manual GB - Automatski sistem
Contents
1. RS200 top view B H 175mm for manual operated doors B H Omm for e operated doors Min 80 flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors 13 manual 92 Panel overlay 22 5 mm INSTALLING VERTICAL TRACK SYSTEM flexifo rce RS200 manual GB 2009 www flexlforce com innovations for overhead doors 13 manual 9 VERTICAL TRACK SET m OPTIONAL REINFORCEMENT HORIZONTAL TRACK SET For heavy doors the horizontal track could be optionally reinforced with plate RX560R L flexifo rce RS200 manual GB 2009 Won sr innovations for overhead doors manual 82 p m A RS200H10 etc INSTALLATION WALL CONSOLES Traditional installation RX563R 1D70B35 SuperClick installation 563CR SuperClick 1070835 1068M T p m flexifo rce RS200 manual GB 2009 innovations for overhead doors www flexiforce com 9 manual 9 CONNECTION HORIZONTAL TRACKS OPTIONAL SUSPENSION HORIZONTAL TRACK TO CEILING flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 9 SHAFT SYSTEM INSTALLATION DOOR W 3000mm Cable drums No key way FF4X8 FF400 8 S FF0402 Central shaft suspension Without key way tube shaft Torsion2. manual 9 RS200 Hardware system for residential garage overhead doors Built in height 200mm springs in front INSTALLATION MAINTENANCE USAGE All rights reserved FlexiForce 2009 flexifo rce 5200 manual GB 2009 www flexiforce com innovations for overhead doors manual A A ATTENTION GENERAL WARNING To install use and maintain this door system safely a number of precautions must be taken For the safety of all concerned pay heed to the warnings and instructions given below If in doubt contact your supplier SPECIAL SAFETY WARNINGS OR REMARKS IN THIS MANUAL ARE INDICATED WITH THIS SYMBOL READ THESE WARNINGS CAREFULLY v This manual has been written for use by experienced fitters and as such is not suitable for d i y purposes or for use by trainee fitters v This manual describes the installation of the hardware set components door sections panels and refers to installation manuals of the electrical operator Be sure to supplement this manual if needed with instructions for any additional components not described in this manual v Before starting read this manual carefully v Certain components may be sharp or have jagged edges As such you are advised to wear safety gloves v the components which have been supplied are designed for use with this specific overhead door Replacement or adding additional components may have an adverse effect on t
3. carried out by qualified overhead door mechanics 2 Replacement of broken or weared components should always be done by qualified overhead door mechanics 3 When checking the door always disconnect the electrical main power supply Make sure that it is blocked against re engaging without you knowing it REGULAR MAINTENANCE After installation 1 Grease running part of the tracks MECHANIC 2 Grease the bearings of the rollers MECHANIC 3 Grease the shafts of the rollers MECHANIC 4 Grease the bearings of the shaft MECHANIC 5 Grease the hinge pins MECHANIC 6 Grease the lock MECHANIC 7 Protect the panels with carwax USER 8 Grease the rubbers slightly with vasaline USER After 3 months 1 Complete inspection visualy MECHANIC 2 Check balancing system and adjust if needed MECHANIC 3 Grease all the above mentioned points if needed MECHANIC Every months or after every 750 cycles 1 Check side seals on damage or wear and tear USER 2 Check top seal on damage or wear and tear USER 3 Check bottom seal on damage or wear and tear USER 4 Grease all above mentioned points USER 9 Clean the panels USER 6 Clean the windows only water wash do not use cloth USER 7 Remove dirt and waste from the door or Its surroundings USER Every 12 months or after every 1500 cycles 1 Check or test the fixation of the springs to the fittings MECHANIC 2 Check the balance of the door and adjust if needed MECHANIC 3 Check the cables for
4. conformity lla declaring the door is according to EN 13241 1 O O O O Visit www flexiforce com for the most recent update of Information on your obligations towards handing over a safe to use door innovations for overhead doors www flexiforce com 22 manual 9 OPTIONAL E OPERATION When you have selected an electrical operator drive LIFTMASTER LM60K R or other then this should be assembled in conformity with the handbook supplied with this operator and above displayed instructions You should clearly follow the instructions for electrical operation in this handbook In order to maintain the closing peak force of the door within the CE standards the attachment point of the drawbar should be fixed at the proper position Ask your supplier for the correct position NB The person installing the door must check thoroughly if the combination between this door and the selected operator is safe to use ITTR approval report Keep in mind the max peak force that is allowed when closing the door People could get hurt if the adjustment of the operator software or the installation of the operator or the selected operator on this door are not checked correctly flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 5 OPTIONAL TANDEM ROLLERS flex M 2 XI ifo rce RS200 manual GB 2009 n innovations for overhead doors 13 manual 9 PANEL ASSEM
5. wear and tear MECHANIC 15 Check the shaft on wear and tear or damage MECHANIC 16 Check the bottom bracket on wear and tear and damage MECHANIC 17 Check the connection of the drum to the shaft keys MECHANIC 18 Check and re fix the bolt of the coupler MECHANIC 19 Check the connections of the track system MECHANIC 20 Check the suspension of the door to the lintel and ceiling MECHANIC Use for greasing PTFE or SAE20 or WD40 Use for cleaning Soft soap with water Do not use aggressive soap or cloth flexi fo rce RS200 manual GB 2009 innovations for overhead doors
6. 74 60 1 larangel S amp 2CEN Alternative hinges 411 series m TAO 1055BV etc Cem Ml uu d L r w flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 5 INSTALLATION TOP PANEL TOP ROLLER CARRIER Close the door and secure the door panel Loosen the two self tapping screws 1055BV securing the top roller holder 417S so that it can be displaced with a slight tick Press the top panel against the side upper seal and slide the top roller holder as far as possible downwards and fix all screws minimum play between door panel and seal The bearing roller lies snugly in the rounding of the bearing tracks Alternative top roller carrier adjustable 4195 series p wu le gt gt Al E ifo rce RS200 manual GB 2009 n innovations for overhead doors ae E 13 manual 9 CABLES amp TORSION SPRINGS Position drum on the shaft ONm flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 9 With key way NB See separate manual spring break device installation 656Manual GB pdf TORSION SPRING TENSIONING CAUTION Torsion springs are subject to considerable tension Proceed at all times with extreme caution Installation maintenance and repair should be carried out only by experienced and properly traine
7. BLY INSTALLING END CAPS 40ES500L etc or alternatives Kingspan panel Tecsedo panel Metecno panel 40ES500L R 40ES610L R 40TS500L R 40TS610L R 40FS500L R 40FS610L R 40ES500WL R 40ES610WL R RAL9010 40TS500WL R 40TS610WL R 40FS500WL R 40FS610WL R 40EM500L R 40EM610L R 40TM500L R 40TM610L R 40FMB5BOOL R 40FM610L R 40EM500WL R 40EM610WL R RAL9010 40TM500WL R 40TM610WL R 40FM500WL R 40FM610WL R p W 45mm manual 9 1031RES6070 or INSTALLING BOTTOM ALU SEAL 1035RES flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 9 CUTTING FINISHING TOP PANEL A NB Make sure that the bottom panel will not be cut for adjusting the panel or door height This should be done with the top section only The attachment of the bottom bracket which is holding the complete door weight is relying on the construction of the panel Danger can occur if the panel is cut at this point Total door panel height Days Opening Height H 15mm dM 74 1034 34 etc T 38TOP 6090 etc flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors FF manual GB rev 0 Feb 09 TROUBLESHOOTING What should be checked if the door is not balanced properly When a door is not well in balance then it is necessary to check first the following details 1 Is the given information corr
8. ations X po flexiforce FF MANJAL 436 Mexitorce c FF MANUAL Superciice flexiforce flexifo rce RS200 manual GB 2009 inii innovations for overhead doors FF manual GB rev 0 Feb 09 IN THIS MANUAL Attention general warnings 2 Guarantee terms and conditions 2 Application range 3 Recommended additional manuals 3 Tools for correct and rapid assembly D Applied fixation materials 5 RS200 System overview Installing vertical track system 7 Installing horizontal track system 8 Shaft system installation 11 Panel lt gt Hardware installation 14 Cables amp Torsion springs 17 Finishing the door 19 Optional E operation 23 Panelassembly 24 roubleshooting 27 Dismantling the overhead door 28 Maintenance and replacement of parts 29 R 9 N eN Un p w 4 na f flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors FF manual GB rev 0 Feb 09 TOOLS FOR CORRECT AND RAPID ASSEMBLY Battery drill with Bit 4 0 mm Bit 4 5 mm Bit 6 5 mm Plug 10 mm Plug 13 mm Hexagonal key 4 mm Socket screw spanner 8mm in Ring open ended spanner 10 mm Ring open ended spanner 13 mm Ring open ended spanner 15 mm Ring open ended spanner 17 mm Socket wrench with 4 square Wrench Gluing clamp Cord Water level hose 2 blocks of ca 20 en 40mm in height Measuring equipment APPLIED FIXATION MATERIALS The ap
9. d overhead door fitters Use correctly fitting and properly maintained tension levers FlexiForce code RES TB Number of turns on the torsion springs Height H 4 panels 5 panels cena 2000mm 7 1 turns 6 8 turns 2125mm 7 6 turns 7 3 turns 2250mm 8 0 turns 7 7 turns 2375mm 8 4 turns 8 7 turns 2500mm 8 5 turns 9 2 turns 9 panels 6 panels 2750mm 9 4 turns 9 2 turns 3000mm 10 3 turns 10 0 turns Insert the 1 tension lever completely into the slot flexifo rce RS200 manual GB 2009 innovations for overhead doors Turn the 1 tension lever a quarter turn such that the spring is tensioned www flexiforce com 18 manual 9 Insert the 2 lever completely into the next slot Take over the tension of the spring from the 1 tension lever to the 2 tension lever Remove the 1 tension lever from the slot Turn the 1 tension lever a quarter turn such the spring is tensioned Repeat until number of turns is achieved Then fix the spring plug to the shaft Check the door balance and adjust the springs if necessary equally both springs 2100 15 flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors 13 manual 9 GREASING DOOR PARTS RE ADJUSTING THE DOOR Open and close the door for checking all the settings When the door panel is not hanging completely horizontally in the lifting cables in almost closed conditions t
10. damage or wear and tear MECHANIC 4 Check the cable connection points on drums and bottom bracket MECHANIC 9 Check the roller on wear and free moving space MECHANIC 6 Check the hinges on breaking MECHANIC flexi fo rce RS200 manual GB 2009 innovations for overhead doors manual 82 7 Check the panels on damage wear and roust MECHANIC 8 Check the spring breaking device acc to instructions in manual MECHANIC 9 Check and test the safety edge system with operator MECHANIC 10 Check the manual operation of the door MECHANIC 11 Grease the springs MECHANIC After two years or after every 3000 cycles 1 Grease all the above mentioned points MECHANIC 2 Check or test the fixation of the springs to the fittings MECHANIC 2 Check the balance of the door and adjust if needed MECHANIC 3 Check the cables for damage or wear and tear MECHANIC 4 Check the cable connection points on drums and bottom bracket MECHANIC 9 Check the roller on wear and free moving space MECHANIC 6 Check the hinges on breaking MECHANIC 7 Check the panels on damage wear and roust MECHANIC 8 Check the spring breaking device acc to instructions in manual MECHANIC 9 Check and test the safety edge system with operator MECHANIC 10 Check the manual operation of the door MECHANIC 11 Grease the springs MECHANIC 12 Check side seals on damage or wear and tear MECHANIC 13 Check top seal on damage or wear and tear MECHANIC 14 Check bottom seal on damage or
11. ect weight of the door leaf including hardware is the division of the weight equal on each panel or are there panels with a different weight than the others for instance by the application of different panels glass pass door with heavy profiles 2 Are the correct parts supplied and fitted especially the drums and springs are important are the correct dimensions supplied oy Is the door properly installed horizontal tracks really horizontally and not with inclination 4 Were modifications made afterwards check if any changes were made during the fitting or if a pass door was fitted later or any reinforcement profiles fitted etc 9 Is the e operator installed and selected properly Is the installed e operator suitable for this door Is the e operator power adjusted properly for this door See installation manual operator Is the connection of the drawbar to the top panel on the right position See attachment and manual operator WHAT TO DO AFTER CABLE BREAK OR SPRING BREAK A NB Also make sure to instruct the user about this After spring breaking the door will be stopped by the 656 series spring break devices The end user must contact immediately a qualified overhead door mechanic The spring breaking device is a so called one shot device After it has acted it must be replaced together will all other possibly damaged components of the door such as torsion springs spring plugs beari
12. he safety of and the guarantee on the door Also the CE approval which has been granted to this door will be cancelled when components are changed or installation is not done according to this manual Installer is responsible for this V Ensure that there is sufficient light during installation Remove obstacles and dirt Make sure that there is no one else present other than the fitters Other people children may get in the way or endanger themselves during the installation GUARANTEE CONDITIONS AND TERMS The general terms and conditions of delivery and payment issued by the Metaalunie and designated as METAALUNIE CONDITIONS are fully applicable to all our quotations contracts and their implementation We expressly reject all other terms and conditions On request we will send you a copy of these terms and conditions free of charge A copy may also be downloaded from our website www flexiforce com FlexiForce strives to deliver 100 96 in conformance with the order In practice in spite of all our controls this is not always possible However we will rectify any errors as quickly as possible in order to minimise the inconvenience caused to you or the user As such it is important that you inform us as soon as possible about any problem with the delivery include the order number and week of production and give us the opportunity to offer a suitable solution FlexiForce will only reimburse third party costs if we have given explicit permiss
13. here are several options for fine adjustment A Loosen the securing bolts of the cable drum and the drum relative to the tube shaft B When a coupling is employed this may be adjusted to ensure a better horizontal setting Horizontal movement of the door can be limited to max 5mm by installing 2065 distance rings on the roller shafts flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual 9 SAFETY LABELS ON THE DOOR LABEL GB etc flexifo rce RS200 manual GB 2009 www flexiforce com innovations for overhead doors manual gt gt flexifo rce RS200 manual GB 2009 Install any additional accessories that you have ordered separately such as Handgrip lock etc See separate instructions in product packaging NB lock may not be fitted to an electrically driven door NB A manually operated door should always be equipped with a hand grip installed at a safe location on the door NB Do NOT INSTALL a pull rope with a power operated door at any time This can cause serious injuries or danger to the user of the door Place your CE identification plate on the door mandated together with any warning labels required Hand over necessary documents to the end user o User manual Dismantling instructions included in this manual Maintenance instructions included in the user manual Service log book Declaration of
14. ion for this in advance The reimbursement is based on normal rates and travelling expenses over distances of 1 hour away at most For large scale projects we strongly advise you to first install 1 door completely before installing the other doors In this way any errors can be detected early on and rectified comparatively cheaply This manual does not confer any rights Technical modifications may be made without written notice FlexiForce has endeavoured to design and put together this hardware set in conformance with the applicable CE norms However we recommend to check our configuration against any local national specification flexi fo rce RS200 manual GB 2009 eo innovations for overhead doors manual 95 FlexiForce has applied the mandated INITIAL TYPE TESTING for doors described in this manual at the SP Institute in Sweden as Notified Body Nr 0402 The INITIAL TYPE TESTING REPORT that has been rewarded can be transferred to the door producing company This is needed to complete your CE files according to product standard EN13241 1 Contact FlexiForce for acquiring this report APPLICATION RANGE FlexiForce has developed a new hardware system for garage overhead doors The system includes the following features e Suitable for single and double garages Wmax 5 000 mm Hmax 3 000 mm e For double doors the horizontal track set can be reinforced with side plate RX560L R e Advised max door weight is 165 kg Each sp
15. ng plates etc The door has to be inspected thouroughly See separate manual 656 spring break device After cable breaking the door will be stopped by the second cable which is designed to be strong enough to hold the weight of the door Again qualified overhead door mechanics must inspect the door and replace all possibly damaged components such as bottom brackets cable roller carriers rollers etc SPRING IDENTIFICATION RHW Red RHW Red LHWaBlacl m LHW HBlack p U DIEI l y L nFF FlexiForce spring gauge WGD10 flexifo rce RS200 manual GB 2009 Won sr innovations for overhead doors 13 manual 95 DISMANTLING THE OVERHEAD DOOR A ATTENTION WARNING To dismantle an existing overhead door a number of precautions must be taken For the safety of all concerned pay heed to the warnings and instructions given below If in doubt contact your supplier Dismantling should only be carried out by experienced fitters This manual is not suitable for d i y purposes or for use by trainee fitters This manual only describes the installation dismantling of hardware for overhead doors and as such must be supplemented with instructions for any additional components FOR ANY DETAILS ON THESE DISMANTLING INSTRUCTIONS WE REFER TO THE INSTALLATION CHAPTERS OF THIS MANUAL WHERE DRAWINGS AND DETAILS ARE DISPLAYED STEP 1 De tensioni
16. ng the torsion spring s AN CAUTION Torsion springs and bottom brackets are under high tension Exercise at all times great caution Use properly fitting and maintained tension irons see drawing Start dismantling of the door by closing the door and securing its movement with a clamp on the vertical track First the tension on the torsions springs and cable has to be released Do this by following these instructions Insert the 1 tensioning iron fully into the tensioning aperture Take over the tension of the spring with this tensioning iron Loosen the bolts in the tensioning plug and remove the key Turn the 15 tensioning iron in the direction required Insert the 2 tensioning iron fully into the next tensioning aperture Take over the tensioning of the spring from the 1 tensioning iron with the 2 tensioning iron Remove the 1 tensioning iron from the aperture Turn the 2 tensioning iron a quarter turn in the direction required Insert the 1 tensioning iron fully into the tensioning aperture 10 Take over the tensioning of the spring from the 2nd tensioning iron with the1 tensioning iron 11 Repeat steps 4 through 10 until all tension is released 12 Remove the last tensioning iron PT WN STEP 2 Disconnect the electrical operator Follow any Instructions given in the separate manual of the operator STEP 3 Loosen the cable drums and remove the keys Act carefully there might be some ten
17. plicable fixation material is described in the drawings of this manuals Below an overview of the applied fasteners and optional alternatives 1055BV self tapping screw Alternatives 1055D screw 6 3x25mm with drill point Max torque 10Nm key 10 1053BV screw 6 3x35mm 10530 screw 6 3x35mm with drill point 1054 25 1054 35 screw with socket hex cap drill point 8 10 1054W 25 1054W 35 screw with socket hex cap RAL9010 p KEN Optional 1055CAP10 white RAL9010 cover for screws key 10 3 zs d 1070B35 bolt M8x25 1006B press bolt 1062B bolt M x16 1068M nut M8 1062M nut M 1062M nut M Max torque 13Nm key 13 Max torque 9 1Nm key 10 Max torque 5 3Nm key 10 E 6 25 10628 M 1062M H M6 1062M M6 1068M H 8 1071BC bolt M8x12 SuperClick secure bolt NB Fixation material for installing to wall and Max torque 10Nm key 13 ceiling is not included in this manual flexifo rce RS200 manual GB 2009 innovations for overhead doors 13 manual 9 RS200 SYSTEM OVERVIEW Shaft system with torsion springs spring break devices drums spring fittings cables etc RS200H10etc Horizontal double track set Connection horizontal tracks Door panels sections With end caps hinges bottom brackets bottom astragal and seal top roller carriers windows etc RSV10etc Vertical set with track side seal and vertical angle Min 200
18. ring break device is approved to 125kg e CE approved when selecting the proper FlexiForce components We wish you every success with the installation of this hardware set If anything is unclear or should you have queries you should of course contact Flexi Force B V or your supplier This set has to be completed with the assembled door sections Panels brands and types according to the list of approved panels NB FlexiForce has introduced a new system for shaft installation so called SUPERCLICK There is a separate manual available for this system attachment In this manual the SuperClick system is marked with this sign K 2 NB FlexiForce recommends to apply our light hardware range for garage doors In this manual only light components are selected Attention In this set the fixing material required to install the track set to the building is not included It is the responsibility of the qualified door installer to make sure that the building stone concrete wood etc is strong enough at the points of fixation to ensure a reliable construction The door installer has to select proper fixing materials RECOMMENDED ADDITIONAL MANUALS ddmanuat Fa manual 33 product specs Su perClick FlexiForce inside stallatior spring breaking device m for residential garage overhead doors ist INSTALLATION MAINTENANCE RES Overview m Da A f panel hardware ty M D combin
19. sion left on the cable Check if the cable is slack Remove the cable by disconnecting it from the bottom bracket and cable drum STEP 4 Dismantle the horizontal track construction STEP 5 Remove the panels one by one from the vertical track construction starting with the top panel Do this by loosening the hinges and rollers first STEP 6 Remove the shaft construction from the lintel after you have dismantled the E operator from the shaft If the shaft is divided and connected with a coupler first disconnect the coupler and carefully remove both halves of the shaft system AN Attention Watch out for parts that might slide of the shaft such as cable drums bearings or keys STEP 7 Remove vertical tracks and angles from the building construction STEP 8 Make sure that you remove all the parts and panels an environment kindly way Check with your local authorities where and how you can leave this as garbage flexi fo rce RS200 manual GB 2009 innovations for overhead doors manual MAINTENANCE AND REPLACEMENT OF PARTS RESIDENTIAL DOORS An overhead door should be maintained and checked regularly to ensure safe operation and use This is described in the EN norms GENERAL 1 Torsion springs brackets and other components which are attached to the springs and cables are under extreem tension If not handled properly injuries or damages might occur So working on these components may only be
20. springs with spring fittings and spring break devices gt P F A CENTRAL SHAFT SUSPENSION 3 ALTERNATIVES USA MINI 312RM 312RM Liftmaster conn 312R USA MINI MR M BOLTS NUTS PRE ASSEMBLED flexifo rce RS200 manual GB 2009 innovations for overhead doors T3 manual 93 SHAFT SYSTEM INSTALLATION DOOR W gt 3000mm double doors Cable drums With key way FF 4 13 FF05NL 12 etc Central shaft suspension With coupler and 2 bearing plates 310CL CR or Torsion springs with spring fittings and spring break devices With key way tube key wayed shaft CENTRAL SHAFT SUSPENSION W 3000mm Traditional installation SuperClick installation Y S Max 23 Nm flexi fo rce RS200 manual GB 2009 innovations for overhead doors manual 8 FIXATION TO THE LINTEL E El Em Traditional installation SuperClick installation 1070835 e 1070835 1071BC 1071BC 1071BC g k ka flexi fo rce RS200 manual GB 2009 Cass TA innovations for overhead doors T3 manual 93 PANEL HARDWARE INSIALLATION x 1055BV 9 SBICEM laranqol 046 atc 5B2CEN black A205 lincl in amp 21K flexifo rce RS200 manual GB 2009 PPM innovations for overhead doors T3 manual 92 574RES 5
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