Cal-Royal A2200 Series Non-Rated Exit Device Installation Instructions

1. Before Installing Device, Please Check:

• Verify door is fitted and hung.
• Confirm exit device size, function, and design.
• Note: 36" devices can be cut to fit doors down to 30" wide.
• Note: 48" devices can be cut to fit doors down to 36".
• Determine the correct hand of the device for the application.

Device Components Overview: The exit device consists of a MOUNTING RAIL, END CAP, RAIL MOUNTING BRACKET, CHASSIS ASSEMBLY (including HORIZONTAL CHASSIS and VERTICAL CHASSIS), STRIKE, DOGGING KIT, and SLIDING SHIM. The device is applied to the surface of the door, which must be flushed.

Handing: The device can be configured for RIGHT HAND REVERSE BEVEL or LEFT HAND REVERSE BEVEL doors.

2. Apply Hardware

This step involves attaching the main hardware components to the door.

• Attach the outside PULL TRIM if used.
• If no trim is used, attach the CHASSIS ASSEMBLY using four #10 wood or chassis machine screws.
• Ensure the VERTICAL CHASSIS is parallel to the door edge.

Components involved: PUSH RAIL, PLUNGER PULL TRIM, RIM CYLINDER, HEAD COVER. CHASSIS MOUNTING SCREWS are used.

5. Prepare Door

This section details how to prepare the door for mounting.

• For doors with a 2-1/8" bore: Position the template over the existing hole and mark the locations for the two chassis mounting screw holes.
• For doors without a bore: Mark the vertical and horizontal chassis mounting points using the provided dimensions.

Installation Type Identification: Determine the correct location for the vertical chassis based on whether it's a SINGLE DOOR or a DBL DOOR WITH MULLION.

Dimensions and Backsets:

• A measurement of 41-7/16" is indicated (likely related to device length or mounting).
• A 2-1/8" bore is specified for use with knob and lever trim.
• Standard backsets are (2-3/4") BACKSET and 3-1/4" BACKSET (for square mullions).

3. Apply Rail Assembly

This step covers the installation of the push rail.

1. Check the device size and determine if cutting the rail is necessary.
2. Calculate the cut-off length "X" by subtracting 1-3/4" from measurement "Y". Mark this point on the MOUNTING RAIL.
3. Depress the arm into the rail opening and slide the rail onto the CHASSIS ASSEMBLY. Ensure the rail is level and fasten the chassis and mounting plate.

Cutting Instructions: Perform CUT OFF AND DEBURR operations as needed. Maintain a minimum of 1-3/4" from the lower pivot point. For doors with a stile, the cut-off must leave a minimum 1/2" overlap with the rail. The rail should be TIGHT AGAINST RAIL.

Mounting: Attach the MOUNTING PLATE to the door using three ROUND HEAD SCREWS. Then, attach the rail assembly to the chassis using two #8-32 3/8" PHILIP TRUSS HEAD screws.

4. Apply Cover and Strikes

This final step involves securing the cover and installing the strike.

• Attach the HEAD COVER to the CHASSIS ASSEMBLY using four #8 TRUSS HEAD MACHINE SCREWS.
• Attach the END CAP to the mounting plate using two COVER SCREWS.
• Attach the STRIKE to the door stop using two STRIKE SCREWS and one WASHER.