Wayne Dalton Garage Door Opener DS 350 User Manual

DS-350 COMMERCIAL ROLL-UP DOORS  
WINDLOAD RATED  
INSTALLATION INSTRUCTIONS  
IMPORTANT NOTICE!!  
Read the enclosed instructions carefully before attempting to install this door. Pay close  
attention to all warnings and important safety notices.  
This manual MUST be attached to the wall in close proximity of the door.  
©Copyright 2002 Wayne-Dalton Corp.  
P/N 291341, DOC #101-0093-1 REV 02  
 
INTRODUCTION  
This manual's main function is to assist the installer in correctly mounting doors with due regard for safety,  
operation, and sound construction practices. Reference must be made to construction codes in your area.  
All Wayne-Dalton DS-350 Windload Rated Commercial Roll-Up Doors follow the general instructions contained  
herein. Additional installation information for the specific door shipped is found with the packing slip and on  
supplementary drawings. There are also bolt and small sealed parts bags with accessory lists, describing proper  
application.  
PREPARATION  
Read the installation instructions thoroughly to become familiar with the names of the various components and their  
relation to each other. It is necessary for the installer to determine the following:  
° Method of operation (push-up, hand chain, or motor operated).  
° Type of jamb (masonry or steel) on which the door mounting angles mount and the fasteners required.  
° The dimensions for the opening width, opening height, headroom, and side room.  
MATERIAL  
Inspect your door for possible damage or shortage of parts. Report any shortages to your door supplier immediately,  
or transit related damage claims to your freight carrier.  
CLEARANCES  
Check the door opening dimensions and available clearances versus the dimensions listed on the packing slip. Be  
sure that the dimensions are correct for the opening you are working on, taking special note of the opening width  
and height. Be sure that the required clearances listed on the Dimension Tables in this manual are available prior to  
installation.  
TOOLS  
The tools recommended for proper installation of each door will vary, but commonly used tools are:  
° Electric drill with 3/8" or 1/2" chuck with nut driver bits  
° Masonry drill or impact hammer and bits.  
° Chain hoist and sling for raising barrel and curtain assembly.  
° Scaffolding, Mechanical Lift, and/or Ladders (ladders not recommended for larger doors).  
° Hammer.  
° Channel Lock Pliers  
° Center punch.  
° Screwdrivers.  
° Drills.  
° Wrenches, vise grips, C-clamps, torque wrench, and a large pipe wrench.  
° Plumb line, tape measure, chalk line, and a water level.  
3
 
STEP 1 UNPACKING DOORS  
Doors shipped by common carrier arrive at the job site packed in cardboard. Before removing the door from the  
packaging, inspect the door and packaging for visible signs of damage. If damage is noted, file a freight claim with  
the freight company immediately. Remove the door from the packaging.  
Do not cut tape that holds door in a roll. You will be told in  
IMPORTANT!  
step #7 when to cut tape.  
No guarantee will be given by Wayne-Dalton Corp. if the door is not erected as instructed. For best operation, follow  
the instructions step by step. Please review all instructions thoroughly before starting installation.  
STEP 2 CHECK THE DOOR OPENING  
Verify the opening measurements with the door packing slip. Consult the factory if the actual opening width varies  
from that shown on the packing slip by more than 2 inches. Check door jambs, header, and floor for plumb/level  
condition. Check that there is sufficient clearance at jambs and head (see Dimension Tables below).  
Left hand operated door shown above. Right hand is opposite.  
NOTE:  
OPERATION  
A
OPENING HEIGHT  
UP TO 8’ HIGH  
B
C
PUSH-UP  
6”  
9”  
8”  
20” 10”  
DIRECT DRIVE CHAIN/MOTOR  
REDUCED DRIVE CHAIN  
FROM 8’ TO 10’ HIGH 22” 11”  
OVER 10’ HIGH 24” 12”  
DIMENSION TABLES - MINIMUM OVERHEAD CLEARANCE (B) INDICATED  
4
 
STEP 3 INSTALLING MOUNTING ANGLES AND GUIDES  
Obtain the appropriate Bolt Line (BL) measurement from the chart below. Use Opening Width listed on packing  
slip. Any variation between the actual opening width and the width listed on the packing slip is to be ignored.  
OPENING WIDTH  
BL  
BL  
ANGLE FACE TO ANGLE FACE  
(STEEL) (MASONRY)  
UP TO 10’ WIDE  
OVER 10’ WIDE  
1-9/16”  
1-7/16”  
4-15/16”  
4-7/8”  
OPENING WIDTH + 6-11/16”  
OPENING WIDTH + 6-7/16”  
Use BL measurement to locate wall mounting angle for one  
jamb only. Second angle will be located using Angle Face to  
Angle Face measurement.  
IMPORTANT!  
Using the BL measurement, loosely  
clamp the right hand wall angle to the  
right hand jamb. Position the wall angle  
such that the BL measurement falls near  
the center of the slots. Adjust the wall  
angle so that it is level and tighten the  
clamp. Install wall angle fasteners in the  
centers of the top and bottom slots only  
and tighten.  
Select the appropriate Angle Face to  
Angle Face equation from the chart  
above. Add the opening width listed on  
the packing slip to obtain the Angle  
Face to Angle Face measurement. Use  
this measurement to locate the left hand  
wall angle on the left hand jamb and clamp in place. Install the top and bottom bolts in the wall angle. Verify that  
both wall angles are level and double check the angle to angle measurement at the top, middle, and bottom to ensure  
that the wall angles are properly located. Using a string and a level, ensure that the mounting angles are parallel to  
each other, shimming if necessary, to achieve both vertical and horizontal leveling. Now install the remaining bolts  
in both wall angles.  
Angle Face to Angle Face measurement  
must be held to ensure proper door  
operation and resistance to windload.  
IMPORTANT!  
Use of any other fasteners than those  
provided must be approved by  
manufacturer or building authority and  
cannot be of lesser diameter or grade.  
IMPORTANT!  
Align the guide slots with the slots in the wall angles and fasten guides with the interior  
windlock return towards the door jamb using the 5/16-18 x 5/8” truss head bolts,  
washers, and flange nuts. Slide guides to set the “H” dimension as shown above at 1-3/4”  
prior to tightening the guide fasteners.  
5
 
Trim the top of each wear strip at a 45° angle as shown and clip onto the appropriate  
leg of each guide. Be sure that trimmed edges of the wear strips end just below the  
flare of the guides. Install the bottom bar stops with the same 5/16-18 x 5/8” truss  
head bolts and flange nuts used to assemble the guides (no washer). Leave the  
fasteners loose to allow the bottom bar stops to pivot out of the wayof the bottom bar  
angle when the curtain will be pulled into the guides. You will be instructed to  
tighten the bottom bar stop fasteners in step #7.  
STEP 4 INSTALL BRACKETS AND DRIVE COMPONENTS  
From the Dimension Tables on page 4, mark the width location of each bracket by using dimension A for the  
operator side and 6” for the non-operator side. If the actual opening width varies from the packing slip width, adjust  
these dimensions by adding or subtracting ½ of the difference to each dimension. Subtract if the opening is larger  
and add if smaller. Mark the height location of the brackets by using dimension C. Verify the ceiling clearance  
minimum from dimension B. Use a string and a level to verify that the brackets are level with each other. Adjust  
bracket height as needed to level. Drill anchor holes and fasten the brackets with the anchors provided.  
Brackets must be level to each other with respect to height.  
Failure to level bracket heights will prevent door from  
operating properly.  
IMPORTANT!  
If the door is to be chain hoist or motor operated, install the components shown below to the operator side of the  
curtain at this time using the fasteners provided. Do not tighten set screws at this time, you will be instructed to  
tighten these in step #9.  
Keep loose clothing, fingers, hands and arms away from all  
moving mechanisms, or serious injury or death could result.  
WARNING  
STEP 5 LIFTING THE DOOR ASSEMBLY  
Door assembly is extremely heavy. Do not allow door  
assembly to fall from lifting mechanism, or serious injury or  
WARNING  
death could result.  
Lift door assembly up to door support brackets. Care should be taken to avoid any damage to the curtain. Make sure  
that the door assembly is centered between the guides and that clearance between the windlocks and the guides is the  
same on both sides. Adjust door assembly location as needed. Place the axle saddle castings under the axle on each  
6
 
side and position the door as close as possible to the door header. Be sure that the door is able to revolve without  
scraping against door header or guides. Rotate door assembly so that bottom bar angle is at bottom of curtain roll.  
To avoid serious injury or death, never walk, stand, or work  
below door assembly before it is secured to support brackets.  
WARNING  
STEP 6 SECURE AXLE SADDLE CASTINGS  
Making sure that the bottom bar angle is at the bottom of the  
curtain roll; place the axle saddle castings around the axle on each  
side, with the flat keeper plate on top. Install the 3/8-24 x 3-1/2”  
bolts, flat and lock washers, and 3/8-24 nuts as shown. Be certain  
to tighten both nuts to a torque of 40 foot-pounds. Spring tension  
will be lost if both axle saddles are not tightly secured.  
Axle saddles hold extreme spring tension. Loose axle saddles  
could result in loss of spring tension, causing door to fall,  
possibly producing serious injury or death.  
WARNING  
STEP 7 PRE-TENSION THE DOOR SPRINGS  
Starting with the bottom bar angle at the bottom of the curtain roll, apply two complete  
turns of pretension to the springs by rotating the curtain roll in the direction shown. The  
amount of tension required may vary slightly. Final adjustment, if necessary, will be made  
in Step #10.  
Spring tension can cause curtain roll to rotate rapidly.  
Securely hold curtain roll from rotating while applying  
pretension or serious injury or death could result.  
WARNING  
Securely hold door curtain until bottom bar stop fasteners  
have been tightened. If not securely held, door may raise or  
drop, possibly causing injury or death.  
WARNING  
Do not apply pretension to larger  
doors using ladders. Ladders may fall  
causing serious injury or death.  
WARNING  
Cut the tape that holds the door in a roll and gently pull the curtain down into the  
guides on both sides until the bottom bar is below the bottom bar stops. Do not pry on  
the bottom bar stops to get bottom bar past, loosen fasteners until bottom bar angle  
easily clears stops. If the door has a tendency to close, secure in position using clamps.  
If the door has a tendency to rise, secure in position using a wood prop as shown.  
While the door is secured from moving, tighten the bottom bar stop fasteners on both  
guide assemblies.  
Tighten bottom bar stop fasteners with impact gun  
to prevent bolts from spinning.  
HINT:  
7
 
STEP 8 INSTALL SLIDE BOLT LOCKS  
Install slide bolt locks, if provided,  
as shown.  
Install the lift handle to bottom bar  
angle at this time.  
STEP 9 LUBRICATE AND ADJUST THE GUIDES  
Lubricate the insides of the guides and wearstrips with weather resistant lubricating spray. Be sure to spraylubricant  
over the flares at the tops of the guides. Move the door up and down to check for proper operation. Adjust the guides  
and mounting angles if necessary to allow for proper clearance and operation.  
If door is difficult to move up and/or down due to spring imbalance,  
continue on to step #10 and return to step #9 once springs are properly  
adjusted.  
HINT:  
STEP 10 CHECK AND ADJUST SPRING BALANCE  
It is strongly recommended that two or more installers perform  
this next step.  
IMPORTANT!  
Never remove bottom bar stops when adjusting tension,  
otherwise, door can spin uncontrollably resulting in serious  
injury or death.  
WARNING  
If the door lowers easily and raises hard, more spring tension is required. If the door lowers hard and raises easily,  
less spring tension is required. Before adjusting the spring tension, be sure that the door is in the full up position.  
Secure the door in the full up position to prevent the door from falling if the adjustment wrench slips. Use one of  
these methods:  
Tie a rope around the door roll and bottom bar angle.  
Place a clamp on guides holding the door securely at the stops.  
Always stand to one side of wrench when adjusting tension.  
Never adjust tension with wrench in front of/above you. This  
will help avoid serious injury if you lose control of wrench.  
WARNING  
8
 
Place a large pipe wrench in position on the door axle as shown and slightly  
loosen both axle saddle castings. Pull down on the wrench for more spring  
tension and let up on the wrench for less spring tension.  
As saddle castings are  
loosened, hold wrench securely.  
WARNING  
Springs are very strong and can  
cause serious injury if not controlled properly.  
Tighten both axle saddle castings per Step #6 while holding the pipe wrench  
firmly to maintain desired adjustment. Let off the pipe wrench tension only  
after the nuts on both axle saddle castings are tightened back to 40 foot-pounds.  
When removing pipe wrench from axle, slowly reduce applied  
tension until wrench is free from axle. This will help avoid  
serious injury in event that saddle castings have not been  
tightened sufficiently.  
WARNING  
Test the door as in Step #9 above. Repeat the above procedure if further adjustments are required. Once all  
adjustments have been made and the door is operating properly, recheck all fasteners and bolted connections to  
ensure that they are in place and properly tightened. Tighten all set screws in the components installed in step #4.  
STEP 11 INSTALLATION OF TOP DRAFT STOP  
Close the door and secure it in the down  
position. Use a pencil to mark the door panel  
corrugation that is parallel with the bottom of  
the header/lintel from the outside of the  
opening. If this corrugation protrudes below the  
header, mark the one just above. Open the door  
until the marked corrugation is accessible.  
Stretch the top draft stop across the door and  
attach it to the curtain on the marked  
corrugation with the #8 x ½” self-drilling  
screws provided, locating the screws every 12"  
on center. Trim the Top Draft Stop to clear the  
guides if required. When the door is closed, the  
draft-stop should seal on the header.  
Top Draft Stop may not seal on header if not installed on a corrugation as  
shown.  
NOTE:  
9
 
REDUCED DRIVE CHAIN HOIST INSTALLATION INSTRUCTIONS (if applicable)  
STEP 12 ALIGN THE SPROCKETS  
Feed the hand chain through the pocket wheel assembly (installed in step #4),  
around the cast iron hand chain wheel, and connect the two end links.  
Align the chain hoist so that the 41B9 sprocket on the pocket wheel assembly is  
in line with the 41A40 sprocket bolted to the barrel. Next, tighten the hoist-  
locking bolts to lock the pocket wheel assembly to the shaft to prevent it from  
shifting or rocking.  
Hoist locking bolts must be tight to ensure hoist cannot shift  
and permit roller chain to come off, thereby allowing door to  
drop possibly causing severe injury or death.  
WARNING  
Next, connect the #41 roller chain between the pocket wheel assemblysprocket and the barrel sprocket. Now run the  
door up and down several times to ensure that the roller chain does not come off. If it does, go back and check the  
alignment of the sprockets.  
Keep loose clothing, fingers, hands, and arms away from all  
moving mechanisms and places where chain meets either  
sprocket, or serious injury or death could result.  
WARNING  
STEP 13 INSTALL THE CHAIN KEEPER  
Now install the hand chain keeper to the wall  
approximately four feet above the finished floor with the  
hardware provided. Refer to the figure in step #7 of this  
manual for an additional view.  
10  
 
Item  
1
Description  
Item  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
Description  
Top Sheets - Give Length  
1/4-20 x 1” Slotted Screw, Washer & Nylon Nut  
Mounting Angle, Give Mounting Condition, Give Length  
Direct Drive Chain Wheel  
2
Intermediate Sheets - Give Length  
Bottom Sheet Assembly - Give Length  
Guide, Left Hand or Right Hand (Right Hand Shown)  
Axle - Give Length  
3
4
Chain Retainer Clip  
5
Direct Drive Chain Guide  
6
Drum Assembly  
1/2" Collar (Not Shown)  
7
Spring - Right - Give Length & Wire Diameter  
Spring - Left - Give Length & Wire Diameter  
Spring Clip  
5/16” Polypropylene Rope  
8
Electric Operator Sprocket  
9
Electric Operator Mounting Bracket  
Electric Operator 3/8” x 3” Bolt & Tube  
Drum Bearing  
10  
11  
12  
13  
14  
15  
16  
17  
Left Mounting Bracket – Based on Door Size - Give Type  
Right Mounting Bracket – Based on Door Size – Give Type  
Axle Saddle  
Bottom Bar Stop, 5/16-18 x 5/8” THMS & Flange Nuts  
Lift Handle (center mounted)  
Keeper Plate  
3/8-24 x 3½” Axle Bolt + Washer, Lock Washer, & 3/8” Nut 31  
3/8” x 5” Wedge Anchor  
Lift Clip - Edge Mounted  
Spacer Nut  
32  
33  
5/16-12 x 1” Self-Drilling Screw and Washer  
Guide Fasteners, 5/16-18 x 5/8” THMS, Washers & Nuts  
Slide Bolt Lock  
11  
 
Roll-Up Sheet Door  
LIMITED WARRANTY  
Wayne-Dalton Corp  
P.O. Box 67- Mt. Hope, Ohio 44660  
The Manufacturer warrants the ROLL-UP SHEET DOOR and hardware fittings for a period of ONE YEAR from the time of  
delivery against any defects in workmanship or material. Manufacturer shall, upon notification, correct such nonconformity at its option, by  
repairing or replacing any defective part or parts.  
NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THE FOREGOING  
WARRANTIES IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.  
The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper  
storage, unauthorized service, alteration of products, neglect or abuse, or attempt to use the products for other than the customary usage or  
for their intended purposes. The ROLL-UP SHEET DOOR warranty becomes null and void if other than Manufacturer’s specified holes are  
drilled. The above warranty does not cover wear or any damage beyond Manufacturer’s control or replacement labor.  
THIS WARRANTY COVERS A COMMERCIAL PRODUCT, THE FOREGOING WARRANTIES ARE IN LIEU OF ALL  
OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESSED OR IMPLIED,  
(INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR  
PURPOSE), ARE MADE BY MANUFACTURER IN CONNECTION WITH MANUFACTURE OR SALE OF ITS PRODUCTS.  
Claims for defects in material and workmanship covered by this warranty shall be made in writing to the dealer from whom the  
product was purchased within the warranty period. Manufacturer may either send a service representative or have the product returned to the  
Manufacturer at Buyer’s expense for inspection. If judged by Manufacturer to be defective in material or workmanship, the product will be  
replaced or repaired at the option of Manufacturer, free from all charges except authorized transportation and replacement labor.  
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES.  
THE LIABILITY OF MANUFACTURER, WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE,  
SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART  
FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE  
LIABLE FOR COST OF REMOVAL OR INSTALLATION OR SHALL NOT BE RESPONSIBLE FOR ANY DIRECT, INDIRECT,  
SPECIAL, OR CONSEQUENTIAL DAMAGES OF ANY NATURE.  
This warranty gives you specific legal rights which may vary from state to state. However, some states do not allow limitations on  
how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations or  
exclusions may not apply to you.  
Wayne-Dalton Corporation  
Door & Systems Division  
2589 County Road 168  
Dundee, OH 44624  
1-800-795-5095  
12  
 

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