Von Duprin 33/3549A & CS 33/3549A Installation Instructions

Introduction

This document provides installation instructions for the Von Duprin 33/3549A concealed vertical rod device, suitable for aluminum and hollow metal doors. It also covers the CS 33/3549A retrofit cabling system for converting 33/3547A Series devices. Refer to page 14 for an explanation of Warnings and Cautions.

Key Components Illustrated:

• 1-Point Latch (LBL): The primary latching mechanism.
• Dogging Key: Used to lock down the pushbar.
• 2-Point Latch: Includes additional parts for securing the top and bottom of the door.

Application Codes:

• AL: For Aluminum Door applications.
• HM: For Hollow Metal Door applications.
• RF: For Hollow Metal Door Retrofit applications.

Customer Service: 1-877-671-7011 | www.allegion.com/us

Cable Identification and Preparation

Cable Identification

For easy identification, each cable is labeled with its part number and location. The following table details cable part numbers based on door opening height for hollow metal and aluminum doors:

*Based on standard centerline of 39 5/8" from finished floor.

Cable Components

The following components are used in the cabling system:

• Casing Cap
• Conduit
• Conduit Lock Nut
• Conduit Lock
• Large Diameter Conduit
• Cable Snap
• Sizing Spacer
• Sizing Spacer Hook
• End Fitting
• Core Wire
• End Fitting Nut

Cable Sizing Preparation

Note: For retrofit installations, begin at Step 19.

Align Sizing Tape to the Horizontal Device Center Line. For Bottom Cable Sizing (if applicable), align Sizing Tape to the Bottom Edge of the Door.

Cable Sizing

Follow these steps to size the top and bottom cables:

1. Step 3: To Size Top Cable
   Align Sizing Spacer Hook to the Top Edge of the Door.
   Diagram showing the sizing spacer hook aligned with the top edge of the door. A caution states not to remove the sizing spacer until indicated.
2. Step 4: Loosen Conduit Lock Nut
   Loosen the Conduit Lock Nut by 1/2 turn. At the opposite end of the cable, pull the Casing Cap to the line on the tape.
   Diagram illustrating loosening the conduit lock nut and pulling the casing cap to a marked line on tape.
3. Step 5: Hand Tighten Conduit Lock Nut
   Hand tighten the Conduit Lock Nut.
   Diagram showing hand tightening the conduit lock nut.
4. Step 6: Wrench Tighten Conduit Lock Nut
   Wrench tighten the Conduit Lock Nut by 1/4 turn.
   Diagram showing wrench tightening the conduit lock nut by 1/4 turn. A caution warns against overtightening.

   WARNING: Failure to properly tighten the conduit lock nut will result in device malfunction and possible lock-in or lock-out situations.

5. Step 7: Tighten End Fitting Nut
   Remove the warning label. While pulling the core wire tight, hand tighten the End Fitting Nut.
   Diagram showing removal of a warning label and hand tightening the end fitting nut while pulling the core wire.
6. Step 8: Remove Sizing Spacer
   Remove the Sizing Spacer. (Do not discard.)
   Diagram showing the removal of the sizing spacer.
7. Step 9: Tighten End Fitting Nut
   While holding the End Fitting in place with pliers, fully tighten the End Fitting Nut with a wrench. Once tightened, the end fitting nut cannot be loosened or readjusted.
   Diagram showing pliers holding the end fitting while a wrench tightens the end fitting nut. A note indicates it's permanent once tightened.
8. Step 10: Cut Core Wire
   Cut the Core Wire flush with the End Fitting.
   Diagram showing cutting the core wire flush with the end fitting.
9. Step 11: Store Sizing Spacer
   Snap the Sizing Spacer onto the Large Diameter Conduit for storage.
   Diagram showing the sizing spacer being snapped onto the large diameter conduit.
10. Step 12: To Size Bottom Cable
    Align the Sizing Spacer Hook to the Top Edge of the Door as before, and repeat Steps 3 through 10.

    For 2-Point Latch Only: Repeat Steps 3 through 10.

Cable Installation

13. Step 13: Flip Top Cable
    
    Diagram showing the top cable being flipped 180 degrees after sizing, as indicated by a tag. A caution advises flipping it before installing.
14. Step 14: Install Top Cable
    
    1. There is an end fitting on one end of the red cable. Position this end to clip onto the center slide.
       Diagram showing the red cable's end fitting being positioned to clip onto the center slide. Correct and wrong orientations are shown. A caution states to ensure the cable end is fully seated in the clip.
    2. Pull the cable into the clip to snap it into place.
       Diagram showing the cable being pulled into the clip.
    3. Push the cable snap against the center slide to secure the cable.
       Diagram showing the cable snap being pushed against the center slide.
    4. Follow steps (a) through (c) to install the opposite end of the red cable to the top latch in the position marked red.
       Diagram showing the red cable being connected to the top latch.

    Cable Removal: If the cable was installed in the wrong position, a cable removal tool is included. The slot in the tool fits over the cable snap, holding the tabs down. Pull on the cable snap to loosen the cable for removal.

    Diagram illustrating the cable removal process using the tool.
15. Step 15: Install Bottom Cable (For 2-Point Latch Only)
    
    1. There is an end fitting on one end of the white cable. Install this end to the remaining top latch position (marked as white).
       Diagram showing the white cable's end fitting being installed to the top latch position. Correct orientation is shown. A caution states to ensure the cable end is fully seated.
    2. Install the opposite end of the white cable to the bottom latch.
       Diagram showing the white cable connected to the bottom latch.

Latch Adjustment (For 2-Point Latch Only)

16. Step 16: Determine if Bottom Latch Retraction Adjustment is Necessary
    

    CAUTION: Critical step.

    Adjustment must be made while the top latch is in the hold-open position.

    1. Flex the cable into an L-shape as shown to simulate the installed condition of the latches.
       Diagram showing the cable flexed into an L-shape.
    2. To determine if adjustment is required, actuate the top latch to the hold-open position by pressing down on the connecting rod. The bottom latch should retract to within 1/16" of flush. If it does not, an adjustment is necessary.
       Diagram showing the connecting rod being pressed to put the top latch in hold-open. The bottom latch is shown retracted to within 1/16" of flush.

    If no adjustment is needed, proceed to Step 18.

17. Step 17: Adjust Bottom Latch Retraction (if necessary)
    

    CAUTION: Adjustment must be made while the top latch is in the hold-open position.

    The conduit lock is used to make this adjustment.

    1. Use a permanent marker or tape to mark the position of the bottom cable conduit.
       Diagram showing a marker or tape used to mark the conduit position.
    2. Loosen the conduit lock nut so the conduit is free to slide.
       Diagram showing the conduit lock nut being loosened.
    3. Pull until one extra wrap of conduit can be seen (1 wrap = 1/8").
       Diagram showing conduit being pulled to create an extra wrap.
    4. Hand tighten the conduit lock nut.
       Diagram showing hand tightening the conduit lock nut.
    5. Repeat Step 16. Confirm the bottom latch now retracts to within 1/16" of flush.
       Diagram showing confirmation of latch retraction.
    6. If not, loosen the conduit lock nut, pull out an additional wrap of conduit, and hand tighten the conduit lock nut.
       Diagram showing loosening, pulling more conduit, and retightening.
    7. Wrench tighten the conduit lock nut 1/4 turn.
       Diagram showing wrench tightening the conduit lock nut by 1/4 turn. A caution warns against overtightening.

       Caution: Do not overtighten.

       WARNING: Failure to properly tighten the conduit lock nut will result in device malfunction and possible lock-in or lock-out situation.

18. Step 18: Confirm Bottom Deadlatching (For 2-Point Latch Only)
    
    1. Lock the top latch. Flex the cable into an L-shape as before.
       Diagram showing the top latch locked and cable flexed.
    2. Push against the flat side of the bottom latchbolt. The latchbolt should NOT release.
       Diagram showing pushing the bottom latchbolt.

    If the latchbolt releases, return the conduit to the position marked in Step 17a. Repeat bottom latch retraction adjustment.

    CAUTION: If no bottom latch retraction adjustment was necessary, yet the bottom latch won't deadlatch, contact technical support.

Door Preparation and Installation

19. Step 19: Retrofit Installation
    
    1. Remove device from existing door.
    2. Remove and discard existing door.
    3. Remove and discard existing strikes.
20. Step 20: Draw Device Center Lines
    With the door laying flat, draw horizontal and vertical device center lines.
    Diagram showing a door laying flat with center lines being drawn. A note mentions referring to templates if no cutout exists. RHR (Right Hand Reverse) is indicated.
21. Step 21: Align Paper Template
    Align paper template to mark and prepare the door, if required.

    See pages 15 and 16 for paper templates.

    Diagram showing a paper template being aligned on the door edge. RHR (Right Hand Reverse) is indicated.
22. Step 22: Assemble Latch Mounting Brackets
    
    • Hollow Metal Only - Top: Diagram shows bracket assembly with dimensions (3/4", 1/4") and screw types (10-32 x 1/4"). It also shows depth from top edge to channel.
    • For 2-Point Latch Only - Bottom: Diagram shows bottom bracket assembly with screw types (10-32 x 1/4").
23. Step 23: Prepare Access Hole for Bottom Latch Adjustment Pin
    

    Hollow Metal For 2-Point Latch Only:

    Diagram shows a door edge with required clearance (4 1/4" depth), distance from push side (5/8"), and hole size (3/4" Dia.). It indicates locations for RHR and LHR (Right Hand Reverse, Left Hand Reverse).
24. Step 24: Prepare Door for Top Strike Cutout (If Necessary)
    
    Diagram shows a door edge with a cutout marked for the top strike, indicating dimensions (1 1/4", 9/16") and the push side of the door. RHR is shown.
25. Step 25: Prepare Top of Door for Latch Mounting (Aluminum Only)
    
    Diagram shows the top of an aluminum door with hole locations and dimensions for latch mounting, including screw types (7/32" Dia. x2, 82° Csk to 3/8" Dia.) and distances from the push side.
26. Step 26: Prepare Bottom of Door for Latch Mounting (Aluminum For 2-Point Latch Only)
    
    Diagram shows the bottom of an aluminum door for a 2-point latch, with hole locations and dimensions for latch mounting, including screw types (7/32" Dia. x2, 82° Csk to 3/8" Dia.) and distances from the push side.
27. Step 27: Remove Center Slide Mounting Nut (If Using 360/386/388 Thru-Bolting Trim)
    
    Diagram shows removing the center slide mounting nut. It notes that thru-bolting trim uses standoffs (360L trim shown) and that the mounting nut has left-handed threading. A 3/8" socket with a 1/4" drive is shown.
28. Step 28: Remove Screw from Center Slide
    This screw will be used to secure the center slide to the door in Step 30.
    Diagram showing the removal of a screw from the center slide.
29. Step 29: Slide Latch and Center Slide Assembly thru Door
    

    Note: Confirm top latch (and bottom latch, if applicable) is in correct orientation before proceeding.

    • 1-Point Latch (LBL): Diagram shows the assembly being slid through the door. Note: It is normal for the cable to bend inside the door, forcing the latch outward.
    • 2-Point Latch: Diagram shows the assembly being slid through the door. Holes should face the push side (notch side) of the door. Aluminum door application is shown.
30. Step 30: Secure Center Slide to Door
    
    1. Secure center slide to door by lightly tightening the lower screw.
    2. Align the upper hole visually.
    3. Insert a small screwdriver into the upper hole to prevent the center slide from rotating.
    4. Fully tighten the lower screw.
       Diagrams illustrate securing the center slide to the door with screws, using a screwdriver to prevent rotation.
31. Step 31: Align Bottom Latch and Install Mounting Screws (Aluminum For 2-Point Latch Only)
    
    Diagram shows aligning the bottom latch and installing mounting screws (10-24 x 3/8") on an aluminum door for a 2-point latch.
32. Step 32: Secure Top Latch with 2 Screws (Aluminum Only)
    
    Diagram shows securing the top latch with screws (10-32 x 1/4") on an aluminum door.
33. Step 33: Install Bottom Latch Mounting Bracket Assembly (Hollow Metal For 2-Point Latch Only)
    

    Note: Confirm correct orientation of assembly before proceeding. Open side of housing should face pull side of door.

    Diagram shows installing the bottom latch mounting bracket assembly on a hollow metal door for a 2-point latch. It indicates push side (notch side), and notes that 1/4" spacer blocks are required for 3/4" undercut doors. A Spacer Block Kit is mentioned as purchased separately. Screws used are #10-24.
34. Step 34: Insert Latch Adjustment Pin to Hold Bottom Latch in Place (Hollow Metal For 2-Point Latch Only)
    

    Pin must go thru both sides of bracket.

    Diagram shows inserting the latch adjustment pin. It also shows the bottom edge of the latch housing should be flush with the bottom of the door (for 3/8" standard undercut). It illustrates assembling the pin and squeezing tabs on the cap before inserting.
35. Step 35: Secure Top Latch Mounting Bracket (Hollow Metal Only)
    

    Note: It is normal for the cable to bend inside the door, forcing the latch outward as shown.

    Diagram shows securing the top latch mounting bracket with screws (#25, #10-24 x 1/2").
36. Step 36: Hang Door on Frame
    

    Caution: For 2-point latches, bottom latch cannot be in locked position while hanging door on frame. Latch must be retracted.

37. Step 37: If Necessary, Cut Device
    
    Diagram shows cutting the device. It indicates a recommended dimension of 1 1/2" (38 mm). It also shows temporarily removing an anti-rattle clip and the cover plate being flush.
38. Step 38: Attach Center Case to Door
    

    Block may need to be pushed down to insert screw. Top mounting screw is secured into upper hole of center slide.

    Note: If using 360/386/388 trim, this screw will pass thru top center slide hole and secure directly into trim.

    Diagram shows attaching the center case to the door. It illustrates using screws (1/4-20 x 1" or 1/4-20 x 1 1/2" depending on door thickness) for thru-bolting trim and sex bolts.
39. Step 39: Mark and Prepare 2 Holes
    
    Diagram shows marking and preparing holes for surface mounting (metal doors only) using #25 and #10-24 screws, or sex bolts. Dimensions for device side and trim side are shown.
40. Step 40: Install End Cap Bracket and End Cap
    
    Diagram shows installing the end cap bracket and end cap using surface mount or sex bolts (10-24 x 3/4" or 10-16 x 3/8" for wood, 10-24 x 1 1/8" for 2 1/4" door).
41. Step 41: Prepare Door Frame for Top Strike (If New Installation)
    

    Use strike to mark location of 2 holes.

    Diagram shows marking the door frame for the top strike. It specifies hole sizes and depths for metal (#25 x 1/2" Deep x2, #10-24) and wood (1/8" Drill Pilot 1" Deep x2).
42. Step 42: Install Steel Cover Plate (If Retrofit Installation)
    Install Steel Cover Plate to Cover Existing 338 Strike Opening in Accordance with the Frame Manufacturer's Fire Listing.
    Diagram shows installing a strike filler plate (purchased separately) and securing it with screws (10-24 x 1/2").
43. Step 43: Install 2 Top Strike Screws Using the Slot Features on the Strike
    
    Diagram shows installing screws (10-24 x 1/2" for metal, #10 x 1 1/2" for wood) into the top strike. Retrofit installation is also indicated.
44. Step 44: Prepare Floor for Bottom Strike (Hollow Metal For 2-Point Latch Only)
    
    Diagram shows preparing the floor for the bottom strike. It indicates chiseling out a pocket 1/2" deep, with dimensions for the strike location (7/8" from edge, 1/2" from edge) and hole size (3/8" Dia. x 1 1/4" Deep). Pull side and push side are indicated.
45. Step 45: Install Bottom Strike (Hollow Metal For 2-Point Latch Only)
    

    Clear holes of debris, then drop in anchors (slotted end first). Secure the anchors using a hammer and punch.

    IMPORTANT: Anchors must be below flush.

    Diagram shows dropping anchors into holes, securing them with a hammer and punch, and installing the strike plate with screws (1/4-20 x 3/4").
46. Step 46: Prepare Threshold (Aluminum For 2-Point Latch Only)
    
    1. After closing the door with the bottom latch installed, mark the location where the bottom latch bolt is contacting the threshold.
    2. Drill a 3/4" diameter hole in the threshold.
       Diagram shows the bottom latch bolt contacting the threshold and a 3/4" diameter hole being drilled.
47. Step 47: Install Lift Finger and Retainer Clip
    

    Note: Lift finger installation must be performed while the latches are in the extended (latched) position.

    For 2-Point Latch Only:

    Diagram shows sliding the L-shaped lift finger through the block in the device center case and into the center slide. It shows pushing the cable aside. It then shows installing the retainer clip against the lift finger, snapping it into the slot of the adjustment screw. Finally, it shows securing the lift finger and retainer clip with a screw (8-32 x 5/16"). It also shows inserting an adjustment screw through the top slot and rotating it clockwise to raise the lift finger until snug.
48. Step 48: Adjust Lift Finger
    

    Note: Lift finger adjustment must be performed while the latches are in the extended (latched) position.

    1. Loosen the retainer clip screw.
    2. While maintaining downward pressure, turn the adjustment screw counterclockwise to lower the lift finger to a point where the top latch unlocks with the push pad depressed halfway.
       Diagrams show loosening the screw, turning the adjustment screw, and the resulting position of the lift finger.
    3. Tighten the retainer clip screw.
       Diagram shows tightening the retainer clip screw.
49. Step 49: Confirm Top Deadlatching
    
    1. Lock the top latch.
    2. Push down on the top latchbolt. The latchbolt should NOT release.
       Diagram shows pushing the top latchbolt.

    If the latchbolt releases, loosen the retainer clip screw, then rotate the adjustment screw clockwise a couple turns to raise the lift finger. Retighten the retainer clip screw.

50. Step 50: Perform Functional Test of Door
    
    1. Depress pushbar. The door should begin to open when the pushbar is nearly fully depressed. If necessary, refer to Step 48 to readjust the lift finger.
    2. With the door closed, the top latch should be secure.
    3. For 2-Point Latch Only: With the door closed, the bottom latch should be secure.
    4. Confirm that the bottom latch does not drag against the floor when the door is opened.

       Hollow Metal For 2-Point Latch Only: If this occurs, remove the latch adjustment pin and raise the latch, then reinsert the pin in the next notch.

       Diagram shows removing the latch adjustment pin and reinserting it in a different notch.
51. Step 51: Adjust Top Strike as Necessary, then Install the Third Strike Screw to Fix the Strike Position
    
    Diagram shows adjusting the top strike and installing a third screw. Screw types for metal (10-24 x 1/2") and wood (#10 x 1 1/2") are indicated.
52. Step 52: Install Center Case Cover
    Remove protective film from the pushbar.
    Diagram shows installing the center case cover using screws (8-18 x 3/8").

Optional Equipment: CD (Cylinder Dogging)

CD Function Conversion:

1. Remove mortise cylinder cam and reinstall in reverse (Figure 1).
2. Insert key and rotate cam to install the cylinder to the cover plate (Figure 2).
3. Remove key to slide cover plate into position in the mechanism case.

Dogging Procedure:

Turn cylinder key approximately 1/8 turn for standard dogging. Depress pushbar.

Warnings and Cautions

WARNING: Warnings indicate potentially hazardous conditions, which if not avoided or corrected, may cause death or serious injury.

CAUTION: Cautions indicate potentially hazardous conditions, which if not avoided or corrected, may cause minor or moderate injury. Cautions may also warn against unsafe practices.

Caution: Cautions indicate a condition that may cause equipment or property damage only.

Device Template (Aluminum and Hollow Metal Doors - RHR)

This section provides a template for the 33/3549A device, including dimensions for stile width (A) and backset (B).

Note: Consult aluminum door manufacturer to confirm backset compatibility. Use of outside trim may alter minimum stile requirement. See trim template.

33/3549A-F

Aluminum Door

1/4" Dia. (Device Side only)
82° Csk to 7/16" Dia.

Hollow Metal Door

1/4" Dia. (Device Side only)
82° Csk to 3/8" Dia.

Sex Bolt (for bottom hole only)

1/4" (device side)
13/32" (trim side)

Thru-Bolting Trim

1/4" Radius (4 places)

1/4" (device side)
1/2" (trim side)