Clopay EZ-SET - User Manual

EZ-SET
®
Torsion Spring System
Assembly Installation Instructions
EZ-SET
®
Torsion Spring
System Assembly
Installation Instructions
These instructions are to be used in conjunction
with your standard installation manual. Follow
the manual up through “Assembling & Installing
the Track” — except leave a minimum of
1
/2" per
side between track and door, and just loosely
(temporarily) attach
3
/8"-16 x
3
/4" carriage bolt
in ag bracket.
Please read and understand these instructions
completely before proceeding with the instal-
lation of the EZ-SET
®
Torsion Spring System.
Carefully follow these instructions to avoid
personal injury or property damage.
Use these instructions for the EZ-SET
®
Torsion
Spring System only. (If you have regular
torsion springs, extension springs, or the
EZ-SET® Extension Spring System see the stan-
dard Installation Manual.)
Tools Needed
•
3
/8" Medium duty reversible power drill
•
3
/8" Open end wrench
•
3
/16" Hex wrench
•
1
/8" Drill bit
•
1
/4" Insert bit (included)
In the interest of safety this symbol means
WARNING or CAUTION. Personal injury
and/or property damage may occur unless
instructions are followed carefully.
ALL REFERENCES TO LEFT HAND AND RIGHT HAND ARE MADE ASSUMING
THAT YOU ARE INSIDE THE GARAGE LOOKING OUT.

Summary

EZ-SET Torsion Spring System Assembly Installation Instructions

Tools Needed

Lists the required tools for installing the EZ-SET Torsion Spring System.

Safety Warning Symbol Explanation

Explains the meaning of the safety symbol indicating potential personal injury or property damage.

Parts List

Installing The EZ-SET Torsion Spring System

Step 1: Bracket Attachment

Attach brackets to the flag bracket and horizontal angle using carriage bolts and flange nuts.

Step 2: Tube Coupler Installation

Insert torsion tube sections into the coupler and secure with sheet metal screws.

Step 3: Measure Spring Length

Measure and record the relaxed length of each torsion spring on a flat surface.

Step 4: Assemble Components onto Tube

Slide springs, drums, winding units, and end bearing support onto the torsion tube.

Step 4 a: Connect Spring Plug to Winding Unit

Connect the spring plug to the winding unit, ensuring color codes and tabs engage securely.

Step 4 b: Install Tube Assembly into Brackets

Lift and place the assembled torsion tube into the wall brackets, ensuring proper seating.

Step 5: Install Center Support

Attach center support to header for doors over 10' wide, ensuring tube is straight.

Step 6: Prepare Drill for Winding

Install 1/4" insert bit or 7/16" socket in drill; set to forward rotation.

Step 7: Tension Springs

Adjust spring length to recorded value and tighten set screws securely. Avoid overstretching.

Step 8: Attach Lift Cables to Drums

Insert cable lugs into drum slots and secure drums to torsion tube with set screws.

Step 9: Install Tube Retainer

Attach tube retainers to the system brackets on both left and right sides.

Step 10: Spring Winding and Adjustment

Wind springs to specified number of turns, adjust tension by lifting door.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The EZ-SET® Torsion Spring System is a garage door spring assembly designed for use with standard garage door installation manuals. It provides the necessary spring tension for opening and closing garage doors.

Function Description:

The system utilizes torsion springs mounted on a torsion tube to counterbalance the weight of the garage door. As the door is lowered, the springs wind up, storing potential energy. When the door is raised, the springs unwind, releasing this energy to assist in lifting the door. This design ensures smooth and balanced operation of the garage door. The system is designed to be installed in conjunction with existing garage door tracks and hardware, with specific instructions for integrating the EZ-SET® components.

Important Technical Specifications:

• Tools Needed:
  • 3/8" Medium duty reversible power drill (1000-2500 RPM, 2-4 AMP variable-speed and reversible)
  • 3/8" Open end wrench
  • 3/16" Hex wrench
  • 1/8" Drill bit
  • 1/4" Insert bit (included)
• Fasteners:
  • 3/8"-16 x 3/4" carriage bolts and 3/8" flange nuts for attaching brackets and tube retainers.
  • 5/16" x 1 5/8" lag screws for securing brackets to the jamb or header (requires 3/16" pilot holes).
  • #14 x 5/8" sheet metal screws for attaching tube coupler to torsion tubes.
  • 1/4" x 1" lag screws for center support (required on doors over 10' wide, requires 1/8" pilot holes).
• Door Thickness Compatibility: Instructions specify different carriage bolt slot usage for 2" thick doors (furthest from jamb) and 1 3/8" thick doors (closest to jamb).
• Track Radius Compatibility: Instructions refer to the standard installation manual for determining track radius (e.g., 12" radius track, 15" radius track).
• Spring Winding: The number of spring winds varies based on door height, ranging from 9 3/8 turns for a 5'9" door to 12 3/4 turns for an 8'0" door. Each 1/8 turn equals 45°.
• Spring Length Adjustment: The spring length on the shaft should not exceed the relaxed spring length recorded in Step 3 by more than 1/2" max.
• Gap between Track and Door: A minimum of 1/2" per side between the track and door is required.

Usage Features:

• Compatibility: Designed specifically for the EZ-SET® Torsion Spring System; not for regular torsion springs, extension springs, or EZ-SET® Extension Spring Systems.
• Installation Sequence: The installation process is integrated with a standard garage door installation manual, with specific steps for assembling and installing the torsion spring components.
• Left and Right Hand Orientation: All references to left and right hand are made assuming the user is inside the garage looking out.
• Door Width Considerations: Doors greater than 10 feet in width are considered double car doors, which may affect the quantity of certain parts (e.g., two springs instead of one).
• Spring Configuration: The system supports both one-spring and two-spring configurations, with specific instructions for orienting components (e.g., "L-GREEN" spring on the left, "R-ORANGE" spring on the right).
• Drum Orientation: Drums are designated as left ("L") and right ("R") and must be oriented with cable slots facing away from the winding unit(s) and end bearing support.
• Cable Installation: Lift cables are inserted into drum slots and slack is taken up by hand-turning the drum before securing.
• Spring Winding: The spring is wound using a power drill with an insert bit, rotating clockwise. The number of winds is determined by a provided table based on door height.
• Safety Precautions:
  • WARNING: Personal injury and/or property damage may occur if instructions are not followed carefully.
  • WARNING: Do not overstretch springs before tightening set screws, as this can cause loss of tension and the door to fall.
  • WARNING: Do not rest hands or any part of the body on the spring or system components while tensioning or untensioning.
  • CAUTION: When tightening set screws, turn them 3/4 to one full turn after contact with the tube; additional turns may damage the tube.
  • Drill Operation: Operate the drill at HALF SPEED during winding. Wait at least five minutes between consecutive winds/unwinds if additional winding is required or if the system needs to be completely unwound. Stop winding and wait if resistance is encountered.
  • Post-Installation Check: Before operating the door or attaching an opener, ensure the door clears brackets and winding unit(s). Proceed slowly and carefully.

Maintenance Features:

• Tube Retainer Lubrication: The tube retainer may be periodically lubricated with a light household oil if squeaking occurs.
• Spring Tension Adjustment: The exact number of winds can be adjusted by adding up to 2 1/4 winds or subtracting 1/2 wind to achieve proper door balance. If the door lifts too easily, reduce winds; if too hard, increase winds. Adjustments should only be made when the door is completely closed.
• Set Screw Tightening: Set screws in the set cone and drums must be securely tightened to prevent slippage.
• Component Alignment: Ensure all components are properly aligned and secured during installation to prevent damage and ensure safe operation.
• Missing Parts: If parts are missing, users are instructed to call the consumer support number listed on the front page of their standard installation manual, rather than returning the product to the store.

Clopay EZ-SET Specifications

General

Brand	Clopay
Model	EZ-SET
Category	Garage Door Opener
Language	English