b d PFT Sectional Panelift Icon Panelift and Insul Shield Instruction Manual
- June 13, 2024
- b d
Table of Contents
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:
- Install the vertical tracks (2.1).
- Attach the door panels (2.2).
- Assemble the bottom and middle panels (2.3).
3.0 Installation
Follow the steps below to install the garage door:
- Install the vertical tracks (3.1).
- Add panels to the door (3.2).
- Fit reinforcing (3.3).
- Install horizontal tracks (3.4).
- Set up the standard spring counterbalance system (3.5).
- Install the torsion bar (3.6).
- Add tension to the spring (3.7).
- 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
4
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
5
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
9
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
10
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
11
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
14
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
16
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
20
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
24
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
26
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