can cause serious injury. DO NOT underestimate the tension in the spring.
WARNING! Keep hands clear of the spring and the spring winding plug at all times.
The number of turns required for each spring is shown on a paper tag attached to the springs. Fig 3.7.1 a) Secure the torsion bar using 2 pipe wrenches as
shown in Fig 3.7.2. b) Turn the spring by inserting winding bars into the
plug holes of the spring and wind up in the direction towards the opening. Fig 3.7.3.

Line Item: 30 Turns: 9.62 Quantity: 2 Ref No: XXX

DH 2,650 mm X DW 5,300 mm Diameter: 50.8 X 2 X 9.4 Wire Diameter: 6.17 mm Delivery No: 82059200 Wgt: 12.9 kg

KSPR: KIT SPRING SECTIONAL OVERHEAD DOOR

Fig: 3.7.1

The label lists how many full turns.

tip

Alternatively, a line is painted along every spring. If the spring is turned 8 times, 8 lines

can be seen along the spring

87654 32 1

always have one hand firmly holding bar while turning

Fig: 3.7.2

WARNING! Always have one winding bar engaged and firmly held while turning and tightening screws.

c) Once you have completed the turns required, remove one winding bar. If spring snaking occurs, tap the remaining bar back towards the spring anchor bracket.

d) Maintain firm tension on the winding bar, while

using a spanner to tighten the two (2) grub screws.

Fig 3.7.4.

grub screw 2

grub screw 1

Fig: 3.7.3
CAUTION: Be careful not to over tighten the grub screws. e) Repeat this procedure if there is more than one spring, remembering to always wind the spring, whether left or right hand, in an up direction towards the opening. f) Check that all screws are properly tightened before removing the wrenches on the torsion bar.

Fig: 3.7.4

maintain tension while tightening both screws

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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3.8 final checks
For optimal performance the door needs to operate efficiently.
a) Manually move the door up and down, the door should move freely without binding or sticking.
b) The maximum force required to move the door should not exceed 20kg.
c) Lift the door to about halfway. When released, the door should stay in place. Fig 3.8.1.
d) Check that the clearances in the vertical tracks as per Fig 3.1.2 is also in the horizontal tracks.
e) If you find that the door is binding, open out the horizontal tracks slightly to create the correct tolerance.
f) Once satisfied that the operation of the door is as near perfect as possible, check that all nuts and bolts are tight.
g) Oil the springs full length to prevent noise and reduce friction. TAL 5 or similar oil rich lubricant in a pressure spray can is acceptable. Fig 3.8.2
WARNING! The safety pull cord or handle must always be fitted to the door

Fig: 3.8.1

pull cord

Fig: 3.8.2

Fig: 3.8.3
Finally, the safety pull cord or handle must always be fitted to the door. h) pass the cord through the white hinge pin on the
bottom panel. Fig 3.8.3. i) Adjust the length and tie in a know at each end. j) Alternatively fit a “D” handle.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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4.0 troubleshooting

Symptom

Possible cause

lifting cables loose when door is opened

cable drums have slipped diagonals out of square lifting cables not wound till taut

Remedy check the screws on the cable drums
check the horizontal tracks are square
loosen screws on cable drums and wind cables till taut, then tighten screws.

torsion bar moving cable drums not adjusted correctly check and adjust

springs not adjusted correctly

check spring tension

shaft collar not fitted (single spring) fit shaft collar, see section 3.5.

end bearing brackets are not straight check end bearing brackets are square and vertical

door will not hold up in open position

spring tension not tight enough incorrect placement of springs

panel reinforcing fitted incorrectly

check the correct number of turns has been made to spring/s. refer to section 3.7.
check the springs are on the correct side/s, refer to section 3.5.
check the reinforcing is placed in the correct postion, refer to section 3.3.

door not level

water level marks incorrect lifting cable not equally taut

check the water level marks are correct
loosen screws on cable drums and wind cables till taut, then tighten screws.

door moving to one side

clearances incorrect
cable drums not close to end bearing brackets

check the clearance/overlap of the door is equal on each side.
loosen screws on cable drums and ensure they are hard up against the end bearing bracket and tighten screws.

door panels jamming / rubbing on tracks

incorrect clearance between wheel and vertical track
door not level
cable drum not lined up correctly

vertical tracks not parallel lifting cables slipping

Check that the clearances per Fig 3.1.2 are the same in both vertical and horizontal tracks.
check water level marks are correct.
loosen screws on cable drums and ensure they are hard up against the end bearing bracket and tighten screws.
Check that the clearances per Fig 3.1.2 are the same on both vertical tracks.
loosen screws on cable drums and wind cables till taut, then tighten screws.

door hard to lift

spring tension
spring may have slipped on set screws wrong spring
panel reinforcing

check the correct number of turns has been made to spring/s. refer to section 3.7.
check sping plug grub screws are tight, refer to section 3.7
check the springs are on the correct side/s, refer to section 3.5.
check the reinforcing is placed in the correct postion, refer to section 3.3.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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common spring problems

symptom
door raises from the floor and hangs down in opening

possible cause cable length too long with cable not on high portion of drum
springs may be too strong (too short) wrong cable drums for springs (too small)

rememdy
shorten cable length until the cable rolls onto the flat portion of the drum when the door starts into the horizontal position
replace spring
replace cable drums

door lifts from the floor and runs away at the top

door is over tensioned. too many turns on spring or wrong spring
wrong cable drums for spring, (too small)

ensure that the correct spring is supplied (if not replace) and that it has the correct number of turns applied
replace cable drums

door falls to the floor and hangs down in the opening
door falls to the floor and runs away at the top
door balances at the floor but runs up or down in between

door is under tensioned too few turns on spring or wrong springs
wrong cable drums for springs (too large)

ensure that the correct spring is supplied (if not replace) and that it has the correct number of turns have been applied
replace cable drums

lifting cable may be too short for high lift cable drum or vertical lift drum and is sitting too high on the spiral portion of the drum

increase the cable length to bring the cable down lower on the spiral

torsion springs too long

shorten springs

cables in wrong position on spiral of the drums

adjust cable length

poor balance throughout

winding spring in wrong direction door weight incorrect springs binding
door not level

wind in correct direction
supply correct springs
fit torsion bar collar lubricate springs
cable lengths are equal equal turns on both springs level door during installation

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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5.0 appendix
5.1 two piece shafts for large doors
TWO PERSON LIFT: For large doors, this process may require two persons to lift into place and a ladder or scissor lift to support while fixing into place.

The springs and drums for the counterbalance system are now colour coded to easily identify which side of the centre bracket the spring is placed. Fig. 5.1.1.

a) Place the 2 x torsion bars B on the floor and slide the 2 x HD spring anchor bracket Q onto the torsion bar, positioning them towards the middle.
b) Slide on the roller bearing and springs I , ensuring the shaft collar is butted up against the HD spring anchor bracket Q and spring I .

cable drum marked with black paint
B slide

c) Connect each assembly together using 2 x 3/8″

washers and bolts.

roller bearing I

d) Place the cable drums on each end.

Q

CAUTION: DO NOT tighten

bolt 3/8″

washer 3/8″

bolts in cable drums yet

washer 3/8″

e) Mount the remaining 2 x spring

Q

bolt 3/8″

anchor brackets to the wall

above the horizontal track.

slide

roller bearing

black plug

B

I

red plug
cable drum marked with red paint

Fig: 5.1.1

torsion shaft couple

TWO PERSON LIFT: Next step may require two persons to lift into place and a ladder or scissor lift to support while fixing into place.

insert key then fix into place with grub screw

f) Lift and thread the right hand side of the assembly through the mounted spring anchor bracket and fix the loose spring anchor bracket securely to the wall.

g) Assemble the torsion shaft couple, without tightening the bolts and slide onto the end of the torsion bar, ready to connect to the other torsion bar.
h) Repeat step f) for the left hand side assembly.
i) Position the torsion shaft couple in the middle as shown in Fig 5.1.1, the axles should be flush with each couple allowing free rotation to occur.
j) Cut torsion shaft key in half and insert into torsion bar at the torsion shaft couple, and fix into place by tightening the grub screws on the shaft couple.

Fig: 5.1.2

torsion shaft key

CAUTION: Be careful not to over tighten the set-screws

Unwind the lifting cable from the tip bottom panel.

a) Attach the lifting cable to the cable drum by slipping the cable into the slot on the outside groove. (the ferrule will prevent the cable from coming out) .

b) Wind the cable by hand by turning the cable drum away from the door.

c) Once the cable is taut, slide the cable drum against the side bearing bracket and tighten the screws to the torsion bar. Fig 5.1.3.

d) Proceed to section 3.7 to tension the springs.

Fig: 5.1.3

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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5.2 rear torsion systems

The rear torsion system involves different bottom hangers, axle assembly and double horizontal tracks.

a) Secure the bottom hanger and bottom panel bracket to the bottom panel with tek screws as shown in Fig 5.2.1.
b) Attach the lift cable to the bottom hanger using a clevis pin, washer and snap pin. Fig 5.2.2
c) Insert the wheel axle through the bottom hanger and bottom panel bracket. Fig 5.2.2.

washer

lift cable

Fig: 5.2.1

snap pin clevis pin
Fig: 5.2.2

wheel axle

The springs and drums for the counterbalance system are now colour coded to easily identify which side of the centre bracket the spring is placed. Fig. 5.2.3.

d) Place the torsion bar B on the floor and slide the spring anchor bracket Q onto the torsion bar, positioning it approximately half way along.
e) Locate the spring/s I and shaft collar V and assemble them as shown in Fig. 5.2.3.
NOTE: Shaft Collar not required in double spring mountings.
f) Ensure the shaft collar is butted up against the spring.

shaft collar
V winding plug marked with black paint.

I

Q B

I
Fig: 5.2.3

winding plug marked with red paint.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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Assemble the track, with cable pulley as shown in Figure 5.2.4. The curve must align and butt up against the vertical track snugly.
Before bracing the horizontal tracks, ensure that they are square to the opening and level. To check whether your diagonals are equal:

K

red drum bracket

red spring

The same colour coded springs and tip cable drums are placed together in
rear torsion systems, which is different to standard installation.
Q
B

a) Measure from the top of the vertical track to the end of the horizontal track.
b) Check both sides.
c) Adjust if necessary.

spacer 0T5252
nut flanged 5/16″-UNC 45713
washer 000785

bolt SQ neck 5/16″-UNCx7/8″ 0T2714
plastic curve OT3170

The track support must be located along the horizontal track approximately at 3/4 door height. For doors higher than 2280mm and/or wider than 4700mm two supports will be required.

nut 3/8″-UNC
006553
140mm sheave pulley 0T5251
nut 1/4″ flanged 0T2702

d) Calculate the horizontal track brace position as per section 1.4.2.

bolt 1/4″x1/2″-UNC 0T2709
Fig: 5.2.4
WARNING! Failure to position supports approximately 3/4 door height along the track can result in the tracks twisting out.

e) Measure along the horizontal track to the desired position and find a structurally sound location to fix your support to the ceiling or side wall.
f) Each installation must be assessed individually for ceiling fixing requirements.

WARNING! For all doors higher than 2280mm and wider than 4700mm two (2) ceiling supports must be fitted per horizontal track.

g) Lift the torsion bar assembly into position, resting on top of the tracks.
h) Connect the side bearing brackets to the end of the horizontal tracks using 3/8″ and 1 1/2″ heaxagonal head bolts and 3/8″ washers and nuts. Fig 5.2.4.
i) Slide the torsion bar B of the torsion assembly through one side bearing bracket and then the other.

cable winds around pulley

K cable drum

j) Place the cable drums into position after a washer, noting that red cable drum with red spring and black cable drum with black spring. DO NOT tighten screws yet.

k) Secure the spring anchor bracket Q firmly into a solid foundation directly or through the use of a steel angle to timber beams onto the ceiling, ensuring the `cut corner’ is pointing in the direction of the opened door.
If Opener is to be fitted, offset from middle to tip ensure room for opener rail.
Unwind the lifting cable from the bottom panel.
l) Thread the lifting cable around the sheave pulley wheel and over to the rear cable drums. Fig 5.2.5.

cable connected to bottom hanger
Fig: 5.2.5
CAUTION: Be careful not to over tighten the set-screws

m) Attach the lifting cable to the cable drum K by slipping

K

the cable into the slot on the outside groove. (the ferrule

will prevent the cable from coming out).

n) Wind the cable by hand by turning the cable drum away from the door.

o) Once the cable is taut, slide the cable drum K against the side bearing bracket and tighten the screws to the torsion bar. Fig 5.2.6. Refer to section 3.7 for spring tension.

Fig: 5.2.6

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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5.3 hinged tapers
Tapers are accomplished using a small customised panel, which results in a slight variation in the installation process.
a) Assemble the bottom panel taking note that there are no wheels or weather strip on the bottom panel, these are both on the taper panel. Fig 5.3.1.
b) Assemble the tapered panel as shown in insert of Fig 5.3.1. The 2 spacers required are to be cut 1012mm long from a white link pin and fitted one to each side as shown.
c) Connect the tapered panel to the bottom panel using 3 x hinge pins provided.

hinge link spacer
wheel axle hinge pin

Fig: 5.3.1
Tracks are assembled as standard with the only difference being that one vertical track needs to be cut down to accommodate the uneven floor. d) Start with both of the verticals tracks from the
ground and measure up to the level datum. e) Cut the tracks as necessary from the ground end. f) Follow the directions in section 3.1 to install tracks,
before proceeding to adding panels in section 3.2.

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

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5.4 single & double end stile quick closer
WITH BRACE PLATES ON SMALL RADIUS CURVE
5.4.1
Headroom = from top of door to top of: · Spring anchor combo bracket, headroom
= 180mm (min). · Cable drum (centre spring anchor bracket
and side end bearing brackets) headroom = 175mm (min). Vertical track length = Small curve door height – 235mm
= Large curve door height – 255mm

Fig. 5.4.1
OPENER-‘C’ RAIL

10 TOP PANEL TO LINTEL
180

235 TRACK CUT LENGTH
(255 WITH LARGE CURVE)

5.4.2
Install the brace plate on top corners of the top panel, locate the plate over the 2 stile screws. Fasten the brace plate with 4 off tek screws.
For a double end stile door install the second brace plate in same position on 2nd stile, Fig. 5.4.6.

Fig. 5.4.2

TRACK-CURVE JOINING LINE

5.4.3 – Single End Stile
Assemble the quick closer with 2 wheels and axles fitted to `back 2 holes’.
With door in closed position, attach the lower hinge plate of the quick closer to the brace plate, ensure the two wheels are sitting on the bottom of the track.
For a double end stile door use 2 quick closers on each side and 2 long axle wheel.

Fig. 5.4.3

BRACE PLATE
QUICK CLOSER

WHEELS AND AXLES INSTALLED IN BACK HOLES

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

27

5.4.4
Fasten the quick closer lower hinge plate to the brace plate, with 2 tek screws.
NOTE: For additional strength on single end stile doors, as shown, drill a 5.5mm hole through the quick closer and brace plate and fix with a tek screw as shown.
5.4.5
For optimal drive through clearance cut the hockey stick and fit as shown. NOTE: Reinforcing may reduce the walk under clearance by 65mm. Follow standard installation procedures.
RECOMMENDATION: For optimal walk in clearance an opener is required to lift door curtain to fully open position. The hockey stick connection to the top panel: position the pivot point at the top of the panel, or as near as practical to the centre line of the quick closer’s pivot point.
5.6.6
Double end stile quick closer installation Part SD0004.

Fig. 5.4.4
SINGLE END STILE
DRILL 5.5 AND FIX WITH A TEK SCREW
Fig. 5.4.5

OPENER-‘C’ RAIL

CUT HOCKEY STICK AS NECESSARY

REO

NOTE 10.

Fig. 5.6.6
SIDE VIEW DOUBLE END STILE QUICK CLOSER
OPENER-‘C’ RAIL

DOUBLE END STILE QUICK CLOSER

REO

Panelift® PFT, PFI & Insul-ShieldTM installation instructions

28

5.5 lock installation
WARNING! In coffin garages (those with no access other than the garage door), the lock handle should be installed immediately after fitting the lock panel.
The lock handle is to be fixed to the middle of the second panel. Using the lock plate as a guide and the parts in Fig. 5.4.1;
a) centre the plate on the central end stile and drill through the end stile and the panel using a 1/2″ (13 mm) drill bit for the large hole and a 3/16″(5 mm) bit for the two holes on either side.
b) Fit the “T” handle to the panel by inserting the lock shaft and the two 3/16″ thread bolts into the panel from the outside, through the lock muntin.
c) Attach the 3/16″ or 4.7 mm nuts and washers securing the `T’ Handle in place.
d) Next insert the lock guide plate (dimples facing away from door) followed by the internal handle, the lock cam and the second guide plate (dimples facing the door).
e) Lock together with 3/16″ nuts and washers, see Figure 5.4.2.
external lock handle

lock strikes

lock catch

lock guide plates

lock cable

external lock internal lock

handle

handle

Fig: 5.5.1

lock cam

washer nuts

internal lock handle

Fig: 5.5.2

lock guide plate

lock guide plate lock washer
nut 4mm
lock cam

Panelift® installation instructions

29

5.6 after installation care
cleaning
COLORBOND® & COLOURED STEEL FINISH
Your B&D Panelift® has been pre-painted with a high durability polyester paint system, especially designed and tested for the harsh Australian conditions. However, all exposed surfaces require some attention to guard against the premature onset of corrosion and any other harmful atmospheric effects. In our atmosphere there are harmful deposits that gather on the door surface and if not removed regularly, will seriously affect the appearance and life of the door.
Washing of the door with clean water and a cloth every 14 days is recommended ­ particular care should be taken to clean areas of the door not normally washed by rain.
lock
Your lock does not require special maintenance, however, if the keyway becomes stiff, the application of powdered graphite is recommended ­ do not grease or oil the lock.
WARNING! Do not disassemble the lock mechanism and do not allow paint to enter the lock keyway.
hinges & hangers
PLASTIC HINGES: No lubrication is generally required, however silicon spray or lithium grease may be used if necessary.
cables
Check the cables regularly for corrosion, fraying or tangling, if any of these are evident call your service provider.

regular maintenance required
B&D recommends that you check the operation of your Panelift® at least every six months (more regularly in extreme environments or frequent use). The effort required to manually open and to manually close the door should be about the same (if door has an automatic opener, put into manual mode before testing door).
If the door is difficult to operate in either direction (up or down) then check that the inside surfaces of the guides are clean and free of obstructions.
If the door is still difficult to operate, then your door will need a service to adjust the spring tension and possibly other operational parts of the door.
This service should only be carried out by an experienced door technician, using the correct tools.
If you have an automatic opener fitted to your door, it is particularly important that you ensure the optimum operation of the door, otherwise you may reduce the effective life of the opener.
To keep your door running well, it is recommended that your door be serviced, by an experienced door technician, every 12 months (more regularly in extreme environments or frequent use), or earlier if required.
spring tension
It is natural for springs to lose tension over time. When spring tension is adjusted or when your door is first installed it is usual to apply a little more tension than is required for balanced operation, to allow for the normal “settling in” of the springs. Lightly lubricate to prevent friction between the coils.
warranty
Warranty conditional on proper care as recommended above. Full details of the warranty are available in your owners handbook, from your nearest B&D office or visit the B&D website www.bnd.com.au

b&d doors office locations

Head Office New South Wales Queensland Victoria South Australia Western Australia International/Export

6-8 Fiveways Blvd, Keysborough 3073 34 Marigold St, Revesby 2212 17 Oasis Court, Clontarf 4019 147-153 Canterbury Rd, Kilsyth 3137 23 Frederick Rd, Royal Park 5014 96 Mulgul Rd, Malaga 6090 34 Marigold St, Revesby 2212

Phone (03) 9791 2000 Phone (02) 9722 5555 Phone (07) 3883 0200 Phone (03) 9237 7766 Phone (08) 8440 4747 Phone (08) 9247 8777 Phone +61 (0)2 9722 5555

Prefixed trademarks are the property of B&D Australia Pty Ltd. B&D Doors & Openers is a division of B&D Australia Pty Ltd. ABN 25 010 473 971. © 2018 B&D Australia Pty Ltd.
www.bnd.com.au

your representative is

References

• B&D Garage Doors - Safe and Secure Australian Garage Doors - B&D Australia

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