574 West Otterman Street • Greensburg, PA • 15601 Toll Free: (800) 979-7300 • Local: (724) 834-7300 Fax: (724) 830-2871 • Email: [email protected] DOOR COMPANY 47" TO 49" M.O. Installation Instructions for Overly GSA Class 5 Vault Door General Information The primary purpose of the Overly Class 51 7/8" FRM. WD. 5 Security Vault Door is to provide protection of records and other valuable or sensitive material against burglary and/or surreptitious attack. If installed as directed the Security Vault Door and Frame unit meets Federal . Specification AA-D-600D (Class 5-V). The T H M. frame is a clamp-on design and is not M.O. intended to be filled with grout after R 83" 4" F installation. O 1/ Each Overly Class 5 Vault Door unit is 84 shipped in one palletized container of GSA 82" T approved dimensions. The container will contain a door and frame; an inside, three piece clamping frame appropriate for the masonry wall thickness specified in the purchase order; and other materials required FIGURE 1 for installation. Net weight for the Class 5 unit is about 1225lbs. Its shipping weight is 2. Remove the lid from the container to about 1400lbs. expose the door unit. Remove all If a GSA Special Item No. 489-154 internal packing and check that the standard Day Gate was specified, it is also following items are included: shipped in the container along with modified inside clamping frame sections. It adds A. Vault Door and frame unit with steel 120lbs. to the shipping weight. spreader permanently attached to the bottom of the frame. (Do not Masonry Opening remove spreader.) The Masonry Opening Dimensions for these doors must have a minimum width of B. Two (2) Inside Clamping Frame 47" and a maximum width of 49", a minimum Vertical Jamb sections notched at height of 82" and a maximum of 83" from the one end. (Top End.) finished floor. C. One (1) Inside Clamping Frame Prior to unpacking the Vault Door, check head section, notched at each end. the masonry opening to make certain that it complies with the above D. One bag containing fifteen (15) 1/2" dimensions as shown in Figure 1. diameter by 1-1/2" long hex head bolts and flat washers for attaching the back frame sections. Installation Procedure 1. Clear all debris and foreign matter from E. One aluminum threshold, notched at around the opening, both on the wall each end, with a bag containing four and floor. (4) 1/4" diameter by 1-1/2" long flat Copyright © 2003 Overly Door Company 1 ENGD-012 Rev#00 01/26/2003 head stainless steel mounting bolts 6. Insert the two all thread rods into the and four expansion shields. anchor blocks located on the interior side of each jamb, approximately 33" F. One box containing either floor- from the top. Tighten them snugly and mounted or wall-mounted doorstop remove the nuts and washers. Place the with related screws and anchors. Temporary Clamping Bar over the all thread and secure the door in position, G. One Temporary Installation Kit, using the two nuts and washers that consisting of two (2) 1-1/2” x 2-1/2” were supplied. wood spreaders, one (1) 2” x 4” wood temporary clamping bar (with 7. The forklift or ratchet hoist and any two drilled holes) and two (2) additional equipment used to raise the lengths of 1/2" diameter all thread door into position may now be removed with nuts and washers. as the door is effectively clamped into the opening. H. One sealed envelope marked "Confidential Information." which 8. Have the inside installer insert the two contains combination lock wood spreaders. Upper spreader is instructions, and change key. This placed 18" down from the top of the sealed envelope also contains two frame. Lower spreader is positioned 18" (2) "Emergency Release Keys", one from the floor. The spreaders must be of which must be supplied to the maintained in position throughout the inside installer before the door is plumbing and shimming operation. hoisted into the opening. (See point 4.). 9. The outside installer, using a 6' or 8' spirit level; places it: 3. Lay the container flat on the floor with the bottom end of the door adjacent to A. Across the frame head flange, to the opening into which the door is to be ensure that it is dead level installed. horizontally. If not, use a pry bar and shims at bottom of appropriate jamb 4. Place one installation person inside the to achieve a true horizontal vault with a flashlight, a pry bar, vise condition. grips, hammer, a ¾” flat open end wrench or an adjustable wrench, the B. On the face of the jambs, to ensure complete temporary installation kit (as that each side is in a true vertical described in part 2.G above), an position. If not use shims behind the emergency release key, and the three outer flange. inside clamping frame sections. It is advisable to provide ear plugs where C. On the edge of the hinge jamb necessary. flange. to ensure that it is truly plumb. Note: Emergency Release Key MUST be supplied to inside installer. 10. The inside installer, using a 3/4" flat open end wrench, extends the 6 hinge 5. Raise the door unit into the vertical side adjustment bolts until they contact position in the doorway and insert into the wall snugly. opening. A forklift or chain hoist may be used to raise the door into position; Do not torque, racking in the frame however, be careful to protect the may occur and cause binding. surface of the door if pushing with a forklift or attaching straps or chains. The 11. The outside installer then, again, checks inside installer should use the pry bar to the edge of the hinge side jamb flange guide the unit into place. to ensure that it remains plumb. If not, instruct the inside installer to tighten Copyright © 2003 Overly Door Company 2 ENGD-012 Rev#00 01/26/2003 or loosen adjusting screws until the the wall. Do not over tighten and warp hinge side is plumb. the frame. 12. Inside installer is to work across head of 16. Take the inside Clamping Frame Head frame, tightening up the adjustment section and insert it into position. Install bolts in 3 locations. the 1/2" diameter x 1-1/2" long hex bolts and washers in each location. Using an 13. Open the door by pressing down on the open end, box end or socket wrench, lever handle. Using only moderate force, tighten the bolts until they are snug. At test for free movement of locking bolts this point the door is firmly secured into and door within the frame. This unit was the opening and the clamping bar. All pre-hung in the factory and inspected for thread and temporary spreaders may be free and easy movement of all parts. removed. Due to manufacturer’s recom- mendations, units shipped with X-09 17. Install the 2 vertical jamb sections in the locks are shipped in the locked position. same manner as the head section. Before attempting to open, the factory Install and snug all 1/2" diameter x 1- combination must be dialed and the lock 1/2” long hex bolts. To final torque bolts, bolt retracted. turn each bolt approximately 1/2 turn. * NOTE: Do not attempt to force the Do not apply excessive torque on the outside lever handle downward as it bolts as this could deform the back contains a shear pin that will break, frame and damage the unit. If the rendering it inoperable. Excessive door has been installed correctly and force on the inside handle when is plumb in all directions, it should following "Emergency Escape" now open easily and freely. procedure may damage it. Avoid Lockouts 14. If door does not open easily, one of two Maintain one person inside the vault conditions has occurred: while working on the door or manipulating the combination lock. A. Frame has slipped out of alignment. This person can override the Double check frame placement with combination by following the spirit level and make appropriate Emergency Escape Procedure adjustment. printed on the label on the face of the access panel. Setting of the B. Someone has manipulated the combination should be done only by combination dial from its factory a qualified Vault Door and safe setting, locking the door. This can specialist. Overly will not pay be determined if the inside installer, charges for correcting lockouts. following "Emergency Escape" procedure is able to unlatch and 18. With the door in the open position, place open the door. the aluminum threshold over the permanent spreader between the jambs Combination must then be reset and mark the floor at each hole location to factory setting following in the threshold. The permanent procedure described under the spreader has been provided with section of the instructions oversize holes that match the threshold, entitled 'Activating Combination drill 1/2" diameter holes to receive Lock at Factory Settings." expansion shields and install the threshold with the supplied fastener. 15. After the door is operating freely, have inside installer make sure that all of the 19. Install doorstop. adjustment bolts are still in contact with Copyright © 2003 Overly Door Company 3 ENGD-012 Rev#00 01/26/2003 Activating Combination Lock at combination and activate its locking mechanism. This may also be done while Factory Settings the door is open, permitting the door to be The Overly door is equipped with a GSA secured automatically upon closing.