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Wayne-Dalton FireStar 540, Installation Instructions Manual

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Wayne-Dalton FireStar 540 Installation Instructions Manual Download Page 20

344940 REV2  03/17/2020

©

Copyright 2020 Wayne Dalton, a division of Overhead Door Corporation

20

Install the chain from the slotted sprocket to the idler sprocket, and if crank operated, install the chain from the drive sprocket on the awning crank to the door sprocket. 
Adjust each chain so that there is 1/4” to 1/2” of 
slack as shown for proper operation and automatic 
closure functionality. The idler sprocket and chain 
tension is adjustable by loosening the mounting 
bolts on the opposite side. (If the idler sprocket 
location is adjusted, the centrifugal clutch chain 
tension will also require adjustment). Re-tighten all 
bolts & nuts.

Now, the push-down spring (connected to the 3/4” diameter shaft) must be wound. The shutter must be in the 

CLOSED

 position. Install the test handle, fusible links, turn-

buckles and cable and attach to the release lever (per Step 11). Rotate the release lever upwards and secure it so that the ratchet tooth engages the tension wheel

NO CHAIN OR CRANK

FOR LIFT-UP DOOR

CHAIN INSTALLATION FOR LIFTUP AND CRANK DOORS

INSTALL CHAIN

IDLER SPROCKET

IDLER SPROCKET

MOUNTING BOLTS

CENTRIFUGAL CLUTCH MOUNTING BOLTS

STOPS ON CLUTCH DISKS (MUST BE ORIENTED AS SHOWN)

NUT (FACTORY INSTALLED ON SLOTTED SPROCKET)

ROTATE THE SLOTTED SPROCKET COUNTERCLOCKWISE

(LOOKING AT END OF OPERATOR BRACKET)

UNTIL ALL THE NUTS ON THE TWO SPROCKETS

AND CLUTCH DISKS ARE IN CONTACT.

SLOTTED SPROCKET

NUT (FACTORY

INSTALLED

ON SPROCKET)

LEFT HAND OPERATED

BRACKET SHOWN 

CUT AWAY

 WARNING

EXERCISE CAUTION WHEN APPLYING, ADJUSTING, AND SECURING SPRING TENSION. CONTACT WITH RAPIDLY ROTATING TENSION WHEEL OR EXPELLED WRENCH CAN 

CAUSE SERIOUS INJURY OR DEATH.

 WARNING

ACTIVATING THE TEST HANDLE WILL RELEASE SPRING FORCES, CAUSING THESE PARTS TO SPIN RAPIDLY AND CAN POTENTIALLY CAUSE SEVERE INJURY TO ANY PERSON 

IN CONTACT. ENSURE RELEASE LEVER AND TEST HANDLE ARE IN THE LOCKED POSITION AND SECURED BEFORE AND DURING THE TIME YOU PERFORM THIS STEP.

Summary of Contents for FireStar 540

Page 1: ...ors may be mounted on openings in fire walls of masonry construction and non masonry construction IMPORTANT NOTICE READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO REMOVE EXISTING SHUTTER OR INSTALLING THIS SHUTTER PAY CLOSE ATTENTION TO ALL WARNING LABELS AND THE IMPORTANT SAFETY NOTICES ON THE FOLLOWING PAGE THIS MANUAL MUST BE ATTACHED TO THE WALL IN CLOSE PROXIMITY TO THE SHUTTER ...

Page 2: ... and the floor or countertop causing severe or fatal injury 7 To avoid possible severe or fatal injury DO NOT stand in the open doorway or walk through the doorway while the shutter is moving 8 Should the shutter become difficult to operate or completely inoperative trained rolling fire door systems technician should be contacted to correct the problem to prevent possible injuries or door damage 9...

Page 3: ...hile Door is moving Do NOT allow children to play with the Door Operator Do NOT operate a Door that jams or one that has a broken spring ELECTRICAL SHOCK WARNING Could result in death or serious injury Turn OFF power before removing operator cover When replacing cover make sure wires are not pinching or near moving parts Operator must be properly grounded HIGH SPRING TENSION WARNING Could result i...

Page 4: ...rs required The dimensions for the opening width opening height head room and side room MATERIAL Inspect your shutter prior to leaving for job site for possible damage or shortage of parts Report any claims or shortages to your door supplier immediately CLEARANCES The installation drawings supplied in the hardware bag contain information on bracket size and head and side room for each shutter Be s...

Page 5: ...0 Wayne Dalton a division of Overhead Door Corporation 5 SECTION 1 SUPPLIED PARTS LIST MAJOR COMPONENTS AND ASSEMBLIES AWNING CRANK WINDING SHAFT CURTAIN ASSEMBLY BETWEEN JAMBS GUIDE FACE MOUNTED GUIDE BOTTOM BAR ASSEMBLY BARREL ASSEMBLY ...

Page 6: ...T HOUSING LIFTUP CRANK TOP MOUNT OPPERATOR BRACKET ASSEMBLY LIFTUP CRANK BOTTOM MOUNT OPERATOR BRACKET ASSEMBLY ADJUSTING WHEEL FRONT HOOD ADJUSTING BRACKET ASSEMBLY TUBE MOTOR OPERATOR BRACKET ASSEMBLY BOTTOM BAR STOP CURTAIN LOCK LIFTUP CRANK DROP MECHANISM COMPONENTS SECTION 2 SUPPLIED PARTS LIST BRACKET ASSEMBLIES AND COMPONENTS ...

Page 7: ...S REQUIRED DRYWALL OVER WOOD STUD MASONRY CONCRETE FILLED DRYWALL OVER STEEL STUD BRICK OR CONCRETE STEEL CHANNEL OPTIONAL FUSE LINK HOUSING FUSIBLE LINK AW PIN TEST HANDLE FUSE CABLE NICO PRESS FITTING COTTER PIN S HOOK TURNBUCKLE SECTION 3 SUPPLIED PARTS LIST BRACKET ASSEMBLIES AND COMPONENTS TYPICAL JAMB TYPES ...

Page 8: ... Refer to Figure 3 Check the opening width A and the opening height B or F and compare with the installation drawing to be sure the opening is the proper size for the shutter Verify the clearances available meet or exceed those given on the installation drawing Rope off the opening prior to beginning work Figure 3 ...

Page 9: ...3 Steel Bolt line BL _____________________________ Divide BL in half BL 2 and measure this distance either side of the opening center mark to obtain the bolt line on each jamb Drop a plumb line down and make a second mark on the wall at the bottom of each jamb Using a chalk line snap a vertical line the length of the F dimension After determining guides are plumb level and properly spaced mark the...

Page 10: ...on of the bolt line BL for the guide mounting bolts on the wall Follow this procedure for either masonry or steel jambs see Figure 4 Choose one guide packout angle to be used as a template Temporarily clamp the assembly in the proper jamb i e left assembly in left jamb at the exact location in the opening the shutter is to be mounted After determining that the guide outer channel is plumb level an...

Page 11: ... 1 1 2 SPACE EXISTS BETWEEN THE TOP OF THE BRACKET AND THE BOTTOM OF THE LINTEL SINCE FIRESTAR SHUTTERS ARE DESIGNED TO EXPAND UPWARD SEE INSTALLATION DRAWING FOR EXACT DIMENSION Clamp the hood straps to the guides temporarily and use the straps as a template to scribe the location of the mounting holes under the lintel Position the flame baffle if provided under the lintel as shown in Figure 6B w...

Page 12: ... sprocket shaft key and snap ring onto the shaft Locate the sprocket so that it contacts the snap ring and tighten the set screws Next move the inner set collar and thrust bearing between the barrel and inside surface of the bracket against the inside bearing race on the bracket and tighten the set screws prevents lateral barrel shaft movement IMPORTANT DETERMINE PROPER ORIENTATION OF BARREL AS IN...

Page 13: ...e barrel and brackets to prevent damage during installation WARNING SECURE BRACKET TO BARREL ASSEMBLY USING SUPPLIED COTTER PIN OR VISE GRIPS TO PREVENT IT FROM SLIDING OFF DURING LIFTING FAILURE TO SECURE BRACKET TO BARREL ASSEMBLY COULD RESULT IN SEVERE OR FATAL INJURY CAUTION ALL PARTS EXCEPT KEYS ARE DESIGNED FOR A SLIP FIT FORCING PARTS TOGETHER MAY RESULT IN DAMAGE LEADING TO MALFUNCTION WAR...

Page 14: ... away from the opening Lift curtain assembly centered between guide assemblies and suspend approximately one foot below the barrel assembly using ropes or straps of adequate strength to safely support curtain assembly weight Remove steel banding from around curtain assembly WARNING SECURE BRACKETS TO BARREL ASSEMBLY TO PREVENT IT FROM SLIDING OFF DURING LIFTING POSSIBLY CAUSING SEVERE OR FATAL INJ...

Page 15: ...Y With the curtain and barrel assembly not shown for clarity now mounted to the guides and secured to prevent curtain from dropping proceed to install the inner guide assembly Position the bottom bar inside the channel shaped outer guides approximately 3 4 below the top of the guide opening Install the bottom bar stops to the inner guides as shown in Detail B Position the correct inner guide into ...

Page 16: ...n steel springs friction etc slight adjustments may be required Install the adjusting wheel and cotter pin as shown Using approved winding bar rotate the adjusting wheel AW slightly in both directions to de termine the neutral point of the tension shaft Insert the two winding bars securely into the holes in the AW as shown on page 18 CAUTION ALWAYS WIND COUNTERBALANCE SPRING TENSION WHEN THE SHUTT...

Page 17: ...OTTOM BAR STOPS THIS IS THE OPTIMUM SETTING AS TOO MUCH TENSION COULD PREVENT THE SHUTTER FROM DROPPING WHEN THE RELEASE LEVER OR FUSIBLE LINK IS ACTIVATED STEP 9 TESTING THE SHUTTER BALANCE Manual Lift Up Crank GCX Motor Operator Only With the adjusting wheel locked operate the shutter through several cycles to check shutter balance If the shutter does not balance properly and requires further sp...

Page 18: ...im needs to be placed The hood may need to be loosened or removed for the application of the shim To apply the shim two laborers might be required Installing the shim D Close the door fully E When door is at bottom make sure door is in hand chain mode F Turn off the power to the motor if applicable to ensure safe application of the shim G Backwind the door using the chain Lock chain in place using...

Page 19: ...key and ratchet tension wheel as shown Fasten the cotter pin in the end of the 3 4 shaft to secure the components from moving laterally Tighten all set screws on the door sprocket and inner set collar Verify that the clutch disks rotate freely Orient the clutch disks and slotted sprocket as shown below STOPS ON CLUTCH DISKS MUST BE ORIENTED AS SHOWN NUT FACTORY INSTALLED ON SLOTTED SPROCKET ROTATE...

Page 20: ... release lever upwards and secure it so that the ratchet tooth engages the tension wheel NO CHAIN OR CRANK FOR LIFT UP DOOR CHAIN INSTALLATION FOR LIFTUP AND CRANK DOORS INSTALL CHAIN IDLER SPROCKET IDLER SPROCKET MOUNTING BOLTS CENTRIFUGAL CLUTCH MOUNTING BOLTS STOPS ON CLUTCH DISKS MUST BE ORIENTED AS SHOWN NUT FACTORY INSTALLED ON SLOTTED SPROCKET ROTATE THE SLOTTED SPROCKET COUNTERCLOCKWISE LO...

Page 21: ...TOR OPERATION Install the GCX operator to the bracket with 4 3 8 16x1 1 4 button cap screws nuts and wash ers as shown Install the door srocket roller chain operator wiring and push button and set the door limits per the GCX operator supplied instruction manual The drop lever must be installed so that it is perpendicular to the floor when the fuse cable in routed and the test handle is engaged The...

Page 22: ...vices see the installation instructions included with them Generally any fusible link must be at least 6 away from any fixed point ex turnbuckle pulleys etc or sufficient enough that the drop out mechanism and tension release arm can swing down see Appendix D for additional infor mation A FUSE LINK HOUSING IS REQUIRED IF A DROP CEILING EXISTS ABOVE THE SHUTTER OPENING IN ORDER TO COMPLY WITH THE P...

Page 23: ...ated shutters if drop speed is less than 6 per second increase the push down spring tension If the drop speed is more than 24 per second reduce the push down spring tension per step 11A If the drop speed cannot be adjusted to within 6 and 24 per second contact Wayne Dalton STEP 15 HOODS SUPPORTS HOUSINGS UNDER LINTEL Skip to next section for brackets mounted above lintel HINT LOWER THE SHUTTER TO ...

Page 24: ...en the hood straps and the front hood see Figure 23 Check to insure the cutouts as provided are large enough so as not to interfere with the drop arm throughout its travel Trim if necessary Now tighten all screws in the vicinity of AW bracket locking hood housings in place Attach the governor bracket housing in similar manner and proceed to tighten all remaining hood screws Remove the temporary fl...

Page 25: ...ecting screws in the bottom of the slots Attach the A W bracket housing and sandwich housing flange between bracket flange and front hood see Figure 23 Check to insure the cut outs as provided are large enough so as not to interfere with either drop arm throughout its travel Trim if necessary Now tighten all screws in the vicinity of A W bracket Attach the governor bracket housing in similar manne...

Page 26: ...ease handle to avoid possible tampering Have the customer or his representative sign off on the installation using the Rolling Fire Door Test Drop Release Form provided in the hardware bag and also fill out the Test Drop Release Form in the back of this manual Return a copy of form in the hardware bag to Wayne Dalton and keep a copy in your maintenance files Exchange all documentation and keys to ...

Page 27: ...so that the casting just clears Appendix B Service Record This manual is intended for the use of the installer on the job site It is meant to be informative but not exhaustive The final word is set out in the specifications and drawings approved by the purchaser before the door was shipped Wayne Dalton doors should be installed by trained industrial door technicians Wayne Dalton dealers have acces...

Page 28: ...f possible problems with the operation of the fire shutter The probable causes listed are the most common and are not meant to include ALL possi bilities With the variety of the product and the field conditions other factors may be involved WARNING ALL REPAIRS ADJUSTMENTS AND MAINTENANCE MUST BE DONE BY A TRAINED ROLLING FIRE DOOR SYSTEMS TECHNICIAN ...

Page 29: ...rs with the coil mounted above ceiling or a typical modification for electro mechanical release devices These are provided as a sam ple and may not be right for every installation The actual field condition at the job site will determine the best cable routings If you need help determining a cable routing for your installation contact Wayne Dalton Technical Service for assistance ...

Page 30: ...344940 REV2 03 17 2020 Copyright 2020 Wayne Dalton a division of Overhead Door Corporation 30 ...

Page 31: ...344940 REV2 03 17 2020 Copyright 2020 Wayne Dalton a division of Overhead Door Corporation 31 ...

Page 32: ...ement of parts not from the original door manufacturer homemade or mismatched parts are not approved and must be replaced 12 Check balance and spring tension of door 13 If chain operated check hand chain for damaged links Replace or repair if necessary 14 If motor operated check door operating jamb sprocket and chain adjust and lubricate as necessary Readjust limits as necessary C Ancillary equipm...

Page 33: ...use neglect accident failure to provide necessary maintenance normal wear and tear acts of God or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments including blowing sand salt water salt spray and toxic chemicals and fumes THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTIES EITHER EXPRESS OR IMPLIED INCLUDING ...

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