PREMIUM BALANCED DOOR - C.R. Laurence

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INSTALLATION INSTRUCTIONSPREMIUM BALANCED DOORWITH GEARBOX TENSIONERALUMINUMPhone: (800) 421-6144 Fax: (800) 582-7501crlaurence.com usalum.com crl-arch.com11M0196 REV A-10-22-18

CRL PREMIUM BALANCED DOOR WITH GEARBOXORDER OF ASSEMBLY AND INSTALLATIONINTRODUCTION. 3STEP 1:Confirm your shipment. 3STEP 2:Check rough opening. 3STEP 3:Verify floor condition. 3STEP 4:Assemble the frame. 4STEP 5:Install the frame. 5STEP 6:Install the hinge tube.5 - 6STEP 7:Install the door. 7STEP 8:Adjust closing force. 8STEP 9:Adjust closer speed. 8STEP 10: Adjust pivot block. 9Component overview. 10Maintenance.11IMPORTANT: READ THIS MANUAL THOROUGHLY BEFORE BEGINNING INSTALLATION.C.R. Laurence, Inc. warrants all products manufactured by it and supplied hereunder to be free fromdefects in material and workmanship in accordance to our contract.This warranty shall not apply to any products not manufactured by CRL, nor to any products which havebeen repaired or altered by others without CRL’s written consent. This warranty shall not include failure ofparts and materials due to improper installation, inadequate support of surrounding structures, and/or lackof proper maintenance.crlaurence.com usalum.com2ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXINTRODUCTIONThank you for choosing the Premium Balanced Door System by C.R. Laurence. We have made every effortto assure the utmost quality in materials and craftsmanship. Each unit has been fully assembled and factorytested prior to shipping. Please read this manual thoroughly before beginning installation.STEP 1: CONFIRM YOUR SHIPMENTCarefully open the shipping container and look for any damaged parts. Most orders are shipped knockeddown and will require on-site assembly. Confirm that the door(s) height and width are approximately the sameas the rough opening. Your package should include:Fully Glazed Door(s)Hinge Tube with Top and Bottom Pivot ArmsHeader AssemblyFloor Mounted GearboxThreshold and Side JambsOptions may include Hinge Tube Cover, Handles, Stanley Operator Motor and Stanley Electrical ControlUnits. Refer to your packing list for details.If any parts are missing or damaged, call the C.R. Laurence Technical Sales Department immediately at1-(800)-421-6144. Refer to the order number on the packing list.STEP 2: CHECK ROUGH OPENINGVerify that the rough opening is square and plumb. Refer to CRL Shop Drawings to confirm rough openingdimensions. It should be slightly larger than the finished door frame including header and threshold.If automatic door options are required, make sure that all electrical wiring is completed to the rough openingand NOT ENERGIZED. Refer to the C.R. Laurence “Site Preparation” drawing and/or your job drawings toconfirm all required electrical connections.STEP 3: VERIFY FLOOR CONDITIONThe floor directly below the rough opening should be clean and in good condition. It is critical that the floorbe sound and level. The Premium Balanced Door threshold and pivot gear box mounts directly to the flooror sub floor surface. It must be able to support the system’s weight and firmly hold the fasteners in place forthe lifetime of the installation. It is also necessary for the floor to be level and square to the jambs to allow asmooth operation of the Balanced Door.crlaurence.com usalum.com3ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXNOTE: Medium to heavy usage of specified components may cause critical fasteners to loosen overtime. C.R. Laurence recommends the use of Cat. No. 24221 Loctite 242 . It is designed for the lockingand sealing of threaded fasteners which require normal disassembly with standard hand tools. Theproduct cures when confined in the absence of air between close fitting metal surfaces and preventsloosening and leakage from shock and vibration. Suitable for applications on less active substrates suchas plated surfaces, where disassembly with hand tools is required for servicing.STEP 4: ASSEMBLE THE FRAMEOpen the interior header access panel(s) and remove all components except the cam assembly as shown.This reduces the weight of the header and allows access to any predrilled mounting holes. Be sure to markthe parts (L/R) because they are matched to the cam assembly.PRY HOLESCAM ASSEMBLY(DO NOT REMOVE)HEADER1. Remove (4) 1/4”- 20 x 1” Socket Head Cap screws.2. Use a large screw driver through Pry Holes of Damper Plateto compress damper plate spring tension.3. Lever off Damper Assembly from door SSEMBLYOPERATORINTERIOR HEADERACCESS PANELDamper Assemblymust be removedbefore door installation.Lay the frame component parts on the floor and assemble with the appropriate fasteners. C.R. Laurenceoffers a variety of optional jamb configurations that will be covered in more detailed supplements attached tothis guide. In general, most systems will consist of the parts shown below:HEADER ASSEMBLYLOCK JAMBBASE PLATEVERTICAL JAMBSTHRESHOLDFRAME SHOWN:RIGHT HAND REVERSEDEXPOSED HINGE TUBECat. No. 24221LoctiteGEARBOXcrlaurence.com usalum.com4ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXSTEP 5: INSTALL THE FRAMEStand the frame up and work it into the prepared opening. If electrical connections are present, route theminto the header as you proceed. (Refer to the CRL shop drawings). Temporarily secure the frame in placewith shims.Using Cat. No. 406065 Digital Level and Cat. No. BDPS105 Plumb Bob,adjust the frame so it is completely level and plumb. Proper operation of thePremium Balanced Door System depends on the squareness of the frame.Tolerance is ( /-) 1/32” (1 mm).When the door frame is in the desired position, permanently mount withfasteners.CRL Plumb BobCat. No. BDPS105CRL PAL Digital LevelCat. No. 406065STEP 6: INSTALL THE HINGE TUBEThe hinge tube assembly carries the full weight of the glazed door and acts as an intermediate hinge to theBalanced Door System. It is very important to install and adjust it properly to achieve free and unrestrictedmovement.(A) If double doors are supplied, use the shape of the pivot arms to identify the left and right hinge tubes.TOP VIEWEXTERIOR SIDEThe flat side of pivot armalways faces exterior.Hinge tube for a right handreverse door shown from top.HINGE TUBERIGHT TOP PIVOT ARM(B) Temporarily lower the cam to install the hinge tube.Remove the bottom bolt andloosen the top shoulder bolt.Slide the cam shaft downuntil it is fully retracted.CAM SHAFT TOP SHOULDER BOLTBOTTOM SHOULDER BOLTcrlaurence.com usalum.com5ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXSTEP 6: INSTALL THE HINGE TUBE (CONTINUED) RIGHT HINGE TUBE(C) Turn gearbox key until it is perpendicular to the jamb. Place thespindle slot of the right hinge tube over the gearbox key and standvertically.HINGE TUBESPINDLE SLOTCAM SHAFTGEARBOX(D) Swing the top of the hingetube into position and insert thecam shaft into the cam socket.GEARBOX KEY CLOSERCAMCAM SOCKETFLAT LOBENOTE: The cam shaft fits only one way into the cam socket.(E) Line the flat lobe of the cam shaft with the flat section in the camsocket. Apply upward sliding pressure on the cam shaft as you turnthe cam from above. When they engage, raise the cam shaft untilit stops. Apply Cat. No. 24221 Loctite to bottom shoulder bolt andinsert to hold cam in place. Remove the top shoulder bolt. ApplyLoctite and re-insert. Tighten bolts completely. CAM SHAFTWhen properly installed, the pivot arms swingfreely in either direction without rubbing theheader or threshold.WARNING: In order to maintain fullengagement of the cam shaft, do not exceedthe 3/16” (5 mm) maximum gap between thetop pivot arm and the bottom of the header. Agreater gap will result in an unsafe condition. MAXIMUMGAP 3/16”TOP SHOULDER BOLTBOTTOM SHOULDER BOLTCat. No. 24221Loctite crlaurence.com usalum.comNOTE: For installations using optional concealedhinge tubes, snap hinge tube cover into place afterinstalling the hinge tube.6ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXSTEP 7: INSTALL THE DOOR (A) Replace the matched damper assembly. Using a largeflat head screwdriver, pry the track up and into position. Thiswill give you the leverage necessary to overcome the returnspring pressure of the damper. When in place, attach thedamper plate with 4 - 1/4”- 20 X 1” Socket Head Cap screws.Apply Cat. No. 24221 to each screw and tighten securely.Cat. No. 24221Loctite Have an assistant hold the bottom pivot arm tokeep the hinge tube stationary while installingthe door.Lift the door at an angle and set the bottomcup of the pivot block onto the pivot arm pinas shown. Hold the top of the door at an angleso it clears the header. Make sure the door issecurely seated onto the bottom pivot arm bygently rocking it.SHIMWASHERIMPORTANTSTEP(B) Place the correct Shim Washer onto theBottom Pivot Pin to prevent the door fromrubbing the Pivot Arm. (3 sizes supplied) A3/32”-1/8” (2-3 mm) gap is recommended.BOTTOMPIVOT PINDOOR BOTTOM VIEW FROM EXTERIORNOTE: A SHIM WASHER MUST BE PLACED ONTOEACH BOTTOM PIVOT PIN PRIOR TO INSTALLINGDOORS. WASHER OMISSION MAY RESULT INDOOR FAILURE.(C) Swing the door upwards as you guide the top roller into the track. If necessary, pry the top pivot arm up slightly until itclears the pivot block. Have an assistant hold the door verticalwhile you align the top pivot arm with the top pivot block.(D) Insert the top pivot arm TOP PIVOT ARM SHAFTshaft into top pivot arm asshown. The set screw fitsGROOVEinto the groove to hold thetop pivot arm shaft in place.Apply Loctite to set screwCat. No. 24221Loctiteand tighten securely.TOP PIVOT ARM(E) Make sure the closing speed and latching speed valves areFULLY OPENED to allow the door to swing unrestricted. (Page 8,Step 9)CAUTION: Use care when adjusting the damper valves.Excessive pressure may strip the threads. To fully open, gentlyturn each valve counterclockwise until it bottoms out against thedamper body.crlaurence.com usalum.comSET SCREW7ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXSTEP 8: ADJUST CLOSING FORCEUse the tension adjustment gearbox at the base of each hinge tube to adjust the closing force of the doors.TENSION ADJUSTMENT GEARBOXRIGHT SIDENOTE: Both damper valves should be fully open from Step 7E. Ifnot, carefully open them before adjusting the closing spring force.Use the Pawl Tool to release the force of the torsion tube spring.Pulling back on the Pawl Tool while holding the Hex Wrenchallows the spring tension to relax in a controlled manner. Withoutthe Hex Wrench in place the torsion spring will rapidly unwind tozero force.PAWL TOOL1/2” HEX WRENCHRemove the Pawl Tool and use the Hex Wrench to ratchet up thetorsion spring force to the desired level. For a right side gearbox,as illustrated, a counterclockwise motion will INCREASE the tubetension.STEP 9: ADJUST CLOSER SPEEDBOTTOM VIEW OF DAMPERCLOSING SPEED VALVELATCHING SPEED VALVEThe damper is a two stage device that regulatesthe speed at which manual closing occurs. Thevalves should be fully opened from Step 8.Have an assistant open the door from the exteriorside to the maximum position. Turn the closingspeed valve 1/4 turn. While gently holding it toprevent slamming, let the door fully close twotimes. Repeat the procedure until the door closesat a desired rate of speed.Repeating the same cycling procedure, close thelatching speed valve until you see a noticeablespeed drop at the last 10 -12” of travel. You mayneed to readjust the closing speed valve until youreach a desired overall performance. Each valveadjustment affects the other.Optimum closing action requires a delicate balancebetween the closing speed, latching speed andspring tension. Adjustment patterns will also varyfrom one door to another. Be sure to let the doorcycle several times before changing the settings.USE 5/16” HEX WRENCH TO ADJUST DAMPER VALVES.(LOOSEN COUNTERCLOCKWISE)crlaurence.com usalum.com8ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXSTEP 10: ADJUST PIVOT BLOCKVIEW FROM EXTERIORThe adjustable pivot blocks located on the top and bottom of eachdoor can be used to reduce small gaps and misalignments. Theretaining screws are easily accessible without removing the door.PIVOT BLOCKOpen the door 45 degrees and block the bottom outside stile up offthe floor with tapered wood shims. Only adjust one pivot block ata time. Loosen but do NOT remove the retaining screws. Adjust tothe desired gap by adding or removing shims. Tighten the retainingscrews, close door and check gaps. Misalignments up to 1/4” canbe corrected with this procedure.DOOR GAPWARNING: Do not attempt this procedure without an assistant.Heavy, uncontrolled doors can cause serious injuries. Do NOTremove the retaining screws. TOP PIVOT ARM NOTE: After adjusting door alignment. Remove onescrew at a time. Apply Cat. No. 24221 Loctite 242 to threads and re-insert.PIVOT BLOCKRETAINING SCREWSCat. No. 24221LoctiteTOP VIEW REFERENCERIGHT HAND REVERSED DOOR SHOWNINTERIOR SIDEGUIDE ROLLERTOP PIVOTBLOCKPIVOT ARMRIGHT JAMB DAMPER ASSEMBLYEXTERIOR SIDECAM ASSEMBLYLHRHLHRcrlaurence.com usalum.com9RHRALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXCOMPONENT OVERVIEWHEADER DETAIL SHOWN FROM INTERIOROPERATORCONTROLLERDAMPER ASSEMBLYCLOSE MODULEOPERATOREXTERIOR VIEWHEADERTOP PIVOT ARMTOP PIVOT BLOCKHINGE TUBEBOTTOM PIVOT BLOCKBOTTOM PIVOT ARMHINGE JAMB BASE PLATELEFT HAND REVERSE DOORcrlaurence.com usalum.comRIGHT HAND REVERSE DOOR10ALUMINUM

CRL PREMIUM BALANCED DOOR WITH GEARBOXMAINTENANCEProper maintenance is critical to the life and operation of the Premium Balanced Door System. It is importantto regularly clean environmental debris from areas adjacent to moving parts such as bearings, roller tracksand gear assemblies.DO NOT LUBRICATE MOVING PARTS. Each component is shipped from the factory with ample lubricationand if kept clean will provide a long service life. Compressed air, soft clean towels and a small brush arerecommended for most cleaning and maintenance procedures.TOP ROLLER TRACK(Check Monthly)*Wipe dirt and debris from inside track with adamp cloth. Check for smooth operation.NOTE: The top roller track (damper and camplates) are manufactured from bronze alloyand are clear coated with a strippable material.Periodic refinishing may be required tomaintain their original luster.TOP PIVOT ARM(Check Monthly)*Wipe debris from arm and pivot block.Blow away any dirt between block andarm joint.WEATHER STRIPS(Check Monthly)*Blow dirt from pyle and wipe off any excessmoisture.DOOR GLASS(Check Regularly)*Clean with conventionalglass cleaners.Avoid build up of roadgrime and hand prints.BRUSHED STAINLESS(Check Regularly)*Wipe down with a damp towel on a regular basis.Remove any build up of salt and road grime.TENSION ADJUSTMENT(GEARBOX OR WORM GEAR)(Check Regularly)*Blow away dirt. Brush or wipegrime away from surroundingarea.BOTTOM PIVOT ARMDry excessive moisture.(Check Regularly)*Wipe debris from arm and pivot block.Blow away any dirt between block andarm joint.*Inspection intervals are suggestions. Inspection and maintenance should be based on actual cycle levelsand environmental conditions.crlaurence.com usalum.com11ALUMINUM

Bottom Pivot Pin to prevent the door from rubbing the Pivot Arm. (3 sizes supplied) A 3/32”-1/8” (2-3 mm) gap is recommended. Have an assistant hold the bottom pivot arm to keep the hinge tube stationary while installing the door. Lift the door at an angle and set the bottom cup of the pivot block onto the pivot arm pin as shown.

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