samsondoors Hold to Run Roller Garage Door Installation Guide

: August 13, 2024
: samsondoors

samsondoors Hold to Run Roller Garage Door

Safety Information

Important: Please read these instructions carefully prior to commencing the installation of the door.

This Hold to Run Roller Garage Door has been designed to provide years of trouble free use. The door will perform efficiently only if it is installed and operated correctly.

Read these important safety rules first:

This equipment must be installed and used in accordance with these instructions. Failure to follow these instructions could result in damage to the integrity of the safety circuits.

Two persons are required to install this product to ensure safe handling procedures.

CAUTION

Do not wear rings, watches or loose clothing while installing or servicing the unit and ensure correct PPE is worn.

To avoid serious personal injury from entanglement, remove any loose objects from the equipment prior to operating door.

DANGER

Installation and wiring must be in accordance with your local building and electrical regulations.

Any electrical work must be carried out by a suitably qualified person, if in doubt consult a qualified electrician.

Use only the mains lead supplied with the Remote Control Unit as failure to do so will invalidate the warranty.

Connect the mains lead to an adjacent 13amp 3 pin switched socket.

The plug must be fitted with a 13 amp fuse.

Note: For optimum electrical safety this unit should be connected to circuit protected by a R.C.D. (max 30 mA trip rating).

This unit should not be installed in a damp or wet space or on a damp or single skinned wall without sufficient spacers.

DANGER

Disconnect electric power to the control unit before making repairs or removing covers.

Install the Control Box in a location where the garage door is visible, but out of the reach of children. Do not allow children to operate push button(s). Serious personal injury from a closing garage door may result from misuse of the operator.

CAUTION

Activate unit only when the door is in full view, free of obstructions and operator is properly adjusted. No one should enter or leave the garage while the door is in motion. Do not allow children to play near the door.

Note to Installer

Please ensure this installation and user manual remains with the end user as it contains important safety and warranty information.

Product Overview

Motor
Axle Assembly
Shaft End cap
Barrel Rings
Guide Rollers
R/H End Plate
L/H End Plate
Overide Eye
Locking Strap
Guide Rails
Curtain Assembly
Bottom Rail
Bottom Weather Seal
Genesis Control Box
CE Label

Component Check

Unpack and check that all components are present.

✓ Curtain Assembly
(inc. set of Pre-fitted Locking Straps)
✓ Axle Assembly
(pre-fitted with Motor, Locking Rings and Dummy End)
✓ Pair of Guide Rails (pre-fitted with brush strips)
✓ Box Assembly Comprised of:

1 pair of end plates (pre-fitted with guide rollers & safety break)
1 motor override eye and manual winding handle
1 fittings pack

✓ Control System Comprised of:

Control unit
Mains lead
Fittings pack

Pre-Installation Check

Important Note : In case of power failure a manual override system is fitted as standard but this can only be operated from inside the garage.

If the garage has no service entrance door then an exterior release kit must be fitted to allow manual operation of the garage door from outside.

BEFORE REMOVING THE OLD DOOR check that the door size and colour correspond with that which was ordered.
Structural condition of opening
Ensure the area around the opening is strong enough to support the door
The surface where the door is to be fitted must be flush and reasonably smooth.
Small irregularities in the brickwork will be acceptable. The lintel must not protrude backwards or forwards from the brick piers. Should the lintel protrude backwards or forwards from the brick piers this will require special instructions, please consult your Allu Guard Approved Installer.
Fitting Notes
It is recommended that 2 people are available for fitting all door sizes.
The door must be fitted square and level, irrespective of the shape of the opening; on no account should any compensation be made to suit an irregular opening.
Ensure all necessary tools are to hand before starting.
The door package and its contents should be checked for obvious damage before removal of the wrapping.
IF THERE IS ANY DAMAGE YOUR SUPPLIER SHOULD BE CONTACTED IMMEDIATELY.
Ensure there is a suitable 13amp 3 pin switched socket adjacent to where the Remote Control Box is to be fitted.
Ensure all tools and door components are gathered together inside the garage prior to starting the installation.

Tools Required:

2 Stepladders
Spirit/laser level
Steel tape
Power drill
10mm A/F spanner
Slot screwdriver
Pozidrive screwdriver
4mm A/F Allen key
3.8 drill bit
7.0 drill bit
11.0 drill bit
Hacksaw
Suitable wall plugs (not supplied)
Small electrical screwdriver
3mm A/F Allen key
Suitable fixings (not supplied)

Check Headroom

The headroom is the clear vertical height required between the top of the guide rails and any obstruction above the shutter as shown in Fig 1 and Fig 2.

This space is required to house the door roll headroom of 205mm / 300mm is required. (AG55 requires 205mm & AG77 requires 300mm)

Limited Head room

If insufficient headroom is available the door can still be fitted (see your survey sheet) but the shorter guide rails will give a corresponding reduction in door opening height as shown in Fig 3. The curtain will require 1 lath to be removed for every 75mm of reduction in the guide height.

Note: Ensure that the headroom above the guides is clear of any obstructions (especially small protrusions or nail heads) which could cause damage to the door roll during installation/operation.

Preparing the Guide Rails

For Fitting Within The Aperture

Check Guide Rail Length
Check that guide rails have been supplied to the correct length as per your survey sheet / order. The correct length is aperture height less 205mm or 300mm as shown in Fig 1.

Drill Fixing Holes

Drill holes through 7mm diameter and counter drill 11mm diameter as shown in Fig 4.

A minimum three holes per rail are required, positioned as shown in Fig 5.

NB. Position holes for best fixing to brickwork.

For Fitting Behind The Aperture

Check Guide Rail Length

Check that guide rails have been supplied to the correct length as per your survey sheet/order.
A. Where headroom of 205mm / 300mm or more is available guide rail length equals aperture height as shown in Fig 6.

B. Where only limited headroom is available guide rail length equals total available height less 205mm / 300mm as shown in Fig 7.

Drill Fixing Holes

Drill holes through 7mm diameter & counter drill 11mm diameter as shown as shown in Fig 8.

A minimum three holes per rail are required as shown as shown in Fig 9.

NB position holes for best fixing to brickwork.

Assemble the Frame

L/H or R/H Motor (Factory Fitted as Standard)

The motor and control unit can be mounted on either the L/H side or R/H side. (Please specify at time of order).

All Allu Guard doors are fitted with a safety brake as standard excluding AG55 Doors shown in Fig 10.

If you want to change the hand of the motor this should be carried out by a suitably trained engineer.
If you do move the Motor & Safety Brake ensure that these are installed correctly otherwise the unit will not activate under normal running conditions.
It is important that the head plates are securely fixed – 2 fixings per head plate.

*End Plates and Safety Brake Device (Safety brake factory fitted as Standard)**

Lay the Head assembly on protective packing, parallel with and just inside the garage opening.

Ensure the motor is situated at the correct end for your installation and that the motor limit adjusters are at the top/bottom as shown in Fig 11.

Fix the motor plate to the end plate by using four M6 x 25 countersunk screws and Nyloc nuts provided.

The safety brake is pre fitted to the end plate as standard (Fig 10). Loosen the safety collar on the dummy end shaft, extend the shaft fully into the safety brake (Fig 10a). Slide the safety collar tight up to the dummy end and tighten.(Fig 10b & 10c).

Fit Guide Rails

Select R/H guide rail and slide fully onto the bottom square tube spigot projecting from the R/H end plate, please ensure that the End Plate is flush with the face side of the guide rail.

Repeat for the L/H guide rail as shown in Fig 12.

Install the Frame

You will have drilled your guide rails, as shown in Fig 4 or Fig 8, for fitting either:-

a ) Within the aperture
b ) Behind the aperture

Please proceed accordingly. (SAFETY NOTE: 2 people required)

Fitting Within Aperture

For installation within the aperture we strongly recommend the use of a cover box as this covers and protects the door curtain roll.

If either half box or full box options are specified these will be supplied factory fitted to the end plates.

Lift the frame assembly into position and align with the front of the aperture.

Ensure the guide rails are VERTICAL (in both directions) and parallel to each other, at the same height and the correct distance apart.

NB: Some width adjustment is available on the sliding shaft end of the axle.

The correct distance is shown in Fig13. – AG77 Door

Ensure the axle assembly is horizontal by using a spirit level.

Once the frame is correctly positioned, mark and drill for fixings (fixings not supplied).

When the guide rails are securely fixed, double check that they are vertical, parallel and correct distance apart and that the axle assembly is level.

Fixing The Head Plates – 2 fixings per head plate.

Fix the head-plates into position ensuring that the head-plates are level and that the locating pegs are fully located into the guide section. Fix securing screws through back of head-plate and attach securely to the wall.
Where a back box is fitted it may be necessary to fix the back box to the opening header to stop any marking of the curtain during door operation. If additional fixings are required in the back box, use countersunk screws, ensuring that the screw heads do not protrude, as curtain damage could occur.

Always ensure that the back box is adequately fixed to eliminate any rubbing of the curtain on the back box during the door operation and fixing are evenly spaced to ensure no bowing of the box.

Fitting Behind Aperture / Fitting to the Front of the Aperture (External Fit)

Lift the frame assembly into position and align centrally with the aperture. Ensure the guide rails are vertical (in both directions) and are parallel to each other, at the same height and the correct distance apart.

NOTE: Some width adjustment is available on the sliding shaft end of the axle. The correct distance apart is shown in Fig 13.

When fitting to the front of the aperture (external fit/reverse roll), once installation is complete, the box must be silicone at the interface with the aperture and along all edges and joints to prevent water ingress. Failure to seal will invalidate the warranty. The bottom slat transmitter must be fitted to the inside face of the bottom slat (concave face). Fitting to the external face of the slat will lead to failure and invalidate the warranty.

Ensure axle assembly is horizontal by using a spirit level.

Once the frame is correctly positioned, mark and drill for fixings (fixings not supplied).

When guide rails are securely fixed, double check for vertical, parallel and correct spacing and that the axle is level.

NOTE: Once the frame is fully fitted and checked, use the plastic plugs supplied to cover the fixing holes in the guide rails to give a ‘fully finished’ effect.

Fixing the Head Plates

Fix the head-plates into position ensuring that the head-plates are level and that the locating pegs are fully located into the guide section. Fix securing screws through back of head-plate and attach securely to the wall.

Where a back box is fitted it may be necessary to fix the back box to the opening header to stop any marking of the curtain during door operation. If additional fixings are required in the back box, use countersunk screws, ensuring that the screw heads do not protrude, as curtain damage could occur.

Always ensure that the back box is adequately fixed to eliminate any rubbing of the curtain on the back box during the door operation.

Installing the Curtain Assembly

Carefully unwrap and remove the outer bubble wrap protection and place over shaft to stop damage to inside of curtain during installation.

Carefully position the curtain assembly in the door aperture, below the axle as shown in Fig 14, slit the packaging to gain access to the curtain but leave some packaging to protect the curtain.

SAFETY NOTE : A minimum two people are required for this procedure to ensure safe handling.

It is essential to place sections of bubble wrap over the axle to prevent marking the curtain as it is installed.

Using minimum 2 people carefully lift the curtain assembly up level with the axle. Practice has shown that it is best to place one hand on the axle, keeping that arm straight, and support the curtain roll on that shoulder as shown in Fig 15.

Feed the bottom lath over the top of the axle and down between the guide rails, as shown in Fig 16 taking care not to scuff the curtain assembly, proceed until half of the curtain has been fed over the axle, carefully unroll the remaining curtain until this is balanced over the shaft, once this is done carefully feed the curtain into the guide until the curtain is reaches the floor.

NOTE: Do not let the curtain ‘free fall’ over the axle as this will result in damage to the Curtain and/or the Safety Edge Transmitter.

Attach the Curtain

Fit the Motor Override

Attach the ‘Motor Override Eye’ fitting to the motor as shown in Fig 17 using 3mm screw.

Position the Axle

Use the motor override to rotate the axle shaft.

Rotate the axle until the locking joint attachment holes are positioned as shown in Fig 18.

Locking Ring

There is a locking ring positioned on the shaft for each locking strap; the number of locking rings will vary according to curtain width and AG55 – 2 rings & AG77- 1 ring per strap.

Position the outermost ring/s to the shaft approx. 150mm in from each end and equally space the other/s as shown in Fig 19.

Slide each locking strap along the top lath and engage the fastening pin into the appropriate hole in the respective clamped locking ring/s, (AG55 Doors).

Slide the loose locking ring to engage the other end of the fastening pin and secure the loose locking ring to the shaft using the self tapping screw on AG55 doors.

Repeat this for each locking strap, as shown in Fig 19.

Locking Ring (AG77)

The locking rings are pre-attached on the barrel, to connect the locking straps, line up with the locking ring hole and insert pin. Space the lock rings with 800mm between them.

The support straps (box stiffeners) should be positioned centrally or equidistant. Support straps are available as an optional extra, should the box require support.

Connect the Electrics

Preparing the Roller Garage Door for Control Box Installation

Unscrew and remove the receiver cover from the unit by loosening the one screw at the base of the unit.

Fixing the Control Box to the Wall

Make sure that the unit is mounted onto internal brickwork and is firmly fixed.
Hold the unit against the wall at a height of at least 1.6 meters and mark where the screw fixings should be as shown in Fig 20.
Take the unit away and drill the holes. Fix unit to the wall.

THIS MUST BE FITTED INSIDE THE GARAGE AS IT IS NOT IP RATED

Plug power lead into 13A socket but DO NOT SWITCH ON at this stage.

Setting the Curtains Open and Close Position

Motor Set-Up

Motor and fall protection wiring.

The receiver must not be connected to the mains power supply during connection to the motor.

Motor Wiring

Connect the motor to the receiver.

Note: the motor’s direction of rotation shall then be checked and reversed if necessary.

Lock the motor cable with the cable clamp provided.

The motor cable must be placed in the receiver’s 230v insulation area.

Connecting the Receiver to the Mains Power Supply

Fully unfold the receiver aerial so that it is pointing downwards.

Screw the bulb supplied into the receiver. (Before connecting to mains power supply)

Replace and screw in the receiver cover.

Refit the integrated light cover.

Connect the receiver to the mains power supply.

All the indicator lights come on and then go out.

If indicator light 1 comes on permanently, fall protection is not connected or incorrectly connected to the receiver.

Checking the Direction of Rotation of the Motor and Adjustment of the Motor End Limits

Press simultaneously on the ^ and v buttons until the motors up and down movement occurs to enter motor adjustment mode.

Indicator light 1 flashes slowly.

Press button ^ or v to check the motor’s direction of rotation.

If the motor’s direction of rotation is correct, move on to step [3] of the motor end limit setting procedure.

If the direction of rotation is incorrect, press button (stop) until the motors up and down movement occurs, check the motor’s direction of rotation again and move on to step [3] of the motor end limit setting procedure.

If the motor end limits are already set, move on to step [8] to exit motor adjustment mode.

If the motor end limits are not set, check that the motor is released: the two push-buttons should be pressed.

Note: The motor end limits can also be set with a setting tool (ref. 9015971).

In this case, set the motor end limits with the cable then move on to step [8] to exit motor adjustment mode.

Press ^ button to position the garage door in the upper position.

Adjust the upper position with buttons ^ and v.

Press the motor’s upper end limit push-button.

Press v button to position the garage door in the lower position.

Adjust the low position with buttons ^ and v.

Press the motor’s low end limit push-button.

Press simultaneously on the ^ and v buttons or press the (prog) button until the motor’s up and down movement occurs to enter motor adjustment mode.

Indicator light 1 goes out.

Progressive Motor Limit Set-up

Limit Switch Adjustment (see Fig 22)

The limits are set at the factory to 8 revolutions of the shaft, A 4mm

‘Allen Key’ limit adjuster is used to adjust them further.

Allow the motor to run downwards without the curtain attached to enable the shaft to determine bottom limit position, without curtain attached to shaft.

Adjustment ‘Up’

Run the motor up with the curtain attached, if the motor stops short of fully open, turn the adjusting screw in the + direction (this is the adjuster indicated by the rotation of the barrel. This will allow the motor to run on in the up direction.

Stop the motor before it gets to the fully open position and wind the adjuster in the – direction until it stops before the fully open position. Keep the open button pressed and at the same time slowly turn the adjuster in the + direction until the door stops at the fully open position. If the motor runs too high, turn the adjustment screw towards the – direction until the motor stops in the correct position.

Adjustment ‘Down’

Run the motor down, if the motor stops short of the closed position, turn the adjustment screw towards the + direction keeping the control pressed in the down direction until the correct position is reached.

If the motor runs too far turn the adjustment screw towards the – direction.

Set open position as shown in Fig 21.

Checking the Limit Positions

Run the motor in both directions until the limit switches cut out the motor travel.

Carry out any fine adjustments. One turn of the adjustment screw corresponds to approximately 70° turn of the roller tube.

In order that the locking joints operate effectively, the position of the shaft in the closed position needs to be finely adjusted.

Do not adjust past this position as this will impose excessive loads on the mechanism.

This motor is fitted with a thermal trip; this stops the motor from overheating.

Be aware that excessive running of the door may cause the thermal trip to operate, if this happens; please wait 20 minutes before trying to operate the door again.

Control Box Set-up

| SW 2| Reverse Direction of Lid Buttons
---|---|---
SW 3| Reverse Direction of Motor
SW 6| Transmitter Program Button
SW 7| On = Impulse Up / Deadman Down

Speciation

Mains Supply Connection

Recommended Power Supply Protection:-
13A fused Spur or Single Pole MCB Type ‘A

230v Tube Motor Connection

Note
This connection will supply 230v AC and is specifically for tube motor operation

Ext Key-Switch Connection

Fit link between ‘G’ and ‘S’

Links must be fitted between: ‘G’ – ‘U’ – S as shown

Ext Push Button Connection

Operating Instructions

Electrically Operated Products

Under UK Legislation the garage door should be operated when it is in view, making sure it is not obstructed. Ensure when the door is running, that you and any other person stands clear of the curtain and keeps hands etc. away from the moving parts. Children should not operate the door or play nearby an opening door.

Control Unit

Your garage door can be activated by pressing and holding the buttons on the front of the control unit.

PLEASE NOTE

When opening or closing the garage door you must monitor the product until it has completed its operation.

Power Failure

Electrically Operated Products

If your roller garage door is not working correctly please contact your supplier for assistance. N.B: Always isolate the power before attempting to make an adjustment or repair.

Power Failure

In the event of disruption to the power supply, or the motor temporarily over heating (the motor is protected by a thermal cut out), the door can be operated manually. Isolate power supply before using the manual override.

To operate: Hold crank handle in line with eye and rotate handle until the door reaches the open/closed position.

If the door is not used during the power failure then no action has to be taken as the unit will reset itself when the power is restored.

Important

If the garage has no service door then an exterior release kit should have been fitted to allow emergency opening from outside. Follow instructions supplied with that kit.

Note

When closing the door manually ensure that the locking joints are set in the fully closed position to ensure security.

Insert the hooked end of the winding handle into the override eye; this is projecting downwards from the drive motor at one end of the curtain roll, rotate the handle to operate the door to open or close.

To operate:

Hold crank handle in line with eye and rotate handle until the door reaches the open/ closed position.

To operate:

Externally fitted doors will need the cover cap or override lock removing and the crank handle inserting.
Rotate handle until the door reaches the open/closed position.

To operate:
Remove lock and insert crank handle and rotate until door reaches the open/close position.

DO NOT OVERWIND

When the main power is reinstalled, ensure that the power isolator is switched back on. If applicable secure the handle back onto the wall. Remember to keep the crank handle in a convenient place.

DECLARATION OF INCORPORATION

We , Allu Guard Limited
Of Rotherham Road, Parkgate Rotherham S62 6FP
Declare that : Power Operated Roller Garage Door
Models: Allu Guard 77 and Allu Guard 55
Manufactured by : Allu Guard Limited

Are in conformity with the essential Health and Safety requirements of the Machinery Directive 2006/42/EC.
And conform with the Low Voltage Directive 2006/95/EC, and the Electromagnetic Compatibility Directive 2016/108/EC.

A technical file of documentation has been compiled in accordance with Annex VII (Part 7 of Schedule 2), part B. Allu Guard undertakes to transmit, in response to a reasoned request by the national authorities, relevant information on this partly completed machinery. Transmission shall be via electronic or paper copies, and shall be without prejudice to the intellectual property rights of the manufacturer of the partly completed machinery.

The product to which this Declaration of Incorporation relates must not be put into service until the relevant machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive.

Kevin Lindeque Managing Director

EC DECLARATION OF CONFORMITY

The above power operated door (door, operator, safety devices, etc.), has been assembled, installed, connected and tested in accordance with the manufacturer’s instructions, at the following site address and is in conformity with the provisions of the Machinery Directive (89/392/EEC as amended by 91/368/EEC and 93/336/EEC), the Low Voltage Directive (73/23/EEC) and EMC Directive (89/336/EEC).

The Transposed Harmonized Standards used in the design of the above door are as follows: EN 13241-1:2016, & 12453:2001.