MUTO Premium XL150/80

1.1 Overview

These instructions are for installation of MUTO PREMIUM sliding door system XL150/80 for the following mounting and style versions: 1. Wall mount.

1.1.1 General information

• dormakaba requires use of tempered monolithic or tempered laminated glass.
• dormakaba glass hardware is not suitable for application in rooms where chemicals (e.g. chlorine) are used, such as indoor swimming pools, saunas, or salt-water pools.
• Never move sliding panels faster than walking speed and always stop the door manually before it reaches end position.
• Do not slide doors with excessive force. Install a limiting stop to prevent the door from opening too far.

1.1.2 Intended use

• For sliding doors in dry indoor areas only.
• For manual, slow opening and closing only.

1.1.3 Glass requirements and fittings

• The substructure/wall must be able to bear permanent loads and be level (max. tolerance: 1/16" [2] per 39" [1m]).
• Fasteners must be sufficiently dimensioned for the substructure/wall and weight of the door.
• When adjusting glass components, always stick to the required clearance for the respective hardware. Adjust clearance so glass does not come in contact with any hard surfaces such as glass, metal, or concrete.
• Do not use excessive force when installing the glass (avoid over-tightening screws).

1.1.4 Requirements for glass panel

• dormakaba requires use of fully tempered glass, which complies with ASTM C 1036 and ASTM C 1048. Secondary heat soaking processes are recommended but not required. This applies to both tempered monolithic and tempered laminated glass.
• Clamping area must be flat and uncoated (no self-cleaning coating!).
• Never use glass with conchoidal fractures and/or damaged edges.

1.1.5 Safety instructions

• Installation requires two people.

1.1.6 Symbols used - Safety/Installation

⚠️ CAUTION: Mounting components must meet the requirements of substructure/wall and door weight. Please read the technical information for fittings.

⚠️ WARNING: Risk of breaking glass. When installing the door, support the door panel with a block of wood or similar object.

? TIPS AND RECOMMENDATIONS: Information note.

CLOSING EDGE

1.1.7 Maintenance, care, repair

• Immediately replace damaged parts.
• Always use original dormakaba parts.
• Clean clamping area with alcohol-based standard commercial cleaning agent before mounting the glass hardware.
• Use a damp cloth for occasional cleaning, especially the track.
• Always use silicone- and oil-free cleaners (e.g., acetone).
• Check glass hardware at regular intervals for proper positioning and smooth operation and correct adjustment.
• High traffic door systems require inspection by properly qualified staff (specialized companies or installation firms).

1.1.8 Disposal

• Disposal in accordance with local, state, and national regulations.

1.2 Specifications - technical data

* Including weight of auxiliary hardware.

1.3 Tempered laminate glass (TLG) and adhesive specifications

Handling time frame

NOTE: Door glass should not be installed until the full cure time has been reached (see chart above).

Important safety-related information for the mounting and use of dormakaba glass hardware.

• 1.3.1 Clean clamping area with alcohol-based standard commercial cleaning agent before mounting the glass hardware.
• 1.3.2 Never clamp metal glass fitting hardware directly to glass surface.
• 1.3.3 Never use clamping product on surfaces with self-cleaning coatings.

² Scotch-Weld™ EPX™ Plus II Applicator with 1:1 Plunger is a trademark of 3M.

³ Scotch-Weld™ EPX™ Plus II Mixing Square Nozzle is a trademark of 3M.

2.1 Overall

Figure 1 shows the components of the MUTO Premium system:

• 1.1 Cover panel
• 1.2 Brush strip
• 1.3 Track
• 1.4 End cap
• 1.5 End stop (x2)
• 1.6 Cover clips
• 1.7 Start/stop guide
• 1.8 Roller carrier
• 1.9 Floor guide
• 1.10 Dormotion units

2.2 Securing track to mounting surface

NOTE: IF MOUNTING TO GLASS, REFER TO THE SEPARATE SUPPLEMENTAL GLASS MOUNT INSTALLATION INSTRUCTIONS.

THEN BEGIN AT STEP 2.4A IN THIS BOOKLET.

2.2.1 Ensure the track is properly level and secure it to the wall per the appropriate measurements on the following page.

NOTE: SEE DIMENSION INSTRUCTIONS ON NEXT PAGE FOR REFERENCE.

2.2.2 Use appropriate fasteners according to the following recommendations.

NOTE: WALL REINFORCEMENT:

The wall reinforcement must be a minimum of 1½" [6] x 3" [76] steel angle, 16 gauge metal stud, or 1-1/2" [38] thick wood blocking secured to the wall studs on a maximum 16" [406] centers for the length of the track. The wall reinforcement may be flush on the wall surface or on the interior of the wall. For masonry walls the track may be secured directly to the wall with lead anchors.

Track mounting screws must fully penetrate the steel angle, metal stud, or wood blocking, utilizing the predrilled holes in the MUTO track.

Consult with a structural engineer to determine if reinforcement is adequate for your specific application or to meet specific codes in your location.

2.3 Door/wall dimensions

Single door mount

A diagram illustrates the vertical track mounted to a wall, with a glass door panel suspended from it. Key dimensions shown include: clear opening height (CH), glass door panel width (DW), distance from the top of the track to the center of the mounting hole (15/16" [24]), and the distance from the bottom of the glass to the floor (3/8" [10]). Horizontal clearances from the door edge to the wall are indicated as 1-3/16" [30] on both sides.

Double door mount

Similar to the single door diagram, but shows two glass door panels. Dimensions include clear opening height (CH), width of each glass door panel (DW and DW2), horizontal clearances (1-3/16" [30] on outer edges, 1/4" [6] between panels), and the same vertical measurements from the track and to the floor.

2.4A Installing roller carriers: on monolithic glass ONLY

Figure 2 illustrates the installation of roller carriers onto monolithic glass. It emphasizes determining the Leading (X) versus Trailing (Z) edge of the glass, defining Leading as the side closest to the latch closed.

Legend: Closing edge of door.

NOTE: FULLY CLEAN SURFACE OF GLASS WITH AN ALCOHOL-BASED MILD GLASS AND SURFACE CLEANER. ENSURE GASKET IS FREE OF DEBRIS. ENSURE ROLLER CARRIER WHEELS ARE FREE OF DEBRIS.

1. 2.4A.1 Slide roller carriers onto glass.
2. 2.4A.2 Slide glass gasket and metal shim between glass and roller carrier. NOTE: Orient gasket with rubber side facing the glass.
3. 2.4A.3 Secure roller carriers to glass using appropriate-size hex key at 10 ft lbs [14 Nm].

2.4B Installing roller carrier: on tempered laminate glass ONLY

Figure 3 illustrates the installation of roller carriers onto tempered laminate glass using adhesive. It also emphasizes determining the Leading (X) versus Trailing (Z) edge of the glass.

Legend: Closing edge of door.

NOTE: THE RECOMMENDED ADHESIVE'S SET-UP TIME IS 20 MINUTES FOR THE DUO-PAK CARTRIDGES.

NOTE: USE 1:1 RATIO PLUNGER WITH THE 3M™ Scotch-Weld™ Urethane Adhesive.

NOTE: FULLY CLEAN SURFACE OF GLASS WITH AN ALCOHOL-BASED MILD GLASS AND SURFACE CLEANER. ENSURE NO DEBRIS IS ON THE GASKET.

ENSURE ROLLER CARRIER WHEELS ARE FREE OF DEBRIS.

1. 2.4B.1 Slide carriers onto glass.
2. 2.4B.2 Replace existing gasket with TLG gasket.
3. 2.4B.3 Slide laminated glass gasket and metal shim between glass and roller carrier. NOTE: Orient gasket with rubber side facing the glass.
4. 2.4B.4 Replace existing set screws with vented set screws.
5. 2.4B.5 Tighten vented set screws at 4 ft lbs [5Nm].

NOTE: Onto scrap material, first dispense approximately 12" of 3M™ Scotch-Weld™ Urethane Adhesive prior to application to prevent mixing errors and ensure optimal hardening.

2.4B.6 Dispense adhesive into vented set screws on both sides of carrier.

Stop application when adhesive can be seen past edge of roller carrier.

DO NOT WIPE any excess adhesive from glass surface. Allow adhesive to dry and scrape off glass surface with a beveled-edge chisel or putty knife.

NOTE: Keep glass flat during curing process.

NOTE: See chart in Specifications section for appropriate curing time.

2.5 Install DORMOTION start/stop

Figure 4 shows the DORMOTION start/stop unit. The product is shipped with a 7/8" [22] pin installed, which can be changed to 1" [25] if necessary.

NOTE: Determine pin length based upon how square and plumb the opening is.

1. 2.5.1 If required, change pin in start/stop assembly: Remove hex screws, remove existing pin and plate, swap in appropriate pin and plate, replace hex screws.
2. 2.5.2 Slide start/stop onto glass.
3. 2.5.3 Center equally between the carriers.
4. 2.5.4 Slide glass gasket between start/stop and glass. NOTE: Orient with gasket facing glass.
5. 2.5.5 Secure start/stop via set screws.

2.6 Disengaging the anti-jump

Figure 5 illustrates how to disengage the anti-jump mechanism on the roller carrier. The anti-jump is shipped engaged.

2.6.1 Disengage the anti-jump on roller carrier.

NOTE: Using the appropriate-size hex key, push anti-jump adjustment screw IN and turn COUNTER-CLOCKWISE 90° to disengage anti-jump.

2.7 Installing the end stops

Figure 6 shows how to install the end stops onto the track. The hex key size is 3mm for XL150/80.

1. 2.7.1 Slide end stops into each end of the track. NOTE: Loosen bottom section of end stop for easier install.

NOTE: FOR XL150 end stops, be sure set screw is flush with back of end stops.

NOTE: Exact location/adjustments will be determined in "Adjustment End Stop Location" step.

2.8 Install glass/rollers in track

Figure 7 illustrates installing the glass and rollers into the track. *If installing/hanging tempered laminated glass panels, ensure carrier adhesive has cured for 48 hours. See Specifications for more information on cure time.*

ENSURE ROLLERS AND TRACK ARE FREE OF DEBRIS.

1. 2.8.1 Place glass on setting blocks on floor for stability.
2. 2.8.2 Tip glass and rollers upward and rest rollers on track.

2.9 Install floor guide

Figure 8 shows the installation of the floor guide. REMEMBER ANTI-JUMP IS DISENGAGED!

1. 2.9.1 Align centerline of glass with centerline of floor guide.
2. 2.9.2 Be sure the glass is plumb.
3. 2.9.3 Mark appropriate floor guide measurements.

TEMPORARILY REMOVE GLASS AND ROLLERS FROM TRACK (TO ALLOW FOR DRILLING SPACE).

4. 2.9.4 Pre-drill into mounting surface using a 5/16" drill bit.
5. 2.9.5 Secure floor guide anchor with included fasteners.

2.10 Install floor guide: continued

Figure 9 shows the floor guide attached to its anchor and securing the glass within it.

1. 2.10.1 SET GLASS AND ROLLERS BACK ONTO TRACK.
2. 2.10.2 Slide floor guide over floor guide anchor and tighten with set screws.
3. 2.10.3 Remove setting blocks. NOTE: Be sure glass is centered in floor guide.
4. 2.10.4 Adjust using set screws.

2.11 Engaging anti-jump

Figure 10 illustrates how to engage the anti-jump mechanism on the roller carrier.

2.11.1 Engage anti-jump on roller carrier.

2.11.2 Using appropriate-size hex key, push anti-jump adjustment screw IN and turn CLOCKWISE 90° to engage anti-jump.

2.12 Adjustment door height

Figure 11 illustrates how to adjust the door height using the height adjustment screws on the roller carrier. The door height adjustment tolerance is ±3/16" [±5] for XL150/80.

1. 2.12.1 Set height of glass door.
2. 2.12.2 Loosen height adjustment locking screws of carrier.
3. 2.12.3 Using appropriate-size hex key, turn height adjustment screw CLOCKWISE or COUNTER-CLOCKWISE to raise or lower glass.

NOTE: Be sure glass is level during this adjustment.

2.13 Adjustment end stop location

LEADING end stop

Figure 12 shows the placement of the LEADING end stop on the track. It indicates that the bumper should touch the edge of the roller carrier when the door is closed. A note for bi-folding doors specifies a 1/4" [6] gap between sets.

Set end stop locations:

2.13.1 Slide end stop to desired location on track. Bumper should touch edge of roller carrier.

TRAILING end stop

Figure 13 shows the placement of the TRAILING end stop on the track. It indicates that the bumper should touch the edge of the roller carrier when the door is opened. A note for bi-folding doors specifies a 1/4" [6] gap between sets.

Set end stop locations:

2.13.1 Slide end stop to desired location on track. Bumper should touch edge of roller carrier.

2.14 Install DORMOTION units

RH DM unit (Right Hand)

Figures 14.1-14.8 detail the installation of the RH DORMOTION unit.

1. 2.14.1 Rotate RH DM fastening plates: Using a 4 mm hex key, loosen fastening plate hex screws. Rotate plates until parallel to the DM unit (Fig. 14.2). Snug hex screws.
2. 2.14.2 Move door to close position. For installation of RH DM unit, door must be in the closed position against the bumper.
3. 2.14.3 Align DM unit in track, engage DM hook in DM trigger: Align DM unit in track (Fig. 14.7). Slide DM unit over the DM trigger block until the DM hook engages the DM trigger (Fig. 14.4).
4. 2.14.4 Use adjustment tool to set DM unit final position: Place adjustment tool flat against DM unit with fork between DM hook and DM end stop (Fig. 14.5). Slide DM unit over until hook and DM end stop are against the fork. This sets a 5 mm gap (fork gap). Trigger height: Adjust so trigger sets on top of adjustment tool (Para. 2.15).
5. 2.14.5 Secure the DM unit in position: NOTE: Insure door is fully closed against bumper before performing this step. Using a 4 mm hex key, tighten DM unit fastening plate socket head cap screws. Fastening plates must engage the track (Fig. 14.6 and .8).

LH DM unit (Left Hand)

Figures 14.9-14.16 detail the installation of the LH DORMOTION unit.

1. 2.14.6 Rotate DM fastening plates: Using a 4 mm hex key, loosen fastening plate hex screws. Rotate plates until parallel to the DM unit (Fig. 14.10). Snug hex screws.
2. 2.14.7 Move door to open position. For installation of LH DM unit, door must be in the open position against the bumper.
3. 2.14.8 Align DM unit in track, engage DM hook in DM trigger: Align DM unit in track (Fig. 14.15). Slide DM unit over the DM trigger block until the DM hook engages the DM trigger (Fig. 14.12).
4. 2.14.9 Set DM unit final position: Place adjustment tool flat against DM unit with fork between DM hook and DM end stop (Fig. 14.13). Slide DM unit over until hook and DM end stop are against the fork. This sets a 5 mm gap (fork gap). Trigger height: Adjust so trigger sets on top of adjustment tool (Para. 2.15).
5. 2.14.10 Secure the DM unit in position: NOTE: Insure door is fully open against bumper before performing this step. Using a 4 mm hex key, tighten DM unit fastening plate socket head cap screws. Fastening plates must engage the track (Fig. 14.16).

2.15 Adjust start/stop pin height (if necessary)

Figure 15 shows how to adjust the height of the start/stop pin.

1. 2.15.1 Adjust HEIGHT of start/stop pin, if necessary: Loosen hex screws. Slide pin and plate up or down.

CORRECT PIN HEIGHT/ ORIENTATION

2.16 Cover clips

Figure 16 illustrates the installation of cover clips into the track.

1. 2.16.1 Insert cover clips into track. (One clip per foot)
2. 2.16.2 Insert perpendicular to track, and turn CLOCKWISE to snap into place.

2.17 Install brush profile

Figure 17 shows the installation of the brush profile into the cover.

1. 2.17.1 Measure and cut brush to appropriate length.
2. 2.17.2 Slide brush into cover.

2.18 Install view protection clips

Figure 18 illustrates the installation of view protection clips onto the cover, and the placement of the view protection profile. This is intended for one or multiple sidelite applications.

1. 2.18.1 Slide door open until it meets the end stop.
2. 2.18.2 Measure and cut view protection profile to fit into empty sliding portion of track - 3/16" [5].
3. 2.18.3 Snap view protection clips onto inside of cover as shown.

2.18.4 Use minimum 1 clip per foot of profile. Exception: If profile is minimum of 1 foot in length, use 2 clips.

2.19 Install cover and view protection profile

Figure 19 shows how to secure the cover to the clips and snap it into place, and how to install the view protection profile.

1. 2.19.1 Secure cover to clips and snap into place. NOTE: Roll cover from the bottom upwards. Ensure the bottom of the cover is supported by the groove in the cover clip.
2. 2.19.2 Tip view protection profile up into track and snap down into cover and onto track as shown.

2.20 Install end caps

Figure 20 shows the end caps being snapped onto the track.

1. 2.20.1 Snap end caps onto track.