MERCOR SA ul. Grzegorza z Sanoka 2 80-408 Gdańsk tel. (058) 341 42 45 fax (058) 341 39 85 www.mercor.com.pl e-mail:mercor@mercor.com.pl
TECHNICAL AND OPERATIONAL DOCUMENTATION GATE mcr TLB Second issue – HD Gdańsk, 05.06.2007
ORDERING PARTY:
steel doors mcr ALPE steel doors mcr ALPE steel doors mcr ALPE steel doors mcr ALPE Gelco Nordic ApS steel doors mcr ALPE steel w w w . g e l c odoors -nordic.dk mcr ALPE
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The technical and operational documentation is subject to recording. Its duplication or distribution without consent of MERCOR SA is forbidden.
Hylkedamvej 70 : DK-5591 Gelsted
Tel.: 45 63 46 54 08 : Fax: +45 6346 5404
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The company MERCOR SA is operating since 1988. We offer comprehensive fire protections for buildings and structures. With our qualified staff and technical facilities, we guarantee a professional service, from evaluation through production to delivery and installation.
The MERCOR SA product range includes:
fire doors, walls and gates, smoke exhaust, heat removal and roof illumination systems, mechanical fire ventilation systems, fire protections of building structures.
CONTENTS TECHNICAL AND OPERATIONAL DOCUMENTATION
1. 2. 3. 4. 5. 6.
Scope and Conditions of Application............................................................................... Execution and Pre-Installation Recommendations.......................................................... Industrial Safety and Fire Protection Regulations........................................................... Gate Installation.............................................................................................................. Terms of Guarantee........................................................................................................ Service............................................................................................................................
page 3 page 3 page 3 page 3 page 17 page 17
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Manufacturer: MERCOR SA, ul. Grzegorza z Sanoka 2, 80-408 Gdańsk, Branch in Gdańsk, 80-722 Gdańsk, ul. Sztutowska 10 The sliding steel fire gates mcr TLB are designed for use as closures of openings in construction partitions of buildings and structures required to be of fire resistance class El 60 or El 120. 1. SCOPE AND CONDITIONS OF APPLICATION The gates can be applied in two positions: as constantly open or as constantly closed. Constantly open gates are held in this position using electromagnetic holders connected to the building fire protection system. During fire, the electromagnet is disconnected automatically and the gate closes automatically in result of the counterweight action. Constantly closed gates serve the function of closures for openings in a construction partition of a specific fire resistance class. These gates are only opened in the cases when it is necessary to walk or drive through. Embedding of fire gates mcr TLB should be performed in accordance with this document. 2. EXECUTION AND PRE-INSTALLATION RECOMMENDATIONS -
Before commencing the installation works, check the completeness (quantity, quality) of the elements of delivery, in accordance with the shipping list enclosed to the delivery. Unloading and storage of elements should be performed keeping the required precautions. MERCOR SA states that they assume no responsibility for modifications introduced by the client.
3. INDUSTRIAL SAFETY AND FIRE PROTECTION REGULATIONS -
Works on installation of gates mcr TLB should be performed in accordance with the rules of industrial safety on the basis of the regulations included in the MBP decree of 28 March 1972, Journal of Laws no. 13, item 93. During installation, operation and repair of fire gates, observe the general industrial safety regulations in force. Works in conditions of special hazard to human health and life should be performed by at least two persons. Employees working at height should wear safety harness as well as connecting and shock absorbing units. Electrical equipment should be connected and operated in accordance with the regulations in force and the operation manuals, and the connection can only be executed by a qualified electrician. Fire-fighting equipment must be installed near the assembly yard. Use of damaged devices or faulty equipment is forbidden. Detailed directions in the scope of industrial safety should be handed to employees against receipt.
Gelco Nordic ApS Hylkedamvej 70 : DK-5591 Gelsted Tel.: 45 63 46 54 08 : Fax: +45 6346 5404 w w w.gelco -nordic.dk
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4. GATE INSTALLATION Gates are delivered in a complete set of component elements. The set includes (fig. no. 1): • Panels • Track • Track fastening bracket • Counterweight shield • Counterweight • Steel line • Built-in handle • Panel connector (upper and lower) • Vertical joint (H-section) • Vertical labyrinth elements (wall) • Vertical labyrinth elements (leaf) • Guard rail element • Shock absorber or guard rail • Closing speed regulator (optionally) • Electrical holder • Electrical holder console • Steel door (in the case of version with door) • Pressing flat bars
Gelco Nordic ApS Hylkedamvej 70 : DK-5591 Gelsted Tel.: 45 63 46 54 08 : Fax: +45 6346 5404 w w w.gelco -nordic.dk
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Figure no. 1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Track Track fastening bracket Panels Counterweight Counterweight shield Steel line Door stop element Built-in handle Upper and lower panel connector Vertical joint Vertical labyrinth elements (wall) Vertical labyrinth elements (leaf) Trolley Electrical holder Electrical holder console Closing speed regulator
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4.1. Preparatory Actions Unpack and identify the elements for assembly. Check whether dimensions of the delivered elements correspond to dimensions of the openings: panels height = opening height + 100 mm track length = opening width x 2 + 575 mm (for single leaf gates) track length = opening width x 2 + 811 mm (for double leaf gates) door stop element height = opening height + 40 mm Also check the directions of opening according to figure no. 2. Figure no. 2
a) gate opened to the left
b) gate opened to the right;
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4.2. Door Stop Element Installation Position the door stop element (for single leaf gates) in a way presented in figure no. 3. For gates opened to the right, the element should be located on the left side of the opening, for gates opened to the left – on the right side of the opening. The base of the door stop element should be located vertically on the floor level. Fasten to the wall using steel anchors, paying attention to correct vertical position of the element. Figure no. 3
1 – Gate leaf, 2 – Door stop element, 3 – Swelling gasket 2x20 mm, 4 – Steel anchor, 5 – Wall
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4.3. Track Installation Suspend the track using the enclosed track brackets (type 1). Keep the distance of 10 mm between the upper part of the door stop element and the track, in order to ensure the track adjustment (fig. no. 4). Pay special attention so that the track is levelled correctly and suspended straight. Figure no. 4
1 – Door stop element, 2 – Track closing box, 3 – Track, 4 – Wall, 5 – Track pins, 6 – Track bracket (type 1) In the case if the track consists of several parts, it should be connected using the pressing flat bars and M6 screws with adequate spacers – the raceways of tracks should be on one level, there should be no offsets. Use brackets of second type in the places of track connection (fig. no. 5). Figure no. 5
1 – Track bracket (type 2), 2 – Track pins, 3 – Track, 4 – Raceways of tracks (on one level), 5 – Pressing flat bar of thickness 6 mm, 6 – Screw M6x25 mm, 7 – Knurled threaded insert M6
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4.4. Closing Speed Regulator Installation Fasten the closing speed regulator (or the bracket with wheel guiding the line, in the case if there is no closing speed regulator) to the track closing box at the end of the track, using M8 screws with nuts (fig. no. 6). Figure no. 6
1 – Door stop element, 2 – Track closing box, 3 – Track, 4 – M8 screw, 5 – Spacer of length approx. 25 mm, 6 – Closing speed regulator Holes in the track closing box: a – holes for guiding the line b – holes for fastening the closing speed regulator c – holes for fastening the line carrying set
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4.5. Suspending the Panels on the Track Before commencing the installation of panels, glue the swelling gaskets 2x20 mm onto the vertical joints (Hsections). In the case of double leaf gates, place the door stop section on one of the H-sections, fasten the entire assembly with screws to the extreme panel of one of the leafs, and apply the gaskets 2x20 mm (fig. no. 7). Figure no. 7
1 – Vertical joint (H-section), 2 – Swelling gasket 2x20 mm, 3 – Door stop section (in double leaf gates), 4 – Panel Then fasten the shock absorber bracket to the first panel of the gate. Fasten the bracket to the panel using four rivets 4x10 mm in the upper part, at the height of the C-section located in the panel (fig. no. 8). Fasten the 3 mm thick steel line to the trolley of the first panel. Figure no. 8
1 – Track, 2 – Panel, 3 – Shock absorber bracket fastened with rivets to the panel Note: the shock absorber bracket should be fastened to the panel before it is suspended in the track.
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Commence the installation of panels from sliding the first panel (with the shock absorber bracket fastened) onto the gate track. Panels are delivered to the construction site with the trolley already fastened. Then put the vertical joint (H-section) against the suspended panel and suspend another panel, pressing it against the Hsection (fig. no. 9). Fasten the suspended panels using the upper connector (omega) with screws M12 (fig. no. 10). Special holes used for fastening the connectors with screws have been prepared in the track. Fasten successive panels in the same way. Fasten the vertical labyrinth with screws to the last panel (fig. no. 12). Finally, fasten the lower connector on both sides of the leaf using self-tapping screws ø4.2x16 mm (fig. no. 11). Figure no. 9
1 – Track, 2 – Panels, 3 – Trolley, 4 – Upper connector of panels (omega), 5 – Vertical joint (H-section), 6 – Lower connector of panels, 7 – Door stop element Figure no. 10
1 – Panel, 2 – Hex head screw M12x40, 3 – Upper connector of panels (omega), 4 – Track, 5 – Hole in the track, making it possible to fasten the panels with screws
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Figure no. 11
1 – Panel, 2 – Lower connector, 3 – Self-drilling screw 4.2x16 Pay attention so that, after installation of the lower connectors, the clearance between the floor and the connector was not bigger than 10 mm. Glue the swelling gaskets to the vertical labyrinth slat of the wall. Fasten the vertical labyrinth slat to the wall on the hole side opposite to the door stop element. Fasten using steel anchors at appropriate distance from the wall edge (fig. no. 12). Figure no. 12
resultant dimension
1 – Panel, 2 – Vertical labyrinth (leaf), 3 – Vertical labyrinth (wall), 4 – Swelling gasket 2x20 mm
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4.6. Guiding Roller Installation Then fasten the guiding roller on the floor, outside the passage opening. Fasten the roller centring the leaf to the floor, using steel anchors (fig. no. 13). Finally, adjust the axial alignment of the guiding elements. Figure no. 13
1 – Guiding roller 4.7. Guiding of Steel Lines Thread the steel line, fastened earlier to the trolley on the first panel, through the line guiding hole in the track closing box (fig. no. 6), then through the closing speed regulator (or the line guiding roller), and through the counterweight roller, and hook it on the closing speed regulator roller (fig. no. 14). Figure no. 14
1 – Trolley, 2 – Steel line, 3 – Track closing box, 4 – Closing speed regulator, 5 – Counterweight
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The lines should run “under” the trolleys of successive panels. The length of the line should be adjusted so that after closing the gate the counterweight does not rest on the floor. The counterweight should be balanced so as to ensure smooth operation of the gate, and so that the force necessary to open the gate does not exceed 250 N (approx. 25 kg). Adjust accordingly the closing speed regulator, using adequate adjustment screw. The speed of the automatic leaf movement during closing should not be less than 0.08 m/s and should not be greater than 0.2 m/s. The gate leaf should move smoothly, with constant speed, without jamming or halting in motion. 4.8. Shock Absorber Fastening Fasten the shock absorber to the shock absorber bracket fastened with rivets to the first panel. Fasten the shock absorber guard rail to the track using self-tapping screws (or rivets) (fig. no. 15). Adjust accordingly the shock absorber. Note: remove the metallic disk protecting the shock absorber magnet. Figure no. 15
1 – Shock absorber, 2 – Shock absorber fastening bracket (fastened with rivets to the panel), 3 – Shock absorber guard rail (fastened to the track), 4 – Panel, 5 – Track, 6 – Track closing box
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4.9. Gluing of Swelling Gaskets The swelling gaskets of cross-section 2x20 mm should be glued in two rows on the top “collars� of panels (fig. no. 16). Figure no. 16
Also glue two rows of swelling gaskets on the upper connectors of panels (omegas) (fig. no.17). Figure no. 17
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Glue three rows of swelling gaskets on the trolleys (fig. no. 18). Figure no. 18
4.10. Installation of the Counterweight Shield and the Track Shield Fasten the counterweight shields to the wall using steel anchors, and to the door stop element using screws. In the case of gates El120, additionally fasten the track shield. 4.11. Final Actions Fasten the hand-rails and finally once again check the gate operation. Remove the protective film.
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5. TERMS OF GUARANTEE 1. MERCOR grants a guarantee for the delivered products for the period of min. one year, unless the guarantee period is specified in a separate contract. 2. The defects revealed in this period, preventing the correct operation of the product, shall be rectified within 21 days from the date of reporting. 3. The guarantee shall be extended automatically by the period from reporting the complaint to completion of the guarantee repair. 4. The products being in the guarantee period, in which any defects are found preventing their further operation, shall be replaced with products of full value. 5. The guarantee does not cover the actions specified in this documentation that should be performed by the user on their own. 6. The manufacturer is absolved from the guarantee and any obligations in the case if: products are damaged mechanically in result of improper operation by the user, the user has made modifications to the construction on their own, defects occur in result of product maintenance performed not in accordance with these instructions, defects occur in result of improper storage or transport, product installation by the user is not performed in accordance with the installation instructions, product data plate is removed. 7. In the case of a complaint related to the product, the manufacturer deducts the equivalent of the elements missing or damaged through the user’s fault, and the cost of their replacement. 8. The condition for granting a guarantee for a period longer than 3 years is the conclusion of a service contract with MERCOR SA. 6. SERVICE In order to ensure correct functioning of the fire gates and to keep the rights resulting from the guarantee, the gates should be subjected to periodical inspections and maintenance at least once per 6 months. After the inspection, replace or repair the damaged or worn parts.
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Arkońska Arkońska Business Business Park Park ul.ul. Arkońska Arkońska 6 bud. 6 bud. A2A2 80-387 80-387 Gdańsk, Gdańsk, Poland Poland tel.: tel.: +48 +48 5858 732 732 6363 0000 fax: fax: +48 +48 5858 732 732 6363 0202 mercor@mercor.com.pl mercor@mercor.com.pl
www.mercor.com.pl www.mercor.com.pl Arkońska Business Park ul. Arkońska 6 bud. A2 80-387 Gdańsk, Poland tel.: +48 58 732 63 00 Hylkedamvej : DK-5591 Gelsted fax: +48 58 732 70 63 02 mercor@mercor.com.pl
Gelco Nordic ApS
Tel.: 45 63 46 54 08 : Fax: +45 6346 5404
w wwww.mercor.com.pl w.gelco -nordic.dk
Arkońska Business Park
Photos: Mateusz Grzanka and company archives Photos: Mateusz Grzanka and company archives ul. Arkońska bud. A2 Gelsted Gelco Nordic ApS Hylkedamvej 70 : 6DK-5591 Tel.: 45 63 46 54 08 : Fax: +45 6346 5404 80-387 Gdańsk, Poland w tel.: w +48 w .58g732 e l63c00o - n o r d i c . d k
fax: +48 58 732 63 02