Assembly, Installation and Operating Instructions for: CSA...

Copyright: Cool-Air, Inc. May 2010, Revision draft

of 39 www.manualhangardoors.com CSA-2.5-FT CSR EXT.pub

Assembly, Installation and Operating Instructions for:

CSA-2.5-FT CSR EXT — Fold-Tite Stacker Door System

This door is built for:

Copyright: Cool-Air, Inc. May 2010, Revision draft


Our doors are easy to operate. However, the instructions must be followed to insure correct as-

sembly and installation. It is imperative that the dimensions, squareness, and levels are adhered

to, to insure that the door is hung properly and operates freely. Not all structures are square and

not all structures have even dimensions from top to bottom and side to side, so allowances will have

to be made to install the door properly. We have carefully highlighted those areas in the instruc-

tions, where the assembly and installation are critical to the operation of the door. Should you

have any questions during the assembly and installation process, we are here to help you through

the project to insure good operation of the door. DO NOT HESITATE to call us. At times we may

be not be reachable at the moment but we will get back to you. Thank you for buying our door.

Contact Info:

Dave Coolman: 518-852-3767

Phillip Coolman: 518-480-5009

email:

[email protected]

[email protected]

Assembly, Installation and Operating Instructions for:

CSA-2.5-FT CSR EXT — Fold-Tite Stacker Door System 2.5 inches Thick — Utilizing Concealed Stay Rollers — Externally Hung

mailto:[email protected]

mailto:[email protected]

Assembly, Installation and Operating Instructions for: CSA-2.5-FT Fold-Tite Stacker Door System

Externally Hung — with Concealed Stay rollers

Copyright: Cool-Air, Inc. 2010 September 2010, Revision 0


Table of Contents

0.1 Table of contents

0.2 Beginning Notes

1.0 Un-crating

2.0 Inspection of box and materials

3.0 Track Installation

3.1 Installation of Track

3.2 Installation of Track Cover Brackets

4.0 Assembly of panels

4.1 Panel Assembly Introduction

4.2 Brace and Lock Panel (Outboard Panels)

4.3 Hinging the Panel sets together

4.4 Panel Assembly Sequence Summary

4.5 Installing the side Hinges

4.6 Installing the trolley & Lock Pins

4.7 Diagram & P/N Identification of Outboard Brace Panel Set

4.8 Assembly of Standard or Excess Panel Set

4.9 Diagram & P/N Identification of Excess Panel Set

4.10 Assembly of Center Offset Panel

4.11 Diagram & P/N Identification of Center Offset Panel Set

5.0 Hanging Panel Sets

6.0 Hinging Panel Sets after hanging the panels.

7.0 Hinge the door to the building Columns (and top view of Hinge placement on column)

7.1 Top view of Column Hinge Placement

8.0 Installation of Concealed Stay Rollers

9.0 Installation of Cable Keeper

10.0 Installation of the exterior Sheeting Operation

11.0 Lock Installation

12.0 Installation of Seals

13.0 Operation of the Door

14.0 Maintenance

15.0 Listing and identification of Part Numbers

16.0 Tools Necessary for the Assembly and Installation

17.0 Print for rain cover

18.0 Overview of door (Fold Out)

19.0 Overview of hinge and doubler placement (Fold Out)

20.0 Print for your specific Door

21.0 Master Structural List for your specific Door

3

4

5

5

5-6

5-6

6

7-18

7

8-14

10

11

12

13

14

15-16

16

17-18

18

19

19-20

20-22

21

23

24

24

25-26

27

28

29

30-33

34

35

36

37

38

39

Page





Beginning Notes:

1. Please take an inventory of all materials received as soon as possible. We strive to be as accurate as

possible, but sometimes there are mistakes. We will insure that any discrepancies will be taken care

of as soon as possible. However, shortages must be reported within 60 days of receipt.

2. This instruction set is general in nature. Please review your print (included in this instruction set)

for exact measurements and number of girts etc. for your specific door.

3. We have taken care to highlight some important text in this instruction set. It is very important

that these highlighted texts be followed to insure that the door operates properly. As an example, it

is very important that the door be level and it is very important that the panels be square and that

there is no bowing in the verticals.

4. Before you start the assembly of the door, it would be very helpful that you read through the in-

struction set and to review the foldout sheets entitled ―Overview of Fold-Tite assembly‖ and

―Overview of Hinge Placement‖. These two foldouts will give you a perspective of how the door is as-

sembled and the placement of key components.

5. You will be utilizing a variable speed drill to insert many TEK screws. It may take a few seconds be-

fore the screw begins to penetrate the steel girt or the steel hinge reinforcement, once the screw

does begin to burrow into the steel, you should be prepared to back off on the torque of the drive

and stop the drill as soon as the screw completes its penetration. Otherwise, you may strip the

screw.

6. Although the text indicates this, it would be helpful to layout the components in front of the door in

panel sets to visualize the placement of the girts and active components (lock pins and Trolleys).

This can be done in combination with reviewing the foldout overview drawings.

7. The panels should be assembled with the front of the panel (front of the door) facing up. When you

do this, observe that the seam of the girt is up or toward the front of the door and the ―J‖ trim of

the verticals is up or facing toward the front of the door.

8. As you hinge the panel sets do NOT rotate the panel from side to side rather turn each panel over

top to bottom. Otherwise the hinge relationship will be changed.

9. We enjoy receiving feedback from our customers, whether good or bad. Please let us know what you

think of this instruction set or the door itself. Should you have a chance we encourage you to send

us photos (hardcopy or electronic). These would be greatly appreciated

10. Should you have any issues or questions during your project, please DO NOT hesitate to call us. We

want your project to be as trouble free as possible. It would be to our mutual benefit if we are able

to address your problems head on and as soon as possible. Our best form of marketing is word of

mouth, and therefore we want you to be successful.

Dave Coolman—President and Phil Coolman—Partner

Cool-Air, Inc.





1.0 Inspect the packaging for damage. Before opening, document (Photos) any signs of damage on the outside which may

result in damage on the inside. Should you find damage to the material on the inside, please contact the shipping carrier.

2.0 Open all structural component and hardware boxes and compare with the itemized packing list. Note: structural com-

ponents and hardware may arrive in separate shipments.

3.0 Installation of the Box Track

3.1 Track Installation — Install box track, with top of track bracket (#714721) located 4.5‖ above bottom of header. It

is very important that the track be level. You can accomplish this by using a chalk line snapped in place utilizing a level. Insure

that the distance from the bottom of the track bracket to the finished floor equals your called clear operating height on your

print from left to right to insure proper hang. The finished floor may not be level. Make adjustments with the track as nec-

essary, up or down, to insure this distance will allow door to hang properly over the entire width of the door. The average

variation should equal the stated print for the opening height. The track brackets are installed 24‖ on center except at eac h

end over the area where the door is stacked when open, where they are mounted 6‖OC. Splice brackets (#714944) will be

used at each joint of the track. Checking the height along opening

Making sure the track is level





Rain Cover Support Bracket #713573

Track Bracket

#714721

6‖ rubber top seal

Rain Cover Support Bracket

Rain cover

(supplied

By others) 6‖

24‖ 6‖

Base of building header

And

called clear oepning

height from this point to

finished surface

4‖

Box track

3.75‖

4.5‖

3.1(Cont) The door has been designed with the track extending at least 4‖ past the opening on each side. The 6‖ rubber top

seal is supplied. This should be installed by placing between the track and the header. Allow 1-1//2‖ of this seal to hang below

the header. Use nails (not supplied) to hold the seal in place. Use Lag bolts #177901 3/8 X 2 1/2‖ to install brackets.

3.2 Installation of the rain cover support brackets — The rain cover support brackets can be installed at the same time as

the track. The Track cover support bracket is supplied and should be placed over the track brackets (24‖ OC). Rain cover will

be installed after the door is installed. The rain cover is not supplied by Cool-Air, Inc. (you will want to match the color of

your door and building on site) A print for the rain cover is located towards the end of this instruction set in section 17.0.

Track brackets (#714721) Rain Cover Support

Bracket and installed using Lag Bolts (#177901

3/8 x 2 1/2‖ supplied). Splice brackets

(#714944) will be used to connect the joints of

the track. Track Cover is installed using smaller

lags.

Each end of the completed track is plugged with

track plug (#714366)

These instructions are intended for a wood

building, for a steel building, see structural

list for correct lag bolt part numbers.

Track Bracket #714721





4.0 Door Panel Assembly Introduction — Panels are assembled individually, then hinged in sets of two. The panels

will be hung as sets. After hanging, the sets are hinged together from the front. The door is then hinged to the side columns.

The standard panel width is 40.25‖, The panels that meet between the two door halves will be wider than the standard panels

by 4‖. This is to allow the trolleys to be inset. By insetting the trolleys, the door will fully close. These two panels a re each

paired with a standard size panel. There also may be an excess panel width on two or four of the panels to adjust the final

width of the total door to meet your specifications for opening width. The print for your door is included in this instruction

set to inform you of the actual dimension of your door to include the panel widths.

As you assemble the panels, it is very important that the panels are square. This will be mentioned several times in this in-

struction set. We have two suggestions on how to insure that the panels are square. The first is to build a jig that utilizes

either metal or wood sides and is the width of the standard panel which is 40.25‖. This way each panel can be easily squared

and bows in the vertical are eliminated. You can adjust this jig for any excess panel widths which may be called out in your

print. Alternatively, after installing the TEK screws in each of the four corners, you can measure from the left upper corner

to the right lower corner and compare this measurement with the same measurement from the right upper corner to the left

lower corner. These two measurements should be identical, which will insure that the panel is square. If they are not the

same, the panel should be adjusted to make the two dimensions equal. At the same time, you should eyeball the verticals to

determine if any bowing is occurring. Any apparent bowing should be eliminated. This will be done by adjusting the fit of the

steel girts in the verticals.

4.1 Panel Overview — Please review fold-out sheets entitled “Overview — Fold-Tite Assembly” and “Overview —

Hinge Installation”. These overviews will give you a perspective of each type of panel, on which verticals the hinges are in-

stalled, whether on the back or on the front of the door. These overviews will also indicate which verticals receive a hinge

doubler. The hinge doubler is installed to provide strength in the vertical where the TEK screws do not screw into the steel

girt but rather screw into the doubler. Screw through the front of the vertical and then into the steel doubler. This over-

view also provides a view of the locations of the trolley and lock pins. It should be noted that other than the excess panels

and the very center verticals, the right side of the door is a mirror image of the left side of the door. Therefore, the trol-

leys and lock pins are located on opposite sides of the corresponding panels. We have included a full page drawing with associ-

ated part numbers of each type of panel set.

4.2 Panel Assembly — We recommend that you physically lay out all of the major components associated with each

panel set in front of the opening of the door. This will help you visualize the panel and how it is hung from the track. We term

the far left and right panels as the Outboard Brace Panel, which is standard width. For this door configuration the Outboard

Brace Panel will have both top and bottom locks. We term the panel which will house the trolley and the lock and latch mecha-

nisms as the active panels. The panel which is neither is an inactive panel. The panels will be assembled separately. Then the

panels will be hinged in sets of two. Then the panels will be hung as sets before hinging the panels sets together with front

facing hinges. The top rail (steel girts) is pre drilled for the trolley and lock pins. We suggest that the panels be assembled in

pairs in the order provided in the instruction set. They should be folded and set aside while you complete each set. Assemble

the panels face up with the ―J‖ trim of the vertical facing up and the seam of the steel girt facing up. This will represent the

front of the door. The exterior sheeting will be installed

in the ―J‖ trim of the vertical.

Bottom Rails

bottom of door

Verticals

Steel girts

top of door





4.3 Outboard Brace Panel Set — Assemble the panels in sets of one active panel and one non-active panel. Assemble the

panels starting with the panel which will attach (hinge) to the column with one outboard brace panel and then an active panel. As-

sembly and part numbers used are shown on page 14. As previously stated, it is important that each horizontal girt is firmly fitted

into the vertical. It is necessary that the panels are square. The SEAM of the steel girt faces the front of the door. Measure

and mark each vertical for the girt spacing listed in YOUR print. This spacing is

from the top of the door to the top of the next girt, use the same dimension to

mark the top of each girt. Please observe that on the active panels the top girts

are pre-drilled for insertion of the lock mechanism and trolley. The RIGHT side of

the door will be the MIRROR image of the LEFT side of the door.

Starting at the top of the out-

board panel, insert the top girt into

the side of each of the two verti-

cals and screw in one 12-14 X 3/4

TEK screw (close to the top, one on

each side– 1st TEK). There is a loca-

tor line on the vertical for place-

ment of the screw. This will locate

the screw in a position that will allow

the sheeting to fit into the vertical ―J‖ trim. Measure the vertical, as indicated to

the left, for placement of subsequent girts. Insert the girts. Insure that the girts

are fitted flush to the vertical. A diagonal brace girt is installed in each bay of the

Outboard Brace panel. These brace girts are sized to fit without cutting and the

supplied butt end of the girt will be stronger than having the end cut at an angle.

One diagonal girt will have to be cut at site. This girt is noted on the diagram page

14. The panel must be square for these to fit properly. 2nd TEK screw inserted

after panel is square.

See your

specific print

for actual

girt spacing.

SEAM of Girt

Gir t SpacingMea sur eand MarkTop to B ottom

Gir t Spacingto top

of eachGir t

First TEK Screw, place along locator line of vertical

View is of the

Top of Panel

and front of

the door.

Insertion of hinge

doubler into a vertical

Fitting the steel girts into the verticals

Top of panel

1st TEK

2nd TEK







Aluminum bottom rail

After installing the horizontal and diagonal girts, install the aluminum bottom rail.

Using one TEK screw in each corner, secure the bottom rail. Then square the panel be-

fore screwing in remainder TEK screws.

Grooves in bottom rail are for the vinyl seal (supplied) or brush seals (optional).

40" St andard

1 .5"

Top views of pre-drilled Steel Girt

# 500891

4.50 in

0.75 in

0.75 inØ0.53 inØ0.53 in

During the process of assembling the

front of each panel, should a gap be-

tween the vertical and girt be noticed

(or bowing of the vertical), remove the

TEK screw, position the girt fully into

the vertical and reposition the TEK

screw at a new location.

View is the Front of

Panel (Front of the

door)

Hole for Trolley Hole for lock





4.2 (Continued) After fitting the horizontal and diagonal

girts, tightly insert the bottom rail to the bottom of the

panel. Insert one TEK screw at each corner using the

locator line on the vertical as a guide.

After insuring that

1. The panel is square

2. The girts fit firmly in the verticals

3. The verticals are not bowed

Insert a second TEK screw near the bottom of each hori-

zontal girt and a second screw beside the first screw in

the bottom rail. After you have completed installing TEK

screws in the horizontal components, install TEK screws

in the diagonal brace girts (two places in each vertical).

Repeat this entire process for the active panel to be

paired with the Outboard Brace Panel. Observe the location of the pre-drilled holes in the top girt. There are no diagonal

braces in the rest of the panels.

4.3 Hinging the Outboard Panel Set

The first hinges to install are on the rear of the Outboard Brace Panel Set. The hinge is attached at each location with four (4)

1/4x20 Lock Head TEK screw (#500803). Use a temporary 1/16‖ spacer between the verticals when installing the hinges to in-

sure proper movement of the panels. You should Pre Drill the rear hinge hole locations with a 1/8‖ bit. Not all joints are hinged

together. On larger doors, the door will operate in 2 or more sections going each way. At joints that are not hinge, an astragal

will be supplied to close off any gap. ONLY attach Hinges to the rear of the two panels and the side hinges to the outboard

brace panel at this time. The Front Hinges will be attached after all panels are hung.

This photo demonstrates the utilization of measuring from corner to

opposite corner and matching the dimension with the opposite cor-

ners to insure that the panel is square.

Bottom of Panel

Temporary Spacer Top of panels

Pre Drill 1/8‖

Bit rear

Hinge only

Standard verticals

Girt

View is of the rear of

the panel







Temporary Spacer

4.4 Sequence of Panel Set Assembly

1. Lay out panel components in front of door.

2. Insert steel doublers where indicated in overview.

3. ―J‖ Trim of Aluminum Vertical is up (toward front of panel or

front of door).

4. SEAM of Steel Girt is up (toward front of panel).

5. Measure and mark girt locations on verticals.

6. Start at top and insert top girt into place and secure with one

(1) TEK Screw in each corner.

7. Place remainder of girt components in place as pictured on

page 14.

8. Fit the Aluminum Bottom rail in place between the two verti

cal.

9. Screw in one TEK screw in the bottom corner securing the

bottom rail then insert TEK screw in the opposite corner.

10. SQUARE the panel using one of the methods provided.

11. Insure that the girts fit tightly and that the verticals aren’t

bowed.

12. Insert a second TEK screw near bottom of each girt and a

second screw beside the first screw in the bottom rail.

13. TEK Screw the horizontal girts.

14. After the horizontal girts are secured, TEK screw the diago-

nal brace girts, two places each vertical.





4.5 Installing Side Hinges — Attach the Outboard Brace Panel side hinges to the side of the Outboard Brace Panel

with 1/4-20 Lock Head TEK screws (# 500803) locating one hinge at each girt. Use a flat surface to facilitate proper attach-

ment.

4.6 Installing the trolley and the lock pins — Install the Lock Brackets #500887 for the top lock pins and support

plate for the trolley. Use standard #500815 TEK screws. Install the trolley and the lock pins. The outboard brace panel will

have a top and bottom lock installed also and the hole in the top girt will be pre-drilled for the lock pins. The other top girts are

pre-drilled for the trolleys and lock pins. When installing the trolleys, should the assembly TEK screws cause interference, take

the TEK screw out and reinstall in an area that does not cause the interference. Measure, Cut Connect the cable between the

top and lower girt. Secure the cable at the lower girt with a TEK screw. Holes in top steel girt may have to be reamed for top

lock (The pin movement must be smooth and easy). The hole for the bottom lock will be site drilled in the aluminum bottom rail—

bracket to be flush on bottom.

Flat Surface

Special vertical with

weather strip channel

on rear flange

Weather strip channel

(Vinyl Weather strip supplied)

Hinge doubler required

Girt

Seam of girt

―J‖ Trim (External sheet-

ing to be inserted here) 1/4-20 Lock Head

TEK screws

#500803

Trolley Double axle

trolley

#714938

Doubler support

bracket

#500890

Thrust Washer #173101

Nut

Jam Nut

TEK screws

#500815





Top Lock Pin

Bottom Lock Pin (For Outboard Brace Panels only)

Floor Mounted Strike

#500866 2 pieces each lock

Floor Mounted

Strike #500866

TOP VIEW

Two pieces each

lock

Mount with Tap Con

Screws Recommend

Construction Adhe-

sive underneath be-

fore attaching

screws.

Bracket #500887 Front View

Bracket #500887 Rear View

Shaft Collar

#500812

Bracket #500887

Rear View Shaft Collar #500812

4‖ Spring #500879

1/2‖ X 12‖ pin #500884

4‖ Spring #500879







Cu t this b rac e to

fi t a t s i te

Pre– drilled Girt #500891

4.7 Outboard panel set for the Concealed Stay Roller (CSR) system. Both panels are

3’4‖(unless specified differently on your print). View of this panel set is from the inside of the

hangar looking out. This panel set will be hung on the left side of the hangar (left as you are fac-

ing the hangar door from the inside).

Outboard

Brace Panel

Girt #500891 Standard Active

Panel

Finished Floor Floor Mounted Strike #500866 Mount with Tap Con #500876

Aluminum Bottom Rail

#791098

Trolley # 714938

(See page 12 for

parts and place-

ment)

Girt #791096 Girt #791096

Girt #791096 Girt #791096

Diagonal Brace Girt

(See structural

Parts List)


#791098

Bottom Lock (see page

18 for Placement and

part numbers)

Top Lock (see page 13

for placement and part

numbers) Diagonal Brace

Girt

(See structural

Parts List)

Outboard

Vertical

For Out-

board panel

#200

(2 per door)

Cut to

length for

your door

Standard

Vertical will be

used for remaining

verticals

#200 CA

All verticals are

cut to length for

your door.

Lock (see page 25)

Rear Hinge # 792864

36‖ steel doublers should

be inserted in the Out-

board Verticals which

hinge to the column and

the standard verticals

where the hinges are in-

stalled on the front. On

some panels you will be

required to install a small

doubler to insure that the

TEK screws are not just

penetrating the vertical

but also a steel doubler.

Rear Hinges #792864 2.5‖x 2.5‖

installed using 1/4X20 Lock

Head TEK Screw

Side Hinges

#792864 in-

stalled using

1/4-20 Lock

Head TEK

Screw #

Rear Hinge # 792864

Recommend construction

adhesive to secure floor

mount strike (not sup-

plied)





4.8 Assembly of the Standard or Excess Panel Set — In order to meet the full dimension of the closed

door, there may be two or four panels which are excess in width (different width than the standard). Please see

your print to determine if you have excess panel set (s) and if you do, your print will provide the dimensions of

the width of the panels in this excess panel set (s).

Utilizing the diagram on the next page, Assemble this panel set just as you had the Outboard Brace Panel set.

There will be no diagonal braces in this panel set. Fold this panel set and gently stack with the previously assem-

bled Outboard Brace Panel set.

Photo showing the placement of the TEK

Screws securing the bottom rail

Photo showing assembly of the lock cable in the lock pin

Installation of top lock in top girt.

Photo is from rear of panel

Photo showing the installation of the trolley.

Photo is from rear of panel.

Top Lock Pin

Install with

TEK screws

#500815

Install with

two TEK

screws

#500815

support plate #500890

Aluminum bot-

tom rail.

Install first

Cable with 1 1/2‖ loop

secured by wire rope

clips #500827







4.9 Standard or excess panel set for the Concealed Stay Roller (CSR) system. View of

this panel set is from the inside of the hangar looking out on the left side of the door. These

two panels will either be 3’4‖ or will be two equal sized Excess Panels as called out on your print.

Trolley #714938

Doublers

Required

this vertical

Doublers

required this

vertical

Two TEK

screws each

joint

#500815

Doubler re-

quired this

vertical

Doublers

required this

vertical

Two TEK

screws each

joint

#500815

Finished Floor

Either standard (#791098) or

Excess Bottom Rail see your

print for actual dimensions.

Either a standard

(#791098) or Excess

Bottom Rail see your

print for actual di-

mensions.

Excess Girt

or standard

girt—see

your print

for actual

dimensions

TEK Screw

#500815

underneath

girt to se-

cure cable

Excess Girt see

your print for

dimension

Standard (# 500891) or

Excess Pre-Drilled Girt.

See your print for actual.

Top Lock

Excess Girt or

standard girt -

see your print

for actual di-

mensions

Cable Keeper

#500864 with

two TEK screws

Lock Cable cut at site

Rear Hinges #792864

apply with #500803

TEK Screw

Bottom of Header

Please note that the excess girt dimensions may be standard or special

depending on the size of door you have. The standard girt p/n is #791096





4.10 Assembly of Center Offset Panel Set — The adjoining panel sets (where the door from the left meets the

door from the right when the door is closed) will have the very center panel assembled with Girts and Bottom Rail measuring

3’8‖. The Trolley is inset 4.5‖ to allow the center two panels (from the left and right side of the doors) to meet without a gap.

One of the center verticals will be a special vertical with a double astragal which provides for overlap when the door is fully

closed. (See diagram next page). Please note that this may or may not be the physical center of the door. If the door has an

odd number of panels (that is odd as you divide by 2 for 10, 14 18), there will be more panels on one side of the door than on

the other. Does not matter which side. The offset panel is paired with a standard panel. When the door is open and stacked

this center offset panel will extend into the hangar.

Folding and stacking the assembled panel sets prior to hanging







Girt #791096

Girt #791096

Girt #791096

Offset Girt

#793778

Pre-Drilled

3’ 8‖ wide

Offset Girt

#793341 3’8‖

wide

Girt #793341


#791098 3’4‖


#793765 3’8‖ wide

Cable keeper

#500864 with two

TEK screws #500815

One of the

Two offset

3’8‖ panels will

have a stan-

dard vertical

and the other

(opposite side

of the door)

will have a

Double Astra-

gal Vertical at

this location.

These two ver-

ticals do NOT

require the

hinge doubler

because no

hinge will be

installed.

Finished Floor

Center Offset Panel Set for the Concealed Stay Roller System. Each of the center panels

(two) is 3’8‖ with the trolley inset by 4.5‖ to allow full closure of the door. This view is from

the inside looking toward the outside. This is the rear of the panel set. Other than the verti-

cal with the astragal, the panel on the right side of the door is the mirror image.

Hinge

#792864

apply with

TEK screw

#500803

Holding the

trolley in

place is a

Small doubler

support plate

#500890

apply with two

TEK screws

#500815

Doublers

required

this vertical

Two TEK

screws each

joint

#500815

Bottom of Header

Cable cut to size

TEK screw #500815

to secure cable

Please note that this offset panel is one of the two panels where the right and left side of the

doors meet when the door is closed. This may or may not be the physical center of the door. If

the door has an odd number of panels (that is odd as you divide by 2 f or 10, 14 18), there will

be more panels on one side of the door than on the other. Does not matter which side.

Please note

that Each

Center offset

panel is mated

with a stan-

dard panel.





5.0 Hanging the Panel Sets — Place wood spacers on the floor. These spacers will support the panel sets until the

panel sets are hinged together.

Utilizing 2 to 3 individuals, insert the trolley for the assembled Offset set (center panel) into the track and move towards the

middle of the opening. Then insert the excess or standard panel set. Finish with the Outboard Brace Panel Set. Repeat on

the other half of the door.

6.0 Hinging the Panel Sets Together — Clamp the adjacent panel sets together. Note: all doors have an even

number of panels but on doors that have an uneven number of panel sets (please see your print for exact number of panels) the

door will have one more set going one way than there is going in the other direction. It does not matter whether the right half

or the left half of the door has the extra panel set. Attach the front hinges at the joint between the panel sets. These

hinges are supported by the steel hinge doublers and therefore you DO NOT have to locate the hinges at the girt. Locate one

hinge at the top and one hinge at the bottom of the door, then another within the 36‖ doubler. Some doors have a single cen-

ter hinge, a smaller doubler (#500894) should have been inserted to support the hinge installation.

Support the Panel sets with wood

spacers before the panels are hinged

together.







6.0 (Continued) Hinging the Panel Sets Together

6.1 Level the door at each trolley by adjusting the nuts to approximately the same height to cause the top of the door

to be 1‖ below the header. After the door is completed and final adjustments are made to the trolley height, jam the lock nu t

to the first nut on the trolley.

7.0 Hinge the door to the building columns — (support the hinged brace panel with wood blocks during this proc-

ess) Center the door in the opening, allowing a little space between the panel with the double astragal and the adjacent panel

such that the joint is not too tight. Temporally screw one screw per hinge for the outboard brace panel to the building column

at the top, center and bottom hinge, this can be a smaller screw than the lag bolts supplied for final attachment. Open the

door and confirm that the outboard brace panel is hinged to the column at the right height. If this panel is hinged to low or

to high, binding will occur and not allow the door to smoothly open. If this is the case, close the door, mark the hinge width

location on the column. Remove the screws from the hinge at the column. Open the door and mark the hinge height with the

door open. Close the door enough to access the hinges and again place screws into the hinge to the column at the width and

height marks. Confirm that the panels will open again. Once this is completed, the hinge height is established unless the trol-

ley height is changed. In that instance, it may be necessary to adjust the hinge height. When the door operates easily, com-

plete the installation by screwing in the remainder of the boltsin the hinges to the column.

1‖

There should be

equal spacing below

the nuts on each

trolley

Small wood supports ―C‖ clamps





4‖ approx, unless install-

ing door past opening

7.1 Top View of hinge placement on Column of the building

Outboard Brace Panel Active Panel

Called clear opening to this point

on the column

Allow for this rotation inward if

installing door past opening.

Next in-active

panel

Track

Center

Line

NOTE: If your door is designed to extend an additional distance past the opening to op-

timize the opening width, then refer to your print to determine dimensions of framing

needed to accommodate the entire door when closed. The framing must be at least 3‖ in

depth in order to accommodate the door panels as they rotate in a stacked fashion. In addi-

tion, the dimension of the offset in the offset panel will have to be taken into account when

determining the depth of the framing.

Trolley location







To see a video of the operation of the door opening and clos-

ing, go to You Tube URL:

http://www.youtube.com/watch?v=g-BUqX16SOU

Photos showing hinging the panel sets together and hinging the door to the columns.








8.0 Installation of the Concealed Stay Rollers — The Concealed Stay Rollers “CSR” must be installed prior to

attaching the exterior sheeting to the panels. Mark the center line of the Bottom Rail on the surface as you open and close

the door. Also mark the path of the Aircraft gear as you move it or other equipment in and out of the hangar. Mark and drill

the floor for the CSR’s locating them at least 12‖ away from the gear path and any other areas you marked. If it is desirabl e

to occasionally remove the CSR’s, we recommend that you install a larger pipe with a minimum 1/2‖ ID as a receptacle for the

CSR. As long as there is no more than one panel that does not have a CSR, that is ok. However, if more than one adjacent

panel does not have a CSR then a manual foot bolt must be installed. Each door panel should have a stay roller and if an area is

marked that is larger than one complete panel, we recommend that you install a manual stay roller which will be lifted out after

door is open. Drill a 17/32‖ hole for the Stay Roller clevis pin or Foot Bolt in floor. This may be oversized if a stub pipe (not

supplied) is to be inserted in the floor to receive the Stay Roller Bolt. Install the Stay Roller in the drilled hole.

Roller #500852

or #500878 Shaft Collar

#500812

1/2‖ X 6‖ Clevis

#500851

Concealed Stay Roller

Gear Path

12‖ Min 12‖ Min







9.0 Installation of the Cable Keeper — All of the lock pins on the panels without the latch system can be operated

from the interior just by pulling the cable and hooking it on the cable keeper. The Keeper, #500864, is installed at a comfort-

able working height to hold the cable and keep the lock retracted as the door is opened. This keeper is TEK screwed to the

girt about 5‖ away from the cable.

10.0 Install the Exterior Sheeting — First Determine where the ribs of sheeting will be located on the panels and

mark the location of the portion of the sheeting which is flat. Locate the where the Lock will be located on the flat area so

that the exterior handle can rotate and not hit the ribs of the sheeting.

This screw pattern layout is for the steel sheeting purchased locally. If polycarbonate is utilized, pre-drill the polycarbonate

with a minimum 1/4‖ drill bit before attaching to the door panel. If Polycarbonate is supplied, a ―J‖ trim is supplied for t he top

of the door and a starter strip for the bottom. Mark the location of the ribs of the polycarbonate on the door panel and TEK

screw the ―J‖ trim and starter at the rib location.

Girt

Cable Keeper #500864

Locate far enough

away to keep cable

tight and lock pins

free from track

Install using two TEK screws

#500815

Door Top Rail Girt and Bottom Rail Screw Pattern

Intermediate Horizontal Girts and Diagonal Braces

Lap Joint Detail

Steel Panel Screw Pattern Recommendations: The top horizontal rail and the bottom rail will have one screw at

each side of each major rib. The remaining horizontal girts and diagonal braces will need one screw at one side of

each major rib. For other configurations of steel sheeting and other types of sheeting, follow the manufactures

recommendations, but use 80 to s100 screws per square of sheeting.

Fasten cable to bottom of

girt using a TEK screw

(#500815)

Wire cable cut to length at site





11.0 Lock Installation — If other access to the building is available, the exterior lock is not required and may be

omitted. The exterior lock handle is installed with #500803 TEK screws and 1/4‖ nuts which will be installed on the inside.

Drill a 1/2‖ hole for the exterior lock handle and install. Additionally, a Tinnerman Nut is supplied to fit onto the lock s haft so

that it cannot be pulled off the door from the outside. The two girts pictured are the horizontal girts on the Outboard Brace

Panel are a standard girt and one additional lock girt. The inside case has an override feature that allows unlocking the door

from the inside with the exterior remaining locked. The exterior lock must be inserted to rotate 180° vertical to vertical. If

this is not working, remove the exterior lock and rotate 90° and re-insert. You may have to rotate the interior case as well.

Girt

Girt

Padlockable Heavy Duty Exte-

rior handle (optional)

#500902, bolts and nuts for

attachment supplied

TEK screw #500815 (16 per lock)

TEK screw #500803 (4 on

inside lock case)

Inside Handle

#500899

Trim lock Shaft

As needed

Tinnerman Nut #500839

Inside Lock Case #500898

L shaped Corner Clip

#715075

(8 per lock)

1" x 1" x 1/2"

TEK screw #500815 (8 per lock)

8-1/2‖ C Channels

#500901 (2 per lock)

Girt

Inside Lock

Case #500898

Inside

Handle

Padlockable Heavy Duty

Exterior handle optional

#500902

8-1/2‖ C Chan-

nels #500901

Cable Cut to length at site

Wire rope clips #500827 1 1/2‖

loop in cable

Wire rope

clips

#500827

1 1/2‖ loop in

cable





Enlarged Photo of inside of lock installed

Girt

L shaped Corner

Clip #715075

(8 per lock)

1" x 1" x 1/2"

TEK screw

#500815 (16 per

lock)

Cable with 1 1/2‖ loop

secured by wire rope

clips #500827 (see

similar photo for lock

pin on page 15)

Girt





12.0 Installation of Seals — The top seal (#500835) is attached between the track & header. (see photo on page 6)

The standard vinyl seal (#500905) is attached to the front of the bottom of the door (in the small channel of the aluminum

bottom rail). You can purchase additional vinyl seal and insert in the back channel. Seals in both channels can be installed. The

vinyl bottom seal extends 1/2‖ on each side. An optional brush seal can be inserted in either channel. The Brush seal must be

cut even with the edge of the Bottom Rail. Foam insulation seal is provide (#500897). This will be placed on one of the verti-

cals which are hinged on the rear and one of the verticals which are hinged in the front. This will seal the gap between the

verticals when the door is closed. Pinch the channels slightly in the side and the bottom rail to prevent the seal from sliding.

Vinyl seal (#725586) is placed in the two side verticals (left and right) to seal against the column. This seal is cut square with

the top and bottom of the verticals.

A vinyl seal #725586 is in-

serted into the special out-

board verticals to seal at

the column. This vinyl seal

is cut square at the top to

allow joint between door to

seal. Pinch aluminum channel

slightly so seal will not slide.

Seal #500905

Inserted into the

channels of the alu-

minum bottom rail





13.0 Operation of the Door

Opening the door:

13.1 First unlock the pins in the panel set closest to the building column.

13.2 Push the hinge joint of this panel set out and pull the remaining panels towards you. The top lock pins will

remain in the top track and the bottom of the door will be secure with the concealed stay rollers still concealed in

the aluminum bottom rail while the door is sliding toward the column as you operate the door open.

13.3 Pull the top lock pin and operate the second panel set the same as the first, then continue until this half

of the door is open.

13.4 Repeat on the opposite side.

13.5 If the exterior handle is installed, this can also be used to secure the door in the open position with the

floor mounted strikes.

Closing the door:

13.6 Close the door by closing one two panel set at a time starting with the panels that will be at the center of

the door.

13.7 Release the lock pin into the top track and guide the aluminum bottom rail over the concealed stay rollers.

13.8 Repeat until the door is closed.

13.9 The door can be locked from the outside, leave a gap at the center by not fully closing one half of the

door, then push in the panel set with the external lock attached and secure the locks in the top track and bottom

floor strike.

For a video presentation of the correct procedure to open and close a FT door, please go to the follow-

ing YOU TUBE URL address:

http://www.youtube.com/watch?v-BUqX16SOU






14.0 Maintenance of the Door

14.1 Lubricate hinges and locks with dry graphite annually or when needed.

14.2 Confirm that all trolley nuts are tight. All trolleys must be adjusted to give equal support. Equal support

generally means that the trolley pendant bolt has the same amount showing below the nuts.

14.3 Trolley lubrication is NOT recommended

14.4 Confirm that all locks move smoothly and fit into the top track a minimum of 1‖. Make sure that the bot-

tom lock fits into the Bottom Floor mounted Strikes a minimum of 1‖.

14.5 Confirm that all hinge TEK screws are tight.

14.6 Check bottom lock systems periodically. Confirm that the con-

cealed stay rollers are turning and are tightly installed in the floor and

fit at least 1‖ into the aluminum bottom rail.

14.7 Lubrication of the upturned edges of the track (where the trolley can rub) at the stack area and for the

next four feet will smooth the initial closing and final opening of the door.

Top Trolley

Amount showing

below the nuts

is equal.

Nut must be

tight

Jam nut must

be tight

1‖

Concealed stay roller in concrete







15.0 Listing and identification of part numbers used

Part Number Name Description Size Where used

#173101 Bearing 1/2" Grade 8 Steel washer for trolley 1/2" Trolley

#177901 Lag bolts wood building track mount-ing 3/8" x 2-1/2" Track brackets

#500801 Tek Screws Steel Column Tek #12-24X1-1/4" 5/16" AF #4.5 Steel Column, Track Cover (steel Bldg)

#500803 Tek Screws Hinge Attachment Tek Screw 1/4' x 20 x 5/8" lock head tek Hinge attachment

#500810 Cable control Cable 1/16" Attach to the lock and lock pins

#500812 Collar Shaft Collar 1/2" Concealed Stay rollers and the lock pins

#500814 Spring Compression Spring 4" on all Lock pins

#500815 Tek Screws Frame Assembly Tek Screws 12-14x5/8"X 5/16" HWH All Assembly Except Hinges

#500827 Wire Rope Clips W/R Clips,WRCG062X100 1/16" cable at lock pins and lock

#500835 Top Seal EPDM Membrane .0600 X 6"x opening width Top Seal

#500839 Tinnerman Nut Nut 5/16" In Lock pack #500864

#500840 5/16 Flat Washer Washer 5/16" In Lock pack #500864

#500846 Lock pack Including hardware and lock components Lock pack

#500851 clevis pin Mount pin for Concealed Stayroller 1/2" x 6" Concealed Stay Roller

#500852 Nylon Roller Bottom Roller - roller only 1-1/4" x 2" Recessed Guide

#500859 Nylon Roller Concealed Stay Roller - Roller only 1-1/2" x 2" Wheel Only Concealed Stay roller

#500864 Keeper Plate Lock Cable retainer Cable hold back for lock systems

#500866 Foot Bolt Strike Floor mount Foot Bolt Strike (pair)

to secure bottom lock pin with floor

#500875 Masonry Drill Bit 1/4" masonry bit 1/4" install Foot Bolt Strike

#500876 Tap Con Screw For Foot Bolt Strike

#500878 Nylon Roller Roller for bottom lock pin 1-1/4" DIA X 1" Bottom lock pin

#500879 Compression Spring 4" Compression Spring 4" 4" spring w/ .845od all lock pins

#500884 Lock pin 10.5" x 1/2" drilled rod 10-1/2" x 1/2" all lock pins

#500886 Allen Wrench 1/8" Shaft collars

#500887 Bracket - Lock pin Guide bracket - Head Bolt / Foot bolt

All top and bottom lock pins

#500889 Tek Screws with seal-ing washer

Sheeting attachment Tek Screws 12-14 12-14x5/8"X 5/16" HWH

Sheeting attachment (optional)








Part Num-ber Name Description Size Where used

#500890 Support plate Girt reinforcement plate under trolley and bottom roller girts.

#500891 Girt - Drilled

Girt drilled one hole 3/4x3/4 and one hole 3/4x4.5 thru the 3.5" direction 40" x 3.5" x 1.5"

Standard active panel top girt for CSR, Standard top and bottom active panel girt for RGC

#500892 Tapping screw THREAD CUTTING SCREW 3/8-16 X 3/4 Track Install for steel tube header - must pre drill

#500894 Hinge Doubler - Small Single doubler for center hinges

center hinges on doors with more than four hinges per vertical.

#500896 Hinge Doubler - 36" 16 Gauge hinge reinforcement angle 36" long

Top and bottom two front hinges

#500897 Foam weather-strip Foam weather-strip Between all hinged verti-cals

#500898 Lock Inside center case Interior Center lock Case with override feature

Lock panel - in lock pack #500864

#500899 Inside Lock Handle Inside Lock Handle on Inside Lock Case -in lock pack #500864

#500901 Aluminum Bracket Lock support plate 8" x 3.625" nominal

one for each lock handle and one for each inside case

#500902 Exterior lock handle Padlockable "L" handle one for each exterior lock (optional)

#500904 Brush Seal Weather seal for door bottom (Optional) bottom seal

#500905 Vinyl seal Weather seal for door bottom Standard bottom seal

#500912 Bolt BOLT 8-32 X 3/4 In Lock pack #500864

#500913 Nut NUT 8-32 In Lock pack #500864

#660697 J-Channel White (optional) Ag tuf J-Channel 10'

Cap door sheeting at top of door

#660699 Base Trim White (Optional) Ag tuf Base Trim 10'

Starter for door sheeting at bottom of door.

#710654 Door Pull White Door pull

Adjacent to exterior lock handle or as preferred by operator

#712218 Lag bolts 1/4 x 2" Lag bolt 1/4" x 2"

Wood building - attach outboard hinge to building column, attach track cover bracket to header

#713573 Track cover Bracket Track cover Bracket

Exterior door install on header to support track rain cover (by Others) print supplied









#714027 Box Track 16 Gauge Box Track 14' 14' Exterior door install on header



#714366 Track end plugs Track end plugs Each end of the track

#714721 Track Bracket Side mount track bracket

all exterior track support locations except joints and ends

#714809 Foot Bolt 12" x 1/2" foot bolt 12" x 1/2" For Manual Foot bolt appli-cations

#714938 Trolley 7-1/2" Straight Bolt Trolley All active panels

#714944 Track Bracket - Splice Side Mount Splice Bracket with hex had bolts All track joints and ends

#715075 Angle bracket Corner brace for lock bracket in-stall 1" x 1" x 1/2"

four per aluminum bracket #500901

#715081 Track Bracket Bolt Hung Bracket

Special interior mount track support bracket - all loca-tion except joints and ends

#715083 Bracket, splice Bolt Hung Bracket Splice bracket with hex head bolts

Special interior mount track support bracket - for joints and ends only

#725586 Seal Vinyl insert for #200 vertical outboard verticals only



#791096 #235 Box Girt Box girt Horizontal - Standard Panel

40" x 3.5" x 1.5" non drilled

All standard panel locations not requiring a drilled girt.

#792864 Hinge 2.5" x 2.5" Stainless Steel hinge 2.5" x 2.5" All hinge locations

#793778 Girt - Drilled

Girt Drilled - Center Panel two holes 3/4 x 4.5" thru the 3.5" di-rection 44" x 3.5" x 1.5"

Active 3' 8" panel in the Offset Panel Set

#793890 #244WS Bottom Rail Aluminum Bottom Rail - STD panel 40' x 3.5" x 1.5"

All standard Panels in con-junction with Concealed Stay Rollers









#391 Aluminum Vertical 4.5" Vertical for outboard hinge per door height All Panels (optional 4.5" thick)

#391 Aluminum Vertical 4.5" Aluminum vertical - Cut to length per door height

All Panels (optional 4.5" thick)

#396 H - Aluminum Verti-cal

Aluminum vertical - with H clo-sure per door height

One Center panel (optioonal 4.5" thick)

#394 Aluminum Bottom rail Aluminum Bottom Rail

All Panels (optional 4.5" thick)

#394 Aluminum Bottom rail

Aluminum Bottom Rail - Center Panel 44"

Center Panels (optional 4.5" thick)

#394 Aluminum Bottom rail

Aluminum Bottom Rail - Excess Panel Excess panel width

Excess panels (optional 4.5" thick)

#235 Box Girt Box girt Horizontal - Center Panel 44" x 3.5" x 1.5" Panels

#235 Box Girt Box Girt Diagonal Brace - starter Panel per door height Starter panel

#235 Box Girt Excess Panel Girt Excess panel width x 3.5" x 1.5" Excess panels

#235 Box Girt

Girt Drilled - .75 X .75" & 4.5" holes in 3.5" direction - Excess panel

Excess panel width x 3.5" x 1.5"

Active Excess panels top girt

#244WS Bottom Rail Aluminum Bottom Rail - Excess Panel Excess panel width Excess panels bottom rail

#791096 #235 Box Girt Box Girt - Lock Attachment 40" x 3.5" x 1.5" Outboard brace / lock panel

#235 Box Girt Reinforcement girt for vertical Panels

#235 Box Girt - Drilled

Girt Drilled - Center Panel two holes 3/4 x 4.5" thru the 1.5" di-rection 44" x 3.5" x 1.5"

Active 3' 8" panel in the Offset Panel Set (optional 4.5" thick)

#235 Box Girt - Drilled

Girt Drilled - .75 X .75" & 4.5" holes in 3.5" direction - Excess panel

Excess panel width x 3.5" x 1.5"

Active Excess panels top girt (optional 4.5" thick)

Girt - Drilled

Girt drilled one hole 3/4x3/4 and one hole 3/4x4.5 thru the 1.5" direction 40" x 3.5" x 1.5"

Standard active panel top girt for CSR, Standard top and bottom active panel girt for RGC (optional 4.5" thick)







16.0 Tools required for the assembly and installation

Screw Gun (or variable speed drill)

Electric Drill (with hammer function for drilling concrete)

Drill bits including

5/16‖ (long enough to drill through the building column)

1/2‖ (metal for lock install)

7/32‖ or 9/16‖ (to ream predrilled trolley and lock pin holes)

1/2‖ or 17/32‖ (Masonry for hole in concrete for stay roller)

Drive sockets for screw gun — 5/16‖, 3/8‖, 7/16‖, 1/2‖

Drift punch to align holes

Square

Chalk Line (to aid in track install)

Level

25’ minimum tape measure

Box end wrenches

Socket and ratchet set

Cable cutter to cut control cable to size

Box cutter to cut bottom seal to length

Allen wrench set

Hammer

―C‖ clamps (4) for holding panels together during hinging

Tin Snips for trimming girt inside vertical at hinge

Hack saw or Cut Off saw for trimming track as required

Wood shims (to aid in supporting door while hinging the panel sets and clamping)







17.0 Print for the rain cover (to be installed after door is completed)

1.00 in

1.25 in

5.12 in

90.00°

137.50°

144.87°

22.50°

0.75 in

2.50 in

Recommended Rain Cover for Track

Rain Cover Not supplied by Cool-Air, Inc.

It will be purchased locally to match

color of building.

29 or 28 gauge painted or galvanized

Steel

For use with Cannonball:HNP #710808

side mount Track Cover Bracket

(supplied)

Bracket and track mount flush to header

without a track board. If a track board

is used, the standard Cannonball track

cover will work, but the vertical column

must be spaced out the same distance as

the track board for hinge attachment.





Overview Fold Out Goes Here





Hinge and doubler overview foldout goes here





Specific Door Print goes here





Master structural list for specific door goes here

Assembly, Installation and Operating Instructions for: CSA...

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