The ProFlex 5-inch Extension Kit is designed to increase the height of a standard ProFlex door opening, allowing taller equipment to pass through an ICRA (Infection Control Risk Assessment) enclosure. This kit elevates the door opening from 73 inches to 78 inches high.

Assembly and Installation Process:

The installation process for the 5-inch Extension Kit involves several steps, starting with preparing the existing ProFlex door.

Preparation:
- Lay the door and its frame on a flat surface with the hinges facing upwards. Sawhorses are recommended for this step to provide a stable working platform.
Threshold Removal:
- To remove the threshold, locate the two button-head screws on the underside of the threshold, one at each end.
- Loosen these screws by approximately a half-turn. This partial loosening is sufficient to allow the threshold to slide off easily.
Door Sweep Removal:
- The door sweep is secured by six button-head screws. Remove all six screws.
- As the screws are removed, two black oval-nuts will slide out of the channels at both ends of the sweep. These nuts, along with the six screws, should be saved as they will be needed for reattachment in a later step (Step 7).
- It's important to note that four other black oval-nuts will remain in the channel. These are left in place for potential future use if the door needs to be returned to its original height.
Adding Door Frame Extension Pieces:
- The 5-inch door frame extension pieces are added to both sides of the door. These pieces come preloaded with a plate containing four button-head screws and two black nuts.
- Slide these 5-inch extension pieces onto the bottom of the existing door frame. Ensure that the plate and its four screws are positioned on the underside of the frame, with the smooth side of the extension piece facing upwards.
- Once the pieces are in place, tighten the screws to secure them.
Adding the Extension Panel:
- The extension panel is then added to the bottom of the door using four mini clamps.
- Align the extension panel carefully with the existing door. The black, oval nuts (which will be used to reattach the door sweep in Step 7) should be positioned in the lower channel, facing upwards.
- Begin by placing two mini clamps on the front side of the panel, but do not tighten them completely at this stage.
- On the underside of the panel, place a mini clamp directly behind each of the front-side mini clamps.
- Alternately tighten all the clamps until the extension panel is securely and evenly attached to the door.
Sliding in the Door Seal Extension:
- Slide the 5-inch door seal extension into the channel.
- Once in position, tighten the seal extension to secure it.
Reattaching the Door Sweep:
- To reattach the door sweep, start by securing the four screws in the middle of the sweep.
- Next, use the two black oval-nuts and screws that were saved from Step 3 to attach the ends of the sweep.
- After all six screws are in place, tighten them to fully secure the door sweep.
Reattaching the Threshold:
- The threshold should still have its black, oval nuts in place.
- Slide these nuts into the channels on the underside of the door frame.
- Once the threshold is properly positioned, tighten the screws to secure it.

Completion and Testing:

Upon completion of all assembly steps, it is crucial to test the door. Ensure that it opens and closes properly. Once this functionality is confirmed, the 5-inch extension kit is considered fully installed.

Maintenance Features:

While the manual primarily focuses on the installation of the extension kit, the design of the ProFlex system, including the use of screws and channels, suggests that components are designed for modularity and potential future adjustments or repairs. The instruction to save specific screws and nuts for reattachment, and the mention of leaving other nuts in place for potential return to original height, indicates a design that supports maintenance and adaptability. The use of standard fasteners like button-head screws and mini clamps implies that common tools can be used for assembly and disassembly, facilitating any future maintenance or modifications. The ability to remove and reattach parts like the threshold and door sweep suggests that these components can be serviced or replaced if necessary, contributing to the overall longevity and maintainability of the door system.

Proflex 4036-KP - Step Six: Install Door Seal