Falcon 2390 Touchbar Concealed Vertical Rod Panic Device Installation Instructions 108178

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2390 Touchbar

ININST.1039

Concealed Vertical Rod Panic Device

Installation Instructions

Index
•
Parts
List

2
•
Before
Installation

5
•
Installation
5
•
RX
Device
Wiring

12
•
EL
Device
Wiring

13
•
Cylinder
Installation
14
•
Touchbar
Dogging

17
•
Setting
Rod Lengths

18
•
Re-handing
Device
19
•
Template

20

PARTS LIST

Package
No.
4270107176
(US28
finish)
or
Package
No.
4270107178
(DC13/DC35
finish)
Item Quantity Description Part
No.
1 1 Hex
rod
guide 		4270101829
2 2 #10-24
x
3/8"
UFPHTC
Typ 		F
Stl
US28
finish 		4299100746
DC13/DC35
finish 		4299101027
Package
No. PKG.
134
(US28
finish)
or
Package
PKG.
finish)
No. 135
(DC13/DC35
Item Quantity Description Part
No.
3 2 Rod
bearing
bushing 		BUSH.108
4 2 Reinforced
retaining
ring 		RRING.108
5 1 2390
lift
bracket 		BRKT.143
6 2 #10-32
x
1/4"
UFPHMS
US28
finish 		963125-00

7 1 5/32" hex dogging key 4270106944

Package
No.CYLASY.1046
(P28
finish)
or
Package
No.
CYLASY.1053
(P35
finish)
Item Quantity Description Part
No.
8 1 2390
NL/HB
bracket
assy. 		BRKTASY.118
9 1 Mortise
locking
collar 		971851-00
10 1 2390
cylinder
housing
P13
finish 		HOUSING.124
P28
finish 		HOUSING.123
P35
finish 		HOUSING.125
11 1 1/4-20
x
3/8"
SHCS 		820975-00
12 2 Mounting
stud 		971585-89
13 2 #10
countersink
washer
DC13/DC35
finish 		WASHER.117
US32D
finish 		964016-00
14 2 #10-24
x
1"
OPHMS
DC13/DC35
finish 		SCREW.1014
US32D
finish 		963120-00
15 1 2390
cylinder
lift
bracket 		BRKT.152
16 2 1/4-28
x
3/4"
SHCS 		SCREW.1034

Package No. CYLASY.1047 (P13 finish) or

Package
No. PB48 		Item Quantity Description Part
No.
Note: Contains PB48
strike,
three
shims,
four 		mounting
screws. 		20 1 Cover
plate 		See
table
Item Quantity Description Part
No. 		21 1 Touchbar See
table
17 1 Strike 22 1 Dogging
assembly
P13
finish 		4270108354 DC13/DC35
finish 		KIT.1022
P35
finish 		4270108355 US28
finish 		KIT.1021
23 1 Dogging
spring 		971493-89
US28
finish 		4270108353 24 1 2390
touchbar
anchor
bracket 		BRKT.137
25 4 #8
x
3/4"
FPHTF 		4270109556
Package No. BRKTASY.155
(for
2"
thick 		doors
only) 		26 2 2390
mounting
end
cap
P35 		ECAP.143
Item Quantity Description Part
No. 		27 2 2390
fixed
cover
P35 		COVER.127
18 1 2390
lift
bracket
2"
door 		BRKT.154 28 4 #12-14
x
1/2"
UFPH
Typ
23 		SCREW.1007
19 2 #8-18
x
5/16"
UFPHSMS 		964327-89 29 2 Touchbar
pin 		PIN.125

Cover Plate Part Numbers (Item 20 in "Parts List")

21"
Touchbar 		Length 24"
Touchbar 		Length
Finish Without
Dogging
Hole 		With
Dogging
Hole 		Without
Dogging
Hole 		With
Dogging
Hole
Champagne EXT.2462 EXT.3011 EXT.2466 EXT.3015
DC13 EXT.2460 EXT.3009 EXT.2464 EXT.3013
DC35 EXT.2461 EXT.3010 EXT.2465 EXT.3014
US28 EXT.2459 EXT.3008 EXT.2463 EXT.3012

Touchbar Part Numbers (Item 21 in "Parts List")

Finish 21"
Touchbar
Length 		24"
Touchbar
Length
Champagne EXT.3003 EXT.3007
DC13 EXT.3001 EXT.3005
DC35 EXT.3002 EXT.3006
US28 EXT.3000 EXT.3004

2390 Channel Package No. 4270108768 (used for mounting muntin to vertical door stiles)

2390 angle bracket Part No. 4204100819 Quantity: 4 pieces

#8-32 x 3/8" FPHTC Part No. 4299100726 Quantity: 8 pieces

#8-32 x 1/2" FPHTC Part No. 4299100741 Quantity: 8 pieces

PARTS LIST (continued)

Muntin Filler Part Numbers

Finish Muntin
Filler
Part
Number
DC13 4270107327
DC35 4270107328
US28 4270107325

Muntin Part Numbers

Finish Muntin
Part
Number
DC13 4270102811
DC35 4270102812
US28 4270102809

Top Rod Assembly Bottom Rod Assembly

Standard 7' Door Top Rod Assemblies (dimensions in inches)

Description Part No. Muntin Center Line Door Height By
Cutting
Top
Rod,
Assembly
Can
Be
Shortened
Up
To
2390
Top
Rod
RHR
AL
=
40.176 		RODASY.10001 42.5 83.188 4"
2390
Top
Rod
RHR
AL
=
41.426 		RODASY.10002 41.25 83.188 6"
2390
Top
Rod
RHR
AL
=
44.801 		RODASY.10003 37.875 83.188 9"
2390
Top
Rod
RHR
AL
=
42.676 		RODASY.10004 40 83.188 5"
2390
Top
Rod
RHR
AL
=
41.489 		RODASY.10005 41.25 83.25 6"
2390
Top
Rod
LHR
AL
=
40.176 		RODASY.10006 42.5 83.188 4"
2390
Top
Rod
LHR
AL
=
41.426 		RODASY.10007 41.25 83.188 6"
2390
Top
Rod
LHR
AL
=
44.801 		RODASY.10008 37.875 83.188 9"
2390
Top
Rod
LHR
AL
=
42.676 		RODASY.10009 40 83.188 5"
2390
Top
Rod
LHR
AL
=
41.489 		RODASY.10010 41.25 83.25 6"

Standard 7' Door Bottom Rod Assemblies (dimensions in inches)

Description Part No. Muntin Center Line Door Height
2390
Btm
Rod
=
41.877 		RODASY.10011 42.5 83.188
2390
Btm
Rod
=
40.627 		RODASY.10012 41.25 83.188
2390
Btm
Rod
=
37.252 		RODASY.10013 37.875 83.188
2390
Btm
Rod
=
39.377 		RODASY.10014 40 83.188

PARTS LIST (continued)

2390 Extension Rod Kit (Part No. EXTROD.1001)

Description Part
No. 		Quantity
3/8-24
jam
nut
Upper
extension
rod
7.5"
Lower
extension
rod
6.5"
Extension
tube
70"
1/8"
x
5/8"
roll
pin 		4299100004
ROD.1049
ROD.1048
TUBE.300
4299100060 		1
1
1
1
2

BEFORE INSTALLATION

  • 1. Check "Parts List" (page 2 and page 3).
  • 2. Prepare door using template on page 18.
  • 3. Set initial rod lengths (see page 16). Rods lengths are factory set as specified on customer order.
  • 4. If necessary, re-hand device (see page 17) and top rod (see Figure 1-1, page 4).

INSTALLATION

1 Install rod assemblies.

1.1. If using outside cylinder, install cylinder lift bracket on top rod (Figure 1-1). Do not tighten completely (final position will be determined in door). For 2" thick doors only , also install lift bracket 2" thick door and screws (#8-18 x 5/16" UFPHSMS) from package No. BRKTASY.155.

Figure 1-1

! NOTE

If using on narrow architectural stile with adjustable astragal, bend one ear only of cylinder lift bracket as shown at right before installing.

1 Install rod assemblies (continued).

1.2. Fit top rod assembly into door.

! NOTE To simplify fitting rod and lift bracket through stile, remove lift bracket and reinstall after top rod is in door (prior to Step 11.5).

  • 1.3. Secure top rod assembly with two #10-32 x 1/4" UFPH machine screws.
  • 1.4. Install top rod bearing bushing and retaining ring. Be sure retaining ring seats securely in groove on rod.

Figure 1-2

2.1. Measure muntin length (Figure 2-1) and stile offset (Figure 2-2).

2.2. If measured muntin length (width between stiles) is less than the minimum listed in Minimum Muntin Length table, the device is too long for the application.

Minimum Muntin Length

Stile
Offset 		Minimum Muntin Length
(width between stiles)
0.115" 27.505"
0.125" 27.495"
0.142" 27.478"
0.156" 27.464"
0.187" 27.433"
Long
Device
(24"
touchbar) 		Short Device
(21"
touchbar)
Stile
Minimum Muntin Length
Offset
(width between stiles) 		Stile
Offset 		Minimum Muntin Length
(width between stiles)
0.115" 27.505" 0.115" 24.505"
0.125" 27.495" 0.125" 24.495"
0.142" 27.478" 0.142" 24.478"
0.156" 27.464" 0.156" 24.464"
0.187" 27.433" 0.187" 24.433"

2.3. Calculate muntin filler length (Figure 2-3) using formula from Muntin Filler Length table and cut muntin filler to length.

Muntin Filler Length

Figure 2-3

Long
Device
(24"
touchbar)
Stile
Offset 		Muntin Filler Length
0.115"
0.125"
0.142"
0.156"
0.187" 		= muntin length–
27.505"
= muntin length–
27.495"
= muntin length–
27.478"
= muntin length–
27.464"
= muntin length–
27.433"
Short
Device
(21"
touchbar)
Stile
Offset 		Muntin Filler Length
0.115" = muntin length–
24.505"
0.125" = muntin length–
24.495"
0.142" = muntin length–
24.478"
0.156" = muntin length–
24.464"
0.187" = muntin length–
24.433"

3 Install traveler.

  • 3.1. Position traveler as shown (Figure 3-1) and place over rod ends.
  • 3.2. Push top rod up until rods are held retracted, traveler is held up (Figure 3-2), and top latch bolt is locked forward (Figure 3-3).

4 Adjust top rod.

  • 4.1. With top rod retracted (see Step 3), press down on traveler end as shown (Figure 4-1). Make sure traveler is held over rod ends and against rod bushings.
  • 4.2. Measure the gap between the bottom of the traveler end and the lower wall of the muntin (Figure 4-1 and Figure 4-2). Adjust top rod per directions in table below.

Gap Directions
1.193" Rod
adjustment
is
correct.
Go
to
Step
5.
1.151" Shorten
rod
one
(1)
turn
and
repeat
Step
4.
1.110" Shorten
rod
two
(2)
turns
and
repeat
Step
4.
1.068" Shorten
rod
three
(3)
turns
and
repeat
Step
4.
1.235" Lengthen
rod
one
(1)
turn
and
repeat
Step
4.
1.276" Lengthen
rod
two
(2)
turns
and
repeat
Step
4.
1.318" Lengthen
rod
three
(3)
turns
and
repeat
Step
4.

5 Prepare hole for EL/RX device. (If device is not EL/RX, go to Step 6.)

5.1. Drill 3/8" diameter hole for EL/RX wiring throughinside face of door, hinge side.

Figure 5-1

6 Install device.

6.1. Place dogged device in door and slide toward lock stile (Figure 6-1) so roller fits under traveler end (Figure 6-2) and baseplate tabs touch lock stile wall (Figure 6-3).

7A Secure RHR device. (See next page for LHR device.)

7A.1. With device seated against bottom of muntin, use a 3/8" open end wrench to tighten two gold color anchor studs to extend anchor pins. Tighten only until resistance is felt.

7A.2. After resistance is felt, tighten two gold color anchor studs 2-1/2 more movements of the wrench through the touchbar openings.

7A.3. Using a 7/16" open end wrench, tighten two silver jam nuts against anchor blocks. Use a 3/8" open end wrench to hold anchor studs in position while tightening jam nuts.

7B Secure LHR device. (See previous page for RHR device.)

7B.1. With device seated against bottom of muntin, use a 3/8" open end wrench to tighten two gold color anchor studs to extend anchor pins. Tighten only until resistance is felt.

7B.2. After resistance is felt, tighten two gold color anchor studs 2-1/2 more movements of the wrench through the touchbar openings.

! CAUTION

Do not overtighten or damage to device may occur.

7B.3. Using a 7/16" open end wrench, tighten two silver jam nuts against anchor blocks. Use a 3/8" open end wrench to hold anchor studs in position while tightening jam nuts.

RX Device Wiring

The RX switch is available only as a factory installed item. Part No. WIRE.1001 can be used only to replace the factory installed RX switch.

RX switch (part No. WIRE.1001)

Switch shown not activated (touchbar not depressed)

  • The RX switch is activated when the touchbar is depressed.
  • Use the Von Duprin EPT-10 power transfer (for three wires), EPT-2 power transfer (for two wires), electric hinge, electric pivot, or door loop to transfer the wiring from the door to the frame.
  • Connect the power transfer wires and switch assembly wires with crimp connectors. Unused wires should be insulated separately.

EL Device Wiring

NOTE

The potted circuit board is a protection circuit. It disconnects power from the solenoid if the plunger does not seat within a specified time. To reset the protection circuitry, remove power from the solenoid and reapply.

Electrical Specifications

Voltage: 24 VDC

Current: 16 A inrush (0.3 sec.)

0.25 A holding

If 871-2 logic board, refer to Von Duprin instructions 941352.

Any reference to Von Duprin EL devices also applies to EL2390.

If other 873 logic board, refer to Von Duprin instructions 941353. Any reference to Von Duprin EL

devices also applies to EL2390.

10 Adjust bottom rod.

  • 10.1. Undog the device(see page 17)and release the top latch bolt so it faces up (Figure 10-1).
  • 10.2. Pull bottom rod out as far as it will extend from door. Do not depress touchbar during this step.
  • 10.3. Measure the bottom bolt extension from the door (Figure 10-2):
    • • If extension equals 7/16" rod is set correctly. Go to Step 11.
    • • If extension is more than 7/16" shorten rod per Table 10-1.
    • • If extension is less than 7/16" lengthen rod per Table 10-2.

Table 10-2 Extension Less than 7/16"

Extension Lengthen
Rod
13/32" 1 turn
3/8" 2
turns
11/32" 2
turns
5/16" 3
turns
9/32" 4
turns
1/4" 5
turns
7/32" 5
turns
3/16" 6
turns
5/32" 7
turns
1/8" 8
turns
3/32" 8
turns
1/16" 9
turns
1/32" 10 turns
0" 11
turns

To change rod length, remove two guide mounting screws,remove guide,rotate bolt, re-install guide. ! NOTE

Figure 10-1 Figure 10-2

Table 10-1 Extension More than 7/16"

Extension Shorten Rod
15/32" 1 turn
1/2" 2
turns
17/32" 3
turns
9/16" 3
turns
19/32" 4
turns
5/8" 5
turns
21/32" 6
turns
11/16" 6
turns
23/32" 7
turns

11 Install outside cylinder. (If no outside cylinder, go to Step 12.)

  • 11.2. Make sure cylinder cam is in position for desired function with key removed (Figure 11-1). If not, remove cam and re-install in proper position.
  • 11.3. Install cylinder into cylinder housing (Figure 11-2). Tighten cylinder retaining nut securely. Make sure end of cylinder housing marked "TOP" is up.

Figure 11-2

11.4. Install cylinder bracket (Figure 11-3). Install studs and screw where shown for RHR or LHR door. Make sure end of cylinder housing marked "TOP" is up.

Figure 11-3

11.5. With top latch bolt released and facing up (Figure 11-4), position bottom of cylinder lift bracket 5/8" down from step in cutout (Figure 11-5). Maintain 5/8" location and tighten cylinder lift bracket mounting screws securely.

Figure 11-4

Figure 11-5

11.6. With key removed, install cylinder housing assembly on door (Figure 11-6). Secure with two #10 countersink washers and two #10-24 x 1" OPH machine screws.

12 Perform functional check.

  • 12.1. Dog device (see page 17). Top latch bolt should pivot freely.
  • 12.2. Undog device (see page 17) and trip top latch bolt so it faces up. Top latch bolt should not pivot.
  • 12.3. If cylinder housing is installed, insert key and rotate 180° for NL or 360° for HB. Top latch bolt should pivot freely. For HB, key should come out of cylinder after clockwise rotation. For both NL and HB, rotate key back counterclockwise to starting position and remove key.
  • 12.4. With device undogged (touchbar and key cylinder), press touchbar and release so top latch bolt locks forward and rods are held up. Bottom latch bolt should be flush to within 1/32" to bottom of door.

13 Install cover plate.

TOUCHBAR DOGGING

! NOTE

EL (electric latch retraction) devices cannot be dogged using the touchbar. If mechanical hold back is required, use pull side HB key cylinder option.

To Dog Device (latch stays retracted)

  • 1. Depress touchbar with hand and hold in.
  • 2. Insert dogging key into hole on touchbar.
  • 3. Rotate key approximately 1/8 turn clockwise.
  • 4. Release touchbar. Touchbar will remain depressed.

To Undog Device (latch locks when door closes)

  • 1. Depress touchbar with hand and hold in.
  • 2. Insert dogging key into hole on touchbar.
  • 3. Rotate key approximately 1/8 turn counterclockwise.
  • 4. Release touchbar. Touchbar will extend from door.

SETTING ROD LENGTHS

Rod lengths are factory set as specified on customer order. For configuring door for door height down to approximately 5.5 feet and up to approximately 10.5 feet, see 2390 Extension Rod Kit (part No. EXTROD.1001) or order rods from factory pre-set.

Determine top rod assembled length TR AL: TR AL = door height — C — 0.516" where C = distance from center line of muntin to bottom of door.

2. Set top rod to nearest 1/32" as determined in Step 1. Jam nut must be tightened so bent end of rod is perpendicular to sides of latch housing. See Figure 1 for handing. See table below for common rod lengths.

Figure 1

3. Determine overall bottom rod length BR: BR = C — 0.632"

where \mathbf{C} = distance from center line of muntin to bottom of door.

Figure 2

4. Set bottom rod to nearest 1/32" as determined in Step 3. Jam nut not required to be tight. End of rod must be oriented as shown in Figure 2 relative to flats on hex bolt.

For common rod lengths, see table below (all dimensions in inches).

Door Height C (distance from center line of muntin to bottom of door) BR
83.188 (83-3/16) 42.5 (42-1/2) 40.176 (40-11/64) 41.877 (41-7/8)
83.188 (83-3/16) 41.25 (42-1/4) 41.426 (41-27/64) 40.627 (40-5/8)
83.188 (83-3/16) 37.875 (37-7/8) 44.801 (44-51/64) 37.252 (37-1/4)
83.188 (83-3/16) 40 (40) 42.676 (42-43/64) 39.377 (39-3/8)
83.250 (83-1/4) 41.25 (41-1/4) 41.489 (41-31/64) 40.627 (40-5/8)

RE-HANDING DEVICE

! NOTE

RHR to LHR conversion shown. To convert LHR device to RHR device, follow figures in reverse order, removing parts in Figures 6 through 4 and re-installing parts in Figures 3 through 1.

1. Remove lock side center case cover. 4. Flip device over and re-install lift arm.

3. Remove lift arm. 6. Re-install center case cover.

TEMPLATE

Consult Falcon or door manufacturer for door-specific template information.

Bottom Plan View, Head Jamb (looking up) Showing Upper Strike Mounting Holes

Top Plan View, Threshold (looking down) Showing Strike Cutout in Threshold for Latch