Amarr 4200 Installation Instructions Manual
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Amarr 4200 Installation Instructions Manual

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4200 Fire Door
(Insulated and Non-
Insulated)
Installation Instructions
ECO# 1914
REVISION# 003
ES 10-474
DATE 10/15/2020

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  • Page 1 4200 Fire Door (Insulated and Non- Insulated) Installation Instructions ECO# 1914 REVISION# 003 ES 10-474 DATE 10/15/2020...

  • Page 2: Table Of Contents

    Section 1 – Safety Check List Section 2 – Safety Check List Section 3 – Freight Receiving Section 4 – Pre-installation Section 5 – Guides Face-Of-Wall Between Jambs (Four Angle Guides) Between Jambs (Two Angle Guide With Tube) Section 6 – Barrel and Brackets Preparation Ring Attachment Hoisting and Installing Barrel Assembly...

  • Page 3: Section 2 - Safety Check List

    Section 1 – Safety Check List Rolling doors are large, movable objects. They move with the help of electric motors or manual operators (chain, crank, push up, etc), and most have springs under high tension. These items and their components can cause injury.

  • Page 4: Section 3 - Freight Receiving

    Section 2 – Freight Receiving Upon delivery, check condition of components for damage.  If damage occurred in transit, the installation should not proceed without authorization.  If the installation proceeds, neither the carrier nor the manufacturer will assume responsibility for replacing the damaged material.

  • Page 5: Section 4 - Pre-Installation

    Section 3 – Pre-installation Read entire instruction manual thoroughly. The manufacturer will not be held responsible for  any charges incurred due to improperly installed components. a. Only trained door systems technicians should perform installation, maintenance, etc. b. Each unit comes with an individual item number. If the job contains multiple units, be sure to locate all the components for each item and separate each.

  • Page 6: Section 5 - Guides

    Section 5 – Guides Face of Wall Units (Figures 4.1 - 4.2):  Note: Determine which guide assemblies the unit has from the job construction drawings and compare to the diagrams below. Figure 5.1 - Face of Wall “Z” Guide OVERALL GUIDE DIMENSION PLUS GUIDE SETBACK HEEL OF TOE OF...
  • Page 7 Section 5 – Guides Figure 5.3 – Face of Wall “E” Guide OVERALL GUIDE DIMENSION PLUS GUIDE SETBACK HEEL OF TOE OF ANGLE ANGLE WALL FASTENER SETBACK WALL ANGLE ASSEMBLY GUIDE FASTENER PACKOFF INNER ANGLE OUTER ANGLE DISTANCE BETWEEN GUIDES GUIDE BRACKET PLATE Figure 5.4 –...
  • Page 8 Section 5 – Guides Figure 5.5 – Face of Wall “Z” Guide (with Formed Stainless Steel Angles & Brush Seal - Fire Door) OVERALL GUIDE DIMENSION PLUS GUIDE SETBACK ONE STEEL WASHER ON EACH SIDE OF DISTANCE FIBER WASHER WALL FASTENER BETWEEN GUIDES WALL ANGLE...

  • Page 9: Between Jambs (Four Angle Guides)

    Section 5 – Guides 6. Place the guide or wall angle against the scribed line, check the top of the guide for level, and mark the location of the wall fastener mounting holes. Note: For fire doors, mark the holes at the top of the wall fastener slot to allow for upward expansion of the guides.
  • Page 10 Section 5 – Guides Figure 5.7 – Between Jambs Four-Angle Guide with Windlock Flat (Shown with fascia mounting channel provided for mounting fascia.) OVERALL GUIDE DIMENSION FASCIA MOUNTING CHANNEL INTERMEDIATE ANGLE ASSEMBLY FASTENER WINDLOCK GUIDE INNER ANGLE FLAT PACKOFF WALL FASTENER DISTANCE BETWEEN GUIDE...
  • Page 11 Section 5 – Guides will be located. Mark the floor at this location and scribe a plumb line up the jambs. 7. Stand the guide/wall angle up to the wall, holding the bottom of the guide on the mark while making the guide plumb.

  • Page 12: Between Jambs (Two Angle Guide With Tube)

    Section 5 – Guides Between Jambs (Two-Angle Guide with Tube) (Figure 5.9):  Note: Determine which guide assemblies the unit has from the job construction drawings and compare to the diagrams below. Figure 5.9 – Between Jambs Two-Angle Guide Mounting to Tubes OVERALL GUIDE DIMENSION INNER ANGLE OUTER ANGLE...
  • Page 13 Section 5 – Guides 6. Locate the Saddles (brackets used to constrain the tube at the bottom). There are two types of saddles: standard saddles and inverted saddles. Both utilize the same steps for installation. The difference is the mounting flange. Fire doors come with inverted saddles for mounting at the bottom of the tube.
  • Page 14 Section 5 – Guides c. Calculate the Tube Length: Tube Length = “Floor to Slip Joint Mounting Member” – “Expansion Allowance” d. Cut the tubes to the calculated “Tube Length”. Make sure you cut the excess tubing from the top. Otherwise you will cut off necessary mounting holes and/or notches. Note: If regular saddles are provided, the tube length will have to be adjusted because the tube will not sit on the saddle flanges instead of the floor.
  • Page 15 Section 5 – Guides Figure 5.13 – Slip Joint - Floor to Wall with Plate Mounting Assembly FIRE RATED WALL (BY OTHERS) FASTENERS AT WALL 1/8"/ft. OF HEIGHT FOR EXPANSION 5 MIN. EMBEDMENT FLOOR TO SLIP JOINT MOUNTING TUBE LENGTH MEMBER (CUT TO LENGTH IN FIELD AS REQ'D)
  • Page 16 Section 5 – Guides Figure 5.14 – Slip Joint - Floor to Wall with Angle Mounting Assembly FIRE RATED WALL (BY OTHERS) REF. FASTENERS AT WALL (SEE SHOP SHEET) 1/8"/ft. OF HEIGHT FOR EXPANSION 5 MIN. EMBEDMENT FLOOR TO SLIP JOINT MOUNTING TUBE LENGTH MEMBER...

  • Page 17: Section 6 - Barrel And Brackets

    Section 6 – Barrel and Brackets Note: Check to see if a hood support will be required. If so, refer to the “Hood Support Installation” section before proceeding to the barrel and brackets. 1. Refer to the job construction drawings to determine the “coil side” of the opening, or the side of the opening on which the coil is to be installed.
  • Page 18 Section 6 – Barrel and Brackets 6. Refer to the job information provided with the door to determine the correct ring type and quantity. If the unit does not require rings, skip to Step 9. Many larger diameter (8”, 10”, 12”, etc.) barrel assemblies do not require rings for curtain attachment.

  • Page 19: Ring Attachment

    Section 6 – Barrel and Brackets UPWARD WRAP LOCATE THE NUB, ON THE DIRECTION INNER PART OF THE RING, IN THE 7/16" DIAMETER HOLE PROVIDED IN THE BARREL 3/8 SQ 3/8 X 1 1/4 HEX HEAD SP0251 Installation: • Use a small pry bar or large standard screwdriver to spread the gap in the ring by prying between bolt flange and the nut cradle of the casting (see above).

  • Page 20: Hoisting And Installing Barrel Assembly

    Section 6 – Barrel and Brackets Figure 6.4 – Brackets and Barrel prior to installation (no spring release fire door brackets shown) COTTER PIN ADJUSTOR PIN ADJUSTOR BRACKET BEARING GEAR END RING OPERATOR BRACKET ADJUSTOR BRACKET HOOD CLIP ANGLE Hoisting and Installing Barrel Assembly ...
  • Page 21 Section 6 – Barrel and Brackets Figure 6.5 – Bracket Mounting Configurations and Hardware 1/2" NUT AND 1/2" NUT AND WASHER WASHER 1/2-13 FLAT HEAD SOCKET SCREW 1/2-13 ROUND HEAD SQUARE NECK BOLT BETWEEN JAMBS WITH FACE OF WALL OR BETWEEN TUBE - FIRE DOOR JAMBS FOUR ANGLE GUIDE 7.
  • Page 22 Section 6 – Barrel and Brackets Figure 6.6 - Sprocket Alignment for Conventional Fire Door Operators (Push-Up Units shown on left; Motor, Crank, & Chain Operated Units shown on right) COMBINATION SPROCKET COMBINATION SPROCKET ALIGN ALIGN SPROCKET SPROCKET ALIGN SPROCKET GEAR / SPROCKET ASSEMBLY ECO# 1914...

  • Page 23: Section 7 - Motor Operator Installation

    Section 7 – Motor Operator Installation Motor Operator Installation:  1. Unpack the motor operator from the shipping box and retrieve the Operator Mounting Bracket and bolts provided in the kit. 2. There are several motor mounting configurations that can be formed with the supplied components.

  • Page 24: Section 8 - Curtain Installation

    Section 8 – Curtain Installation Curtain Installation  1. Remove the stoppers from the guides, or position them so they do not protrude into the opening. 2. Open the curtain packaging. Leave the plastic straps that keep the curtain from uncoiling in place. It may also be beneficial to leave some of the packaging under the curtain to protect the finish during installation.
  • Page 25 Section 8 – Curtain Installation 11. Feed the bottom bar into the guides and lower the curtain until the bottom bar is below the stopper location. Figure 8.2 - Installing the Curtain 12. Since there is no spring tension holding the curtain open, the curtain may fall if released.

  • Page 26: Section 9 - Spring Release Setup

    Section 9 – Spring Release Set-up Applying Spring Turns:  1. Refer to the job information or markings on the shaft for the number of spring turns required on the unit. 2. To apply spring charge, remove cotter and stop pin from adjusting wheel. Lower the Dropout Pawl for Conventional spring release units.

  • Page 27: Fusible Link Assembly - Conventional Fire Door

    Section 9 – Spring Release Set-up 9. Holding the rod(s) firmly, disconnect the dropout assembly and lower until it clears stop pin on the adjustor wheel. Note: Units without spring release do not require a dropout assembly. 10. Remove cotter pin and stop pin from adjustor wheel and begin to increase or decrease tension. •...
  • Page 28 Section 9 – Spring Release Set-up Figure 9.2. Fusible Link Installation for Conventional Fire Doors 12" MIN. 12" MIN. ECO# 1914 REVISION# 003 ES 10-474 DATE 10/15/2020...

  • Page 29: Fusible Link Assembly - No Spring Release Fire Door

    Section 9 – Spring Release Set-up Figure 9.3. Fusible Link Installation for no spring release Fire Doors ECO# 1914 REVISION# 003 ES 10-474 DATE 10/15/2020...

  • Page 30: Fusible Link Assembly - Through Wall Conduit

    Section 9 – Spring Release Set-up Installing Through Wall Conduit for Fusible Links  Note: Read these instructions carefully before installing through wall conduit. Refer to Figure 9.4. 1. When a through wall fusible link is specified the hardware package will be supplied with a length of 1/2”...

  • Page 31: Z" Shaped Seal

    Section 10 – Lintel Seal ”Z” Shaped Seal  Figure 10.1 - “Z” Shaped Lintel Seal Cutout Note: The Lintel Seal should be installed before the hood and fascia, and after all other door components are installed and operational. 11. Clean and inspect the top of the opening where the Lintel Seal will be installed.
  • Page 32 Section 10 – Lintel Seal 17. Replace the lintel seal in the opening and insert the fasteners. Make any adjustments the Lintel Seal and properly orient the multi-piece lintel seal (if present) and tighten the fasteners. 18. Operate the door and ensure that the lintel seal sustains sufficient contact with the curtain (The curtain should always touch the Lintel Seal and not hit the extrusion) ECO# 1914 REVISION# 003...

  • Page 33: L" Shaped Seal

    Section 10 – Lintel Seal ”L” Shaped Seal  Note: The Lintel Seal should be installed before the hood and fascia, and after all other door components are installed and operational. 1. Clean and inspect the top of the opening where the Lintel Seal will be installed. See shop drawings for details.

  • Page 34: Section 11 - Drop Test

    Section 11 – Drop Test Drop Testing Conventional Fire Doors  Note: Perform door and electrical operator maintenance. It is important to make sure that the door operates properly in the normal mode of operation before testing the automatic closing mechanisms.

  • Page 35: Section 12 - Hood Support Installation

    Section 12 – Hood Support Installation Hood Support Installation  1. Refer to the job information to determine the type and quantity of hood supports required for your door. Hood supports will be noted on the elevation view of the job construction drawings. See Figure 12.1 for hood support types.
  • Page 36 Section 12 – Hood Support Installation 2. Determine where the support(s) will be located between the guides. a. If multiple supports are required, see the job construction drawings to determine the centerline of each. b. If a single support is required, it will be located at the center of the unit. 3.

  • Page 37: Section 13 - Hood, Fascia, And Covers

    Section 13 – Hood, Fascia, and Covers Hood and Fascia Installation  1. Determine what type of hood is provided. See Figure 13.1 for possible hood configurations. This can be done by: Looking at the brackets and identifying a half-circle shaped flat (D-shaped hood) or ...

  • Page 38: Covers

    Section 13 – Hood, Fascia, and Covers both brackets. Pre-drill with a #21 or 5/32” drill in at least one place on every face of the hood, at both the left and right sides. See Figure 13.3 for recommended fastener locations. 4.
  • Page 39 Section 13 – Hood, Fascia, and Covers Figure 13.3 – Recommended Fastener Locations 7. If the door is mounted in a weathered or exterior location, caulk the part of the hood that contacts the wall. Cover installation  1. Once the unit is installed and operating correctly, the covers can be installed. 2.
  • Page 40 Section 13 – Hood, Fascia, and Covers Note: Mechanism covers differ from operator and adjustor covers in that operator and adjustor covers provide a complete enclosure. 4. If an operator or adjustor cover is provided, individual installation instructions are provided with each cover along with the necessary hardware to attach the cover.

  • Page 41: Section 14 - Torque Specifications

    Section 14 – Torque Specifications Table 14.1 – Torque Recommendations for Guide Assembly and Wall Fasteners Bolt size/type Torque (ft-lbs) 1/4-20 Grade 2 steel bolt 5/16-18 Black Oxide Socket Cap 3/8-16 18-8 stainless steel bolt 3/8-16 Grade 2 steel bolt 3/8-16 Grade 5 steel bolt 1/2-13 Grade 5 steel bolt 1/2-13 Grade 8 steel bolt...

  • Page 42: Section 15 - Maintenance Schedule

    Section 15 – Maintenance Schedule Maintenance Schedule  Note: If any of the following problems exist, do not operate the door until repaired. What to look for and how often the Component Weekly Monthly Quarterly What to do if problem exists: components must be inspected: Are any curtain components Contact Service about...
  • Page 43 Section 15 – Maintenance Schedule Remove hood/fascia. Repair if possible. If not leave Is hood/fascia dented or damaged? hood/fascia off and contact Service. Is curtain rubbing against the Hood/fascia may have been hood/fascia? damaged. Contact Service. Check fasteners, they may be Hood and Is hood/fascia level? loose or missing.

  • Page 44: Operator Troubleshooting

    Section 15 – Maintenance Schedule Operator Troubleshooting  Note: If you suspect you are having an issue with your operator, use the following table to determine the potential causes. If the provided solution does not eliminate the issue, or the table does not address your particular problem, contact the Service Department.

  • Page 45: Appendix A - Chain Sprocket Adjuster

    Appendix A – Chain Sprocket Adjuster Chain Sprocket Adjustor  1. Loosen the shaft collar set screws. Remove the shaft collar and support strap from the adjusting wheel stud. 2. Place the bracket plate onto the inner shaft. 3. After the shaft sprocket is on the inner shaft, remove the 3/4”-10 x 1-1/2" bolts. 4.
  • Page 46 Appendix A – Chain Sprocket Adjuster 4. Use a 1-1/8" high x 3/8" thick x 40" long ASTM A36 minimum bar to apply spring torque. See the job construction drawing (elevation view) for the number of initial spring turns to apply to the small adjusting wheel and the direction of rotation.

  • Page 47: Appendix B - Sealant Application For Nfpa 105 / Ul 1784 Compliance

    Appendix B – Sealant Application for NFPA 105 / UL 1784 Compliance Sealant application for NFPA 105 / UL 1784 compliance  Note: Read this sheet before installing unit. • Assembly must be properly sealed with caulking and brush gasketing must be installed for unit to function in accordance with the performance criteria of NFPA 105.

  • Page 48: Appendix C - Leakage Rating Information

    Appendix D – Field Connection Detail for FGH / FIREGARD MC Leakage Rating Information  Note: The following information was taken from: http://www.ul.com/global/eng/pages/ under “Certifications”. Leakage rated assemblies — Rolling Steel Fire Doors file R1422. • The assembly consists of integral guides, anchors, a curtain, barrel assembly, automatic •...

  • Page 49: Appendix D - Field Connection Detail For Fgh / Firegard Mc

    Appendix D – Field Connection Detail for FGH / FIREGARD MC Field wiring detail for interconnection between FGH operators and FIREGARD MC Release  Device Note: See Figure 19.1 for field interconnection between the release device and the FGH operator when both are provided for a door. Figure 19.1 –...

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