GDO 55mm Roller Garage Door Instruction Manual

GDO 55mm Roller Garage Door

Specifications:

• Product: 55mm Roller Garage Door
• Model: GDO ROLL55
• Manufacture Date: October 2023
• Manufacturer Contact: Tel: 01926 463 888, Website: www.garagedoorsonline.co.uk

Product Usage Instructions

Safety Rules:

It is crucial to adhere to the following safety rules when installing and using the garage door:

• Install and use the equipment according to the provided instructions to maintain safety circuits.
• Always have two persons for safe handling during installation.
• Avoid wearing rings, watches, or loose clothing while working and use appropriate Personal Protective Equipment (PPE).
• Remove any loose objects near the door to prevent entanglement.

Installation and Wiring:

Follow these guidelines for installation and wiring:

• Ensure installation and wiring comply with local building and electrical regulations.
• All electrical work should be done by a qualified person; consult an electrician if in doubt.
• Use the supplied mains lead for the Remote Control Unit to maintain warranty validity.
• Connect the mains lead to a nearby 13 amp 3-pin switched socket with a 13 amp fuse.

Location and Operation:

Consider the following for the location and operation of the garage door:

• Install the Control Box and Switch Control where the door is visible but out of reach of children.
• Avoid operating the door via security cameras or doorbell cameras.
• Do not allow children to operate the controls to prevent accidents.

Pre-Installation Checks:

Prior to installation, conduct the following checks:

• Verify delivery note, order sheet, door dimensions, and opening dimensions for accuracy.
• Inspect components for any damage, especially guide rails and curtain roll.

FAQ

• Q: What should I do if I encounter damaged components during pre-installation checks?
  • A: If you find any damaged components, do not proceed with the installation. Contact the manufacturer or supplier for replacement parts before continuing.
• Q: Can I install the garage door in a damp area?
  • A: It is not recommended to install the unit in damp or wet spaces without proper spacers for safety reasons. Ensure a dry and suitable location for installation.\

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

IMPORTANT SAFETY RULES

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 13 amp 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 a circuit protected by an 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 and/or Switch Control in a location where the garage door is visible, but out of the reach of children. The door must be in direct sight of the control and must not be operated via security or doorbell cameras. Do not allow children to operate push button(s) or remote control(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 the 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.

PRE-INSTALLATION AND COMPONENT CHECK

Always check on delivery that the order details are correct and the door is undamaged, especially before removing any existing doors.

Sequence of Installation & Contents

1. Pre-Installation and Component Check
2. Installation Options
3. Prepare the Guide Rails
4. Fix Guide Rails & Axle Assembly
5. Fit Emergency Overrides
6. Install the Curtain in the Guides
7. Attach the Curtain
8. Set-up the Control Unit (where supplied)
9. Set the Motor Limits
10. Commissioning

Check:

1. Delivery note
2. Order sheet
3. Door dimensions/colour
4. Opening dimensions/clearances
5. Components
6. Check for any damage to the guide rails or the outside roll of the curtain

Do not proceed further with the installation unless you are sure that the door is the correct size, and all components are present.

WIDTHS

• Manufacturing Width = Over Guide Width
• Drive Through Width = Over Guide Width less
• 120mm for 60mm guides

HEIGHTS

• Manufacturing Height = Guide Height
• Total Height = Guide Height + End Plate
• Headroom/End Plate up to 2.3m Guide Height = 205mm
• Drive Through Height = Guide Height less 50mm

PRE-INSTALLATION CHECK

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.

The structural condition of the opening.

1. Ensure the area around the opening is strong enough to support the weight of the door.

2. The surface where the door is to be fitted must be flush and reasonably smooth. Small irregularities in the brickwork will be acceptable.

3. No obstacles in fitting the footprint eg. no sharp objects, pipes, cables, bumps etc. sticking out from the pillars, lintel or header to twist the guides, distort the fascia or catch on the curtain.

4. The lintel must not protrude backward or forwards from the brick piers. Should the lintel protrude backward or forwards from the brick piers this will require special instructions, please consult your supplier.

5. The floor must be flat/level. If necessary install a sub-frame to ensure secure, flush and level fixing (recommended minimum 70 X 70 PAR). The lintel must not protrude backward or forward from the brick piers. Should the lintel protrude backward or forwards from the brick piers this will require special instructions, please consult your installer.
   Fitting Notes

6. It is recommended that 2 people are available to fit all door sizes.

7. 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.

8. Ensure all necessary tools are to hand before starting.

9. 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.

10. Ensure there is a suitable 13amp 3 pin switched socket adjacent to where the Remote Control Box is to be fitted.

11. Ensure all tools and door components are gathered together inside the garage prior to starting the installation.

Recommended Tools for Assembly

• 2 stepladders
• Spirit/laser level
• Tape measure
• Power drill
• 10mm A/F spanner
• Slot screwdriver
• Pozidrive screwdriver
• 3.5mm drill bit
• 7.0mm drill bit
• 11.0mm drill bit
• 3mm A/F Allen key
• 4mm A/F Allen key
• Hacksaw
• Suitable wall plugs (not supplied)
• Suitable fixings (not supplied)

COMPONENT CHECK

1. 90o Fascia
2. Motor (fitted into axle)
3. 60mm Octagonal Axle
4. Axle Cap (fitted into axle)
5. R/H End Plate
6. L/H End Plate
7. 4 No. Locking Straps
8. Guide Terminals (fitted to end plate)
9. Optional 45º Box Cover
10. Control Unit (where supplied) *
11. Guide Rails
12. Brush Insert (fitted to guide)
13. Curtain
14. End Locks (fitted to curtain)
15. Bottom Slat (fitted to curtain)
16. Rubber Seal (fitted to bottom slat)
17. Override Eye * (not supplied with external fit doors)
18. 6 No. M8 X 21mm Penny Washers *
19. 10 No. 4mm X 8mm Rivets * (for securing endlocks)
20. Crank Handle (removable 45° crank handle supplied with external fit doors)

• Supplied in Accessory Box

Recommended Fixings (not supplied) 12 x 1” Self Tapping Screws for Steel 12 x 2 1⁄2” Countersunk Screws for Masonry and Wood

Box, axle and guides will be packed together in box. The curtain and accessories are packed in a separate box a QR code that links to the fitting instructions and end user operating and maintenance guide.

INSTALLATION OPTIONS

PREPARE THE GUIDE RAILS

If the guides require cutting down refer to the ‘Widths and Heights’ information on page 2. If face fixing where possible set the guide height at least 50mm above the structural opening height to maximise drive-through height. If you need to reduce the length of the guide rails you must cut from the bottom of the guide rails.

1. Position guides
2. Drill a minimum of 4 guide fixing holes, with a 7mm pilot hole and 13mm outer hole. Position the first hole position 250mm from the top of the guide and the second hole 250mm from the bottom of the guide. Equally space out the remaining holes with a maximum gap of 500mm between each fixing. Avoid mortar joints and edges of bricks etc.

FIX GUIDE RAILS & AXLE ASSEMBLY

Note: Before positioning check that there are no sharp objects or bumps sticking out from the pillars, lintel or header to twist the guides or that will catch the door during operation. If in doubt pack the guides and end plates out by at least 10mm.

1. Slot end plate lugs into guides (see Drawing A) remembering the guides are handed.
   Note: Extreme care should be taken while manoeuvring the door into place to avoid the possibility of snapping the end plate lugs. It is imperative that fixings are put through the end plates into the wall as the aluminium lugs are not designed to carry the weight of the door.

2. Position guides and end plates against opening.

3. Hold or prop securely the assembly in position.

4. Drill fixing holes (min 4 in guides and 2 in each end plate).

5. Fix guides/end plates with minimum No. 12 x 21/2” countersunk screws (and plugs) to masonry/timber or 12 x 1” self tapping screws to steel.
   Note: If end plates are fitted within the reveal, the side of the end plates must be fitted to the structure with at least 2 fixing points. Ensure that fixing heads are clear of the curtain operation to prevent damage when the door is in use.

6. Fix fascia every metre with minimum 12 x 1” screws. Penny washers supplied must be used to spread fixing load on end plates and fascia.

7. Stick brush strip to inside edge of 90o fascia (optional see Drawing B).

8. Secure Motor Power Lead with Cable Clips so that it is tight against the end plate – see Drawing C. You must ensure that you allow for a drip loop in the motor cable to prevent water from running down the cable and into the motor. Spare cable ties can be attached to the motor cable to act as drip loop to prevent water entering the motor

FIT EMERGENCY OVERRIDES

The motor limits are accessible from two sides. This enables the motor to always be fitted to the end plate so that limits are facing down and so that the override is towards the front of the end plate

Possible Override Exit Options

Standard Manual Override

Standard manual override internal fitting (see Drawing A):

1. Drill hole for overriding eye through end plate flange.
2. Remove the screw and the upper collar.
3. Insert override eye in hole in motor adjacent to limit adjusters.
4. Locate and tighten the upper and lower collars around the motor.
5. Insert and tighten the holding screw and washer from above.
6. Hook crank handle in eye.
7. Secure clear of the shutter with crank handle clip

Optional Low-Level External Override

Note: It is recommended that the override exits as per diagram 2 above. More detailed installation instructions are supplied with the override kit. Fixings are not supplied.

1. Drill hole for overriding eye through end plate flange.
2. Insert hexagonal bar through hole in motor adjacent to limit adjusters (see Drawing B).
3. Mark the position for a hole through the wall adjacent to guide rail at the bottom end of the crank (see Drawing C). The crank can exit at 90° if door tight to return wall (see Drawing D). Length of shaft can be shortened to adjust the operating height.
4. Drill 22 mm hole through the wall (see Drawing C).
5. Secure the universal joint bracket to wall.
6. Insert tube (cut to length) and fix plate to the wall (see Drawing E).
   Externally Fitted Doors: The crank handle is not permanently attached and is only inserted as required

On a left-hand door the motor cable will exit the motor vertically down. On the right-hand door the motor cable will exit the motor vertically up. You must ensure that you include a drip loop to prevent water from entering the motor. This will ensure that you do not have to cut down the roller plate to enable the override eye to be fitted.

INSTALL THE CURTAIN IN THE GUIDES

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

1. Carefully unwrap and remove the outer bubble wrap protection and place it over the axle to stop damage to the inside of the curtain during installation.
2. Using a 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, keep that arm straight, and support the curtain roll on that shoulder (see Drawing A).
3. Feed the bottom lath over the top of the axle and down between the guide rails taking care not to scuff the curtain assembly. Proceed until half of the curtain has been fed over the axle.
4. Carefully unroll the remaining curtain until it is balanced over the axle (see Drawing B).
5. Slide the auto lock straps onto the top slat, ensuring they are\ equally spaced with more than 800mm between each one.
6. With 1 person positioned at the top of the door and one person positioned at the bottom, carefully feed the curtain into the guide until the curtain 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.
Note: The door is manufactured with the curtain height to suit the length of the guide supplied. The door will not lock down properly if the curtain is either too tall or too short. If the guide height has been adjusted on site, check that the top of the curtain is between 1/2 to 11/2 slats above the top of the guide (see Drawing C). If the curtain is too tall, remove slat(s) by following the steps below. If too short notify the supplier.

Curtain Adjustment (also used for repairs)

1. To remove slat(s), first remove the curtain from the guides by carefully raising the curtain until half of the curtain has been fed over the axle. Carefully balance the curtain on the axle.
2. Remove the attachment straps.
3. Carefully remove the staples from the end lock and remove the end lock (see Drawing D) before sliding out the slat (see Drawing E). Preferably remove slats from the top of the curtain to save having to remove and refit the bottom slat.
4. If replacing damaged slats as part of a repair, slide in the new slat(s).
5. Re-secure the endlock(s) with 2 No. 4mm x 8mm rivets supplied (see Drawing F).
6. Re-install the curtain by repeating the steps above.

ATTACH THE CURTAIN

1. Use the motor override or a test lead to rotate the axle until the rectangular locking strap attachment slots are positioned facing toward the top of the curtain.

2. Attach the locking strap hooks into the rectangular slots on the axle (see Drawings A & B).
   Note: Ensure the green locking strap dials are all in the UNLOCKED position (see Drawing C).

3. Turn the green locking strap dials to the LOCKED position (see Drawing D).

4. Use No.8 x 1/2” pozi pan screws supplied to securely fix the straps to the axle (see Drawing E).
   Note: It is recommended to drill 4mm pilot holes before fixing the screws. Take care not to damage the motor inside the axle.

5. Use the motor override or a test lead to raise the door slightly. Check that the attachment straps coil up flush with the axle.

SET-UP THE CONTROL UNIT (WHERE SUPPLIED)

Control unit set up instructions are provided in the control poanel accessory box along with the control unit.

SET THE MOTOR LIMITS

Both the up and down limits require setting.

Note: Incorrect setting of the limits risks damage to the motor, curtain and attachment devices. Important: When the door is fully closed, the autolock strap should be positioned with a slight bend which locks the collar out (see Drawings A, B & C).

Which limit is up and which limit is down?

The up and down limit is determined using the direction arrows next to the limit adjusters and the direction of axle rotation to either close or open the door.

Closed/Down Limit Setting

1. Carefully close the door using either a motor test lead or the control unit so that the curtain is fully down and the top slat is pushed forward.

2. Use the limit adjusting tool to adjust the down limit of the door until the motor stops in the correct position.

   • Turn the down limit in the ‘+’ direction to increase the travel of the door.
   • Turn the down limit in the ‘–’ direction to reduce the travel of the door.
     Open/Up Limit Setting

3. Carefully open the door using either a motor test lead or the control unit so that the curtain is fully open.

4. Use the limit adjusting tool to adjust the up limit of the door until the motor stops in the correct position.

   • Turn the up limit in the ‘+’ direction to increase the travel of the door.
   • Turn the up limit in the ‘–’ direction to reduce the travel of the door.

Note: Do not use a drill to adjust the limits.

Check 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 axle.
• 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.

COMMISSIONING

Final Checks

1. Remove any protective plastic coverings.
2. Wipe the curtain & guides with damp cloth.
3. Touch up any small scratches.
4. Check all electrical & operating equipment is installed and functioning correctly (especially the safety edge) and complete UKCA marking label and paperwork.
5. Check the direction handle needs winding to open door and fit the appropriate label supplied to the crank handle.

N.B. Check the front of the curtain to make sure that it is not rubbing on the lintel. The manual override will not function after the door is operated by remote control until the power to the motor has ‘timed out’. This will take a few moments to occur. If you wish to demonstrate the manual override immediately after opening the door press either the stop button on the handset or simulate a power cut by switching off the power to the Control Unit. Upon completion it is your responsibility to train the customer how to operate the door correctly and safely and provide them with the operating and maintenance instructions supplied.

• Tel: 01926 463 888
• www.garagedoorsonline.co.uk

References

• Garage Doors, Roller Shutter Garage Doors, Sectional, Hormann Up and Over Residential Garage Doors Online UK

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