Installation tips for AJ Manufacturing’s HVAC Access Doors

Follow these four steps for trouble-free door operation:

1. Be sure the cabinet is level when you install our doors!

2. Shipping clips: what are they for?

All AJ access doors are packed with shipping clips. These plastic or metal spacers are misnamed. They’re really intended to be aids in the door installation process by maintaining the proper spacing of the door panel within the frame until installation is complete.

3. Seal the frame.

It’s essential that you provide a 100% effective seal between the cabinet wall and the installation flange of our door frame. You can use foam tape or sealant, but whichever you choose, keep these points in mind:

  • The seal must be continuous all around the frame. Be certain that there are no pinhole gaps in sealant. If you use foam tape, force in extra material at butt joints so that it can’t shrink back. Avoid overlaps of foam tape to insure uniform contact.
  • Foam tape should be 1/8” to 3/16” thick. Any thinner and it may not fill surface irregularities. Any thicker and it may cause waves in the installation flange between the installation screws.
  • If sealant is used, apply both under the installation flange prior to door installation, and again around the edge of the installation flange after door installation.
  • Do not pressurize the unit until sealant has had a chance to fully cure. High operating pressures can blow pinholes through uncured sealant.
  • AJ applies sealant to the cut ends of the frame prior to frame assembly, so it’s important that you prevent frame corners from bending during handling and installation, or this seal will be broken.

4. Adjust the latch.

Improper latch adjustment is the #1 cause of field complaints!

  • Be certain that the door is square within its frame. Loosen, re-square, and re-tighten installation screws if necessary.
  • Latch cams/pawls cannot be properly adjusted with the shipping clips in place, so remove and discard shipping clips before final latch adjustments are made!
  • There is a metal stop leg on AJ access door frames that prevents over-compression of the door gasket. Regardless of which latch you have chosen for the door, for proper adjustment, the cam (pawl) of the latch must draw the door panel down to “kiss” the stop leg. The door panel may flex slightly between latches, but it should touch the stop leg at every latch!</li?
  • The door panel does not kiss the frame at the hinge side, and that’s okay. Just be sure that it does on the latch side.