Detailed Installation Guide for Industrial Overhead Doors

1. Installing Side Tracks

• Select tracks 5-10cm longer than the door panel height

• Ensure vertical alignment with ≤2mm/m deviation using a level

• Pre-drill mounting holes at ≤60cm intervals and secure with M10 expansion bolts

2. Fixing Main Tracks

• Install with a 1:1000 slope (1cm tilt per 10m height)

• Track joint misalignment must be ≤0.5mm

• Bottom track should be 50±2mm from the wall

• Verify alignment using a laser level

3. Installing Key Components

Install in sequence:

1. Bearing brackets

2. Torsion spring (must match door weight within ±5%)

3. Cable drum (marked with rotation direction)

4. Fixing flange

• All fasteners must be torqued to specifications

4. Assembling Door Panels

• Ensure levelness with ≤3mm deviation across full length

• Hinge installation sequence:

• Install load-bearing bottom hinges first

• Middle hinge spacing error ≤5mm

• Install top hinges last

• Panel gaps must be ≤2mm

5. Winding Torsion Springs

Safety Precautions:

• Requires two-person operation

• Establish a safety perimeter

• Use specialized winding tools

Calculation:Number of turns = (Door height × Door weight) / (Spring coefficient × πD) Cable tension must reach 120% of design value

6. Motor Installation

• Motor shaft and drive shaft alignment ≤0.1mm

• Wiring specifications:

• Power cable ≥1.5mm²

• Grounding resistance ≥10MΩ

• Set overload protection parameters

7. Testing & Commissioning

Test Procedures:

• 10 no-load operation cycles

• 5 load-bearing operation cycles

• Emergency manual operation test

• Photoelectric safety sensor test

Acceptance Criteria:

• Operating noise ≤65dB

• Lifting speed meets design requirements

• All safety devices function properly

Frequently Asked Questions (FAQ)

Q1: How to calculate torsion spring specifications?

A: Use the formula: Spring torque = (Door weight × Door height) / (2 × π × Safety factor). Consult an engineer for precise calculations.

Q2: Why must tracks be installed with a slope?

A: The 1:1000 slope ensures the door naturally leans toward the building during operation, preventing wind-induced sway and reducing track stress.

Q3: What causes frequent motor overload protection triggers?

A: Potential causes: ① Insufficient spring balance ② Excessive track resistance ③ Voltage fluctuations ④ Motor power mismatch. Troubleshoot systematically.

Q4: How to address operational noise?

A: Check: ① Track lubrication ② Hinge tightness ③ Cable wear ④ Spring tension balance. 85% of noise stems from inadequate lubrication.

Q5: What routine maintenance is required?

A: Key maintenance tasks:

1. Monthly track and hinge lubrication

2. Quarterly cable wear inspection

3. Biannual safety device tests

4. Annual professional spring system servicing

Maintain a service log for all maintenance activities. Contact the installer for professional support when needed.