Vertical-Lifting Partition Wall – Step-by-Step Installation Manual

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0. Pre-Reading & Responsibilities

•  Only personnel certified for “Powered Movable Walls” and trained by the wall manufacturer may install.

•  Read the entire manual once before opening any crate.

•  Comply with local fall-protection, electrical and CE/UL codes.

•  Keep this booklet on site until final hand-over is signed.

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1. Tools & Consumables (check-box provided)

□  2 × magnetic builders’ levels (1 m & 2 m)

□  1 × total-station or theodolite (accuracy ≤ 1″)

□  1 × laser distance meter (±1 mm)

□  1 × torque wrench 10–100 Nm + certificates (annual)

□  1 × cordless impact driver, ½” square drive

□  1 × 500 V insulation tester (Megger)

□  1 × hydraulic lifting gantry or 3 m fork-spreader (SWL ≥ 2 × panel weight)

□  Fall-arrest kit (helmet, full-body harness, lanyard with shock pack)

□  Non-slip footwear, cut-resistant gloves, safety goggles

□  Thread-locker (medium strength), alcohol wipes, marking paint

□  Manufacturer-supplied shim packs (SS316, 0.5 / 1 / 2 mm)

□  Copper anti-seize paste for rail splices

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2. Delivery & Unpacking

2.1  Inspect crates for impact marks; photograph any damage.

2.2  Lay crates on 100 × 100 mm timber bearers; avoid ground contact.

2.3  Check packing list against shipping document; missing parts ≤ 24 h report.

2.4  Store panels flat (< 2° tilt) at 15–25 °C, RH < 60 %.

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3. Pre-Installation Survey

3.1  Structural slab must be ≥ C25/30 concrete, level ±3 mm in 5 m, clean, free of release-agents.

3.2  Use total-station to establish primary datum line (PDL) at finished-floor level (+FFL).

3.3  Mark centre-line of rail; tolerance ±1 mm over entire run.

3.4  Verify clearance envelope:

–  200 mm above stored panel stack (maintenance access)

–  100 mm each side (guide-shoe travel)

–  80 mm below soffit for counter-weight clearance

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4. Rail & Structural Fixing

4.1  Position laser at PDL; shoot rail mounting holes every 400 mm (max).

4.2  Drill M12 × 120 mm chemical anchors; brush-blow-brush, inject epoxy, set studs.

4.3  Place rail sections starting from fixed-end; use 0.5 mm shims to maintain ≤ 0.5 mm step between splices.

4.4  Tighten rail clips to 45 Nm in a “middle-out” pattern; re-check level every 2 m (≤ 0.2 mm).

4.5  Apply 5 mm bead of approved structural sealant along top flange to prevent dust ingress.

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5. Counter-Weight & Sheave Head

5.1  Bolt sheave head frame to rail top with four M16 A4-80 bolts (torque 110 Nm).

5.2  Reeve 8 mm 316-grade wire rope; maintain 1:4 fall ratio.

5.3  Attach counter-weight blocks; total mass = panel weight + 5 % (factory tag). Secure with double 11 mm wire-rope grips – “saddle on live end”.

5.4  Adjust rope so weight rests 550–600 mm above floor when panel is fully UP; lock turnbuckle and seize thread.

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6. Panel / Carriage Assembly

6.1  Lift panel with spreader bar at designated lifting points only (labelled).

6.2  Hang carriage on rail; install anti-derailment fingers immediately.

6.3  Insert guide rollers; pre-load spring to 2 mm compression (factory colour mark).

6.4  Connect lifting belts to panel top rail with 10-ton rated shackles; verify equal length ±2 mm.

6.5  Install acoustic seals: bottom drop-bar first, then side fin-seals; overlap joints 20 mm and glue with cyanoacrylate.

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7. Drive & Control

7.1  Mount 24 VDC motor to carriage; align coupling within 0.1 mm TIR.

7.2  Route encoder cable inside drag-chain; minimum bend radius 75 mm.

7.3  Connect limit switches in series (normally closed); test with multimeter – must open within 5 mm of target.

7.4  Apply initial power; run “slow-jog” from hand-held pendant; check direction and brake holding torque (≥ 1.5× full-load).

7.5  Programme stop positions: bottom (FFL), mid (1 100 mm), top (clear height – 200 mm). Save to non-volatile memory.

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8. Wall-Bracket / Lateral Restraint

8.1  Install first bracket when panel reaches 3 m height, then every 6 m or as drawing.

8.2  Bracket tube must be horizontal ±2°; use turnbuckle to pre-load 0.5 kN against rail.

8.3  Drill 4 × M16 through-bolts into structural column; torque 120 Nm, mark with torque-seal paint.

8.4  Re-check rail verticality both axes; adjust shims or turnbuckle until ≤ 1/1 000.

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9. Final Adjustment & Commissioning

9.1  Run full travel ten cycles; record current draw (must be < 4 A @ 24 V).

9.2  Measure acoustic performance: field-tested Rw ≥ 45 dB (1 m from panel, 100–3 150 Hz).

9.3  Perform safety-edge test: 50 mm balsa block centred on drop-bar – panel must stop and reverse ≥ 30 mm within 0.5 s.

9.4  Label all emergency stops, hand-wind location and serial number.

9.5  Complete “Installation & Commissioning Certificate” (Appendix A); obtain client sign-off before hand-over.

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10. Safety & Prohibitions

⚠  Never work under a suspended panel – use exclusion zone barricades.

⚠  No installation in wind > Beaufort 5, rain, snow or thunder.

⚠  Torque-critical bolts (rail, counter-weight, brackets) must be double-checked by second technician and paint-marked.

⚠  Lock-out / tag-out power whenever hands are inside rail profile.

⚠  Maintain 2-point fall-arrest attachment while on ladder or MEWP.

⚠  Dispose of chemical-anchor cartridges as hazardous waste – keep SDS on site.

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11. Maintenance Hand-Over

Provide owner with:

•  As-built drawings (PDF + DWG)

•  Torque & test certificates

•  Spare parts kit (rollers, seals, 1 × motor brake pads)

•  Quick-start card (laminated A4)

•  24 h service hotline sticker affixed to control box

Installation complete – system ready for daily operation.