GB INSTALLATION MANUAL RES70
Contents
1. ES For sloping floors one of the bearing tracks may be compensated for example with a wedge FITTING RETURN PULLEY AND BRACKET TO THE END PLATE The side plate contains 3 holes in which to fit a return pulley A B and C See figure 4 Application holes cable pulley and cover plate Clear Width 2500 gt 2500 5000 CUm wmm pulle plate pulle plate Manual A EE dme eme vas Insert the M8 press bolt 1008B through the cover plate R70PL80 or 70 1 60 the return pulley 570 60 or 570 80 the spacer 2060 27 and hole A B and C see figure 5 of the reinforced end plate of the assembled horizontal track set The spacer should be fitted with the flat side against the end plate Fit the M8 nut 1068M and tighten it orig R70 manual GB no2 6 MANUAL R7OPLEORH Z 5 N y 10088 R7OPLBORH ASSEMBLY HORIZONTAL TRACK SET Attach a piece of rope to the ceiling or the roof Ei 6 structure to maintain the elevation of the rear side Pu MUR of horizontal tracks during the assembly process Slide the horizontal tracks in the direction ofthe 7 5 6 vertical track set Ensure that the flange of the lt 7 7 vertical angle comes to rest between the end plate and the shortened upper bend of the horizontal tracks The end plate will now be on the exterior of the vertical angle line See figure2. Atto N d 12 MANUAL lexilorce E Place the remaining panels and secure the side and central hinges may be pre fitted to the panels Figure 16 Figure 16 Adjust the bearing roller to the side hinge such that the nylon bearing roller is located in the rounding of the track and that the play between panel and side seal is at a minimum The shaft of the bearing roller should remain capable of turning by hand Slide the plastic bush 418BUS over the bush of the top roller holder 418 W Then slide the shaft of the bearing roller 576 into the bush of the top roller holder Figure 19 25 Place the bearing roller in the shortened upper bend and fix the top roller holder 418 WO to the upper side of the top panel with 2 self tapping screws 1055BV in both slotted holes The remaining self tapping screws 1055BV will be secured at a later stage Figure 19 2 OSSBV orig R70 manual GB no2 13 MANUAL FITTING CABLE AND TENSIONING THE SPRING Align the shaft Guide the cable from the bottom bracket behind the bearing roller shafts and over the return pulley to the cable drum See figure 20 Figure 20 Hook the end of the cable with the end of the pressure clamp circular into the cable drum and turn the cable drum until the lifting cable is taut
3. position of the bearing plate support for an available installation space of at least 100 mm Always for electrical drive and for manual operation when there is sufficient gt 90 mm height available Position B the position of the bearing plate support for an available installation height between 70 and 100 mm Always for manual operation a 540 Position A electrical Position B manual operation Depending on the option selected under G page 3 one of the following instructions will apply The construction and assembly for suspension of the horizontal tracks will be determined by others a 0000 0000 orig R70 manual GB no2 8 Figure 9 V le ll ol 2 Figure 10 13 MANUAL With vertical suspension profile of horizontal tracks to ceiling roof structure Figure 9 Fit the perforated angle 30B0750 to the bearing plate support 340 with 2 M8 press bolts and nuts 1070 3 5B and 1068M al Boog 1 With horizontal connecting profile between the horizontal tracks CW 2500 Figure 10 Shorten when necessary the long C profile The profile may then be used as measuring rod L Clear Width 134 mm The ends of the 50SU profile will then correspond with the exterior of the bearing plate support Slide first onto both sides the short 48SU profile into the 50 SU profile Then slide long C profile with slotted holes 5050275
4. projects The set includes the following features Suitable for single and double garages to W gt 5000 Spring package behind the horizontal tracks Fitted with cable within the tracks and spring breaking device meeting CE standards Restricted installation sizes In this handbook we shall restrict our instructions for the proper assembly of our hardware set parts For the installation of the complete door including any components added by the supplier as well as for a user handbook we refer you to the supplier of the complete overhead door who is also responsible for the correct CE marking of the door These instructions have been prepared for use by experienced professional fitters and are therefore not suitable for the DIY fitter or the apprentice fitter The article codes of the parts are given in parentheses The hardware set consists as standard of A The track set vertical and horizontal B Standard parts and or fastening material including spring break device C Hardware hinges bottom brackets top roller holder etc in version selected D The assembled cable set E Tubular shaft F Torsion springs galvanized or powder coated in version selected Att The attachment material required to secure the track set to the wall or to suspend it from the walls or ceiling is not part of the delivery G Connection suspension profiles for horizontal track set H Top seal for on the lintel Electric drive RES E 500 drawbar
5. support will depend on the available installation height Figure 13 ER U 26 e Position A the position of the bearing plate support for an available installation height of at least 100 mm Always for electrical drive and may be possible for manual operation illustration above Position B the position of the bearing plate support for an available installation height between 70 and 100 mm In many instances for manual operation illustration below FIT q TO H Gen fid ol EE Fi 651 667 the panel material Guideline value for steel insulated panels is 4 5 mm orig R70 manual 2 11 ES Place the bottom panel truly level between the bearing tracks on ca 20 to 40 mm high blocks Insert two M6 pressure bolts 1006B at the rear through the bottom bracket 431 431W and secure the bottom brackets with the self tapping screws 1055BV Figure 14 ES Insert the shaft of the bearing roller 577 through the loop of the lifting cable K3x k4x until the loop rests in the recess in the shoulder of the bearing roller shaft Insert the shaft of the bearing roller in the bearing roller holder 447Z 447Z W Place the bearing roller holder with bearing roller on the 2 protruding M6 pressure bolts of the bottom bracket and secure them with 2 M6 flanged nuts 1062M See figure 15 orig R70 manual GB no2 MANUAL Figure 14
6. type K Warming labels J 1 box packaging 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 orig R70 manual GB no2 3 MANUAL l3 ACCOMPANYING FASTENING MATERIAL oe 9 1068M z M6x25 us 1008B M8x55 1070B 3 5 N 1055BV LY 6 3 25 1062M 1062B M6 Fastening of return pulley 570 60 en 570 80 spacer 2060 27 bracket 554BEU to the side plate 562 70 of the horizontal tracks Number Description Fasteningtorque Keysize 2 UB 2 1068M Flanged nut xm B Fastening of horizontal track set to the vertical track set Number Code Descipion Fasteningtorque Keysze 6 oss 6 QM xm n 4 8 L4 FlangednutM6 xm o Bearing plate support at end of double horizontal tracks Number Code Desorption Fasteningtorque Keysue 8 10628 1062M Flanged mute xm 0 Fastening of spring break device to bearing plate support Number Code Description Fasteningtorque Keysze 4 1835 L4 FlangednuM8 xm n Fastening of 8 pieces side hinges 8 pieces ce
7. 0 on both ends into the rectangular recess of the bearing plate support 340 as mutual connection The closed side should rest on the flange of the bearing plate support 340 With horizontal connecting profile between the horizontal tracks CW 22500 Figure 10 Slide both C profiles into each other Mark of a length of L CW 134 mm This length is the external side of the bearing plate support The closed side should rest on the flange of the bearing plate support 340 Connect the 50 SU profile to the bearing plate support 340 with 2 M8 mushroom bolts and nuts 1070 3 5B and 1068M Then slide the short profiles 48SU out until they reach a potential suspension point sidewall where they can be secured Then secure finally the securing nuts of the connection between horizontal and vertical track set CW 2500 Slide the shaft through both springs The tensioning plug of the left wound spring is coded black and should be fitted on the left See figure 11 Figure 11 orig R70 manual GB no2 9 MANUAL CW gt 2500 ETE Slide each of the two keywayed tubular shafts 705GB through a spring The tube shafts are of unequal lengths to avoid the coupling 7035 from the centre and when there is an electric drive sitting under the drawbar The tension plug of the CU BS wound plug is coded black and should be fitted on the left See figure 325 lt 11a Fit to both shafts a bearing USA
8. 6 Insert the 2 M6 press bolts 1006B from the inside through the holes in shortened upper bend the slotted holes in the vertical angle line and the side plate Fit the M6 flanged nuts 1062M and secure hand tight Position the end of the bend in line with the vertical tracks and drill a hole of 6 5 mm through the hole in the bend the vertical angle line Insert the M6 press bolt from inside to outside through the drilled hole Fit the M6 flanged nut Insert the 2 M8 press bolts 1070 3 5B from outside to inside through the holes in the side plate and the holes in the vertical angle line Fit the M8 flanged nuts 1068M and secure these hand tight orig R70 manual GB ja3 1 MANUAL ASSEMBLY SEAL OPTIONAL clips 1083 figure 7 The top sealing profile 1085 replaces the top rubber 1036 36 This prevents the top rubber 1036 36 scraping along the ceiling ER The seal profile 1085 to the lintel using the 4 spring The fastening material required to attach the track set to the wall or to suspend it to the side walls or the ceiling is not included in the delivery ASSEMBLY BEARING PLATE SUPPORT AND SPRING PACKAGE Fit the bearing plate support 340 to the end of the horizontal tracks The position of the bearing plate support relative to the E horizontal tracks will depend on the height available for installation Figure 8 Position A the
9. Align the cable drum in such fashion on the tube shaft that the lifting cable is free to wind up through the recess in the bearing plate see figure 21 and the cable cannot interfere with the plastic bush 418BUS Secure finally the drum with 4 the hexagon bolts to the shaft without keyway tightening 7 moment 10Nm For a tube shaft with a keyway the drum SS RR H must be secured with a cotter 7114 75 and bolts Block the shaft with for example a wrench Secure the other cable in the same fashion Both cables must be tensioned equally while the door panel is truly level ES Ensure that the door does not elevate You can do this for example by placing wrenches in the vertical bearing tracks orig R70 manual GB no2 14 MANUAL lexilorce Tension the springs by the prescribed number of tums see packaging list in the box pull the spring 5 mm apart to reduce friction and 34 secure the spring to the tube shaft using the screws of the tension plug 17 Nm 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 trained overhead door fitters Use correctly fitting and properly maintained tension levers Tensioning the spring Make sure that the marking strip on the spring forms a s
10. B a bearing holder lt N E un 325 each with 2 M8 press bolts and nuts 1070 3 5B USA MINI ser and 1068M to the bearing plate USA MINI 325 V I Then fit disassembled halves of the coupler 703S T with a cotter 7114 38 Fit the spring breaking devices 651 667 to the stationary spring plugs following the drawings that are included in the packaging with every spring breaking device See handbook enclosed for the 651 667 spring breaking device RE Slide on both sides a cable drum FF 4X8 for CW 2500 and FF 4 13 for CW 2500 onto the shaft The cable drum coded RH should be fitted on the left side Turn the securing bolts of the cable drum FF 4 8 to secure these hand tight to the tube shaft Secure each cable drum FF 4 13 with a cotter 7114 75 CW 2500 Fit the bearing plates with spring breaking device with shaft and spring package in conformity with figure 12 to the bearing plate supports each with 2 M8 press bolts nuts 1070B3 5 and 1068M orig R70 manual GB no2 10 MANUAL CW gt 2500 Fit the bearing plates with spring breaking device with shaft and spring package in conformity with figure 12a to the bearing plate supports each with 2 M8 press bolts nuts 1070B3 5 and 1068M and the bearing plates each with 1 press bolt and nut 1070B3 5 and 1068m See for correct position figure 13 The position of the bearing plate relative to the bearing plate
11. Hexiforce 215H 300 59 9 2156 2 300 01 215V 915VBR RES70 hardware set residential garage overhead doors built in dimensions 70mm 3 000 mm 5 000 mm INSTALLATION MANUAL MANUAL ATTENTION GENERAL WARNINGS To install use and maintain this hardware set 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 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 This manual only describes the installation of the hardware set components and as such must be supplemented with instructions for any additional components Before starting read this manual carefully Certain components may be sharp have jagged edges As such you advised to wear safety gloves All the components which have been supplied are designed for use with this specific overhead door Including additional components may have an adverse effect on the safety of and the guarantee on the door During tensioning springs exert large forces Work carefully Use the proper eduipment Ensure that you are standing in a steady position Ensure that there is sufficient light during installation Remove obstacles and dirt Make sure that there is no one else present other than t
12. I Close the door and secure the door panel Loosen the two self tapping screws 1055BV securing the top roller holder 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 minimum play between door panel and seal For a manually operated door the bearing roller should be displaced downwards The bearing roller lies snugly in the rounding of the bearing tracks For an electrically driven door the bearing roller should be displaced upwards The bearing roller lies snugly against the flat side on the bearing tracks Then secure the 2 self tapping screws When the top panel cannot from outside be pushed inwards the remaining self tapping screws may be secured When option G is selected the suspension profiles of the horizontal connection profile SU may finally mounted FINISHING THE DOOR Fit any additional accessories that you have ordered separately such as Handgrip Lock Bolt a bolt may not be fitted to an electrically driven door NB Only lock 650 may be employed because it does not touch the cable Fit the rubber doorstop supplied with a press bolt M6x16 1062B and nut M6 1062M to the end of the top horizontal tracks Figure 22 Oil all hinges and all bearing rollers with one drop of oil 37 Grease the cables Grease the bearing roller shafts The torsion springs are already lightly oiled Plac
13. e your CE identification plate on the ES door together with any warning labels required OPTION ELECTRICAL DRIVE When you have selected option Electrical drive RES E 500 then this should be assembled in conformity with the handbook supplied with the drive You should clearly follow the instructions for electrical operation in this handbook In order to maintain the closing force of the door within the standards set the attachment point of the drawbar should be 230 mm from the upper hinge point orig R70 manual 2 16 MANUAL GENERAL SYSTEM DRAWING Min 100 A WIL i 7o Roo E Min 70 Min 70 Iro 0 orig R70 manual GB no2 17 MANUAL Hexiforce E J A 21 Seealso figure 1 Enclosure A orig R70 manual GB no2 18 RESIDENTIAL HARDWARE BOXES Cartons quincaillerie Kartons Beschl ge Beslagdozen R200BOX1 R200BOX2 R70BOX1 R70BOX2 570 60 RTOPLBOLH 6 1 FF 1 10 comH 1 1058 1B ese 1 serm 1 1058 8 TATS RBOXW UJ ro m UO m T 2 G m aos 8 8 8 4S 8 8 8 10 10 15 1 2003 orig RES200 70 stuklijsten
14. harp line Insert the 15 tension lever completely into the tensioning slot Turn the 1s tension lever a quarter turn such that the spring is tensioned Insert the 2 tension lever completely into the following tensioning slot Take over the tension of the spring from the 1st tension lever to the 2 tension lever Remove the 15 tension lever from the slot Turn the 2 tension lever a quarter turn such that the spring is tensioned Repeat steps 2 through 7 until the spring has realized the prescribed number of turns Secure the spring plug on the shaft by turning the bolts in the tension plug in the tube shaft Remove the final tension lever Check the number of turns by counting the number of turns that the marking strip has made a f g h j Number of turns spring CW 4 panels 5 panels 2100 7 1 turns 6 8 turns 2125 T 6 turns 7 3 turns 2250 8 0 turns 7 7 turns 2350 8 4 turns 8 7 turns 2500 8 5 turns 9 2 turns Remove the restriction from the door in the tracks and from the shaft and check whether the door is properly balanced When this is not the case you should correct this by tensioning or relaxing by at most 1 turn per spring Make sure when doing this that both springs are equally corrected Correction of the spring tension Insert the 1st tension lever completely into the tension slot Take over the tension from the spring with this tension lever Loosen the bolts in the tension pl
15. he 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 nl Flexi Force 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 permission 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 Tech
16. nical modifications may be made without written notice Flexi Force has endeavoured to design and put together this hardware set in conformance with the applicable CE norms However please check our interpretation with your local national specifications body Flexi Force B V P O Box 37 3770 AA Barneveld The Netherlands Tel 31 0 342 427777 Fax 31 0 342 414679 E mail ff flexiforce nl Internet www flexiforce com orig R70 manual GB no2 2 MANUAL INDEX Warranty terms and conditions Introduction Accompanying fixing material Tools required for correct and rapid assembly Control dimensional details Assembly vertical track set Assembly return pulley and bracket on the end plate Assembly horizontal track set Assembly top seal Fitting bearing plate support and spring package Fitting the door panels 12 Fitting cable and tensioning of the spring set 14 Finishing the door 16 Option electric drive 16 Panel assembly Enclosure A Assembly instructions spring breaking device 651 667 incl BG approval Enclosure Installation and user instructions electric drive option Enclosure Parts list content boxes Enclosure TUV approval COND amp W Introduction Flexi Force has developed a completely new hardware set for residential garage overhead doors Especially designed for situations where the available space is at a minimum renovation
17. ntral hinges 1 pair bottom bracket and 1 pair top roll holders to the door panel Number Code Description Fasteningtorque Keysze 104 1 1055BV_ _ Self tapping screw6 3 x 25 MO Nm 1 10 Fastening of bearing roller holder slide to sheers of side hinge when applicable Number Code Description Fasteningtorque Key size 16 10628 headbotM x55 e om FlangednutM6 0o Fastening of bearing roller holder slide to bottom bracket Number Code Description Fasenngtoque Keysie 4 4B oem FlangednutM6 xNm Fastening of rubber cap as bumper in track Number Code Description Fasteningtorque Keysze 2 18 2 FlangednutM6 xNm o Fastening of connection suspension Number Code Description Fasteningtorque Key size 8 woss orig R70 manual GB no2 4 Hexiforce MANUAL oem _ Flanged nut V Fastening of bearing holcler bearing plate Fastening torque Number Coe 4 100835 4 1068M Flanged nuLM8 y Nm Fastening of bearing plate suspension profile Number Code Description Fasteningtorgue Keysze 2 woss 2 8 TOOLS REQUIRED FOR CORRECT AND RAPID ASSEMBLY Bat
18. tery drill with Bit 4 0 mm Bit 6 5 mm Plug 10 mm Plug 13 mm Hexagonal key 4 mm 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 CHECKING DIMENSIONAL DETAILS Before assembling the set the details below should be checked on the basis of this figure Figure 1 A Clear width B Clear height C Side area D Top area Panel assembly 1 See enclosure Installation area reduired Side area C minimum 70 mm Top area D minimum 70 mm for manual operation minimum 100 mm for electric drive Clear passage height based on manually operated flat panel CH 70 mm Electrically driven CH 56mm For an upper space between 70 and 100 mm we recommend that top seal be fastened to the lintel For fitting of this see Assembly top seal orig R70 manual 2 5 MANUAL ASSEMBLY VERTICAL TRACK SET First mark A and on both piers using a spirit level or EM water level hose and then mark C Figure 2 Fit both vertical tracks with the lower surface on mark line C and the edge 64 mm along the pennant figure 3 The B two bearing tracks should be parallel to one another PM T bh
19. ug Turn the 1 tension lever in the direction required Insert the 2 tension lever completely in the next tension slot Take over the tension of the spring from the 1st tension lever to the 2 tension lever Remove the 1st tension lever from the slot Turn the 2 tension lever a quarter turn in the direction required Insert the 1st tension lever completely into the next tension slot Take over the tension of the spring from the 219 tension lever to the 1s tension lever Repeat steps 4 through 10 until the correction required has been realized Secure the spring plug on the shaft by turning the bolts in the tension plug in the tube shaft Remove the final tension lever 3 orig R70 manual GB no2 15 MANUAL When the door panel is not hanging completely horizontally in the lifting cables in almost closed condition there are three options for fine adjustment When the connection suspension profile behind the horizontal tracks has not been finally adjusted the bearing plate support in the slotted holes may be adjusted relative to the horizontal tracks B Loosen the securing bolts of the cable drum and the drum relative to the tube shaft For slight movements there is always a risk that the securing bolts slide into the same shallow in the tube shaft and the adjustment is not improved C When a coupling is employed this may be adjusted to ensure a better horizontal setting CL W
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