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GB INSTALLATION MANUAL IND-BS

1. HANDLEIDINGEN IND manual GB no3 3 1 Generd Installation manual 2 Lift systems Normal Lift Low Head Room High Lift Vertical Lift Following The Roof Normal Lift Following The Roof Low System Following The RoofHigh System 3 Chain hoists Rope Chain hoist1 1 Chain hoist1 3 Chain hoist1 4 Chain hoist 1 4 direct Coupler1 1 Chain 4 Hinges Toprollercarrier Intermediate hinges Intermediate hinges lengthened blade reversed pin Intermediate hinges lengthened blade Intermediate hinges Inox Side hinges Side hinges lengthened blade Side hinges Inox Toproller bracket adjustable 100101161 bracket for low headroom Single or double side hinges and rollers 5 Screws 6 3 diameterand 25mmlong 6 3 diameterand 35mmlong 6 3 diameterand 16mmlong 6 Tracks 2 tracks and 2H bends 2 tracks and 2G bends 3 tracks 7 Vertical angle and side seales Standard angle with seal on length Standard angle with raised seal Angle with shortlip and rollable seal Speciale angle for3 tracks with seal 8 Locks Slide bolt USA type slide bolt Slide bolt with black knob Heavy cilinder lock with slide bolt 9 Grips Black plastic grip foot pedal Black grip 2 piece black grip in outside HANDLEIDINGEN IND manual GB no3 MANUAL Art code NL LHR HL VL FTR FLH FHL 1056B 722A 721A 724 725 702ST 1 2 723A 450HZ 420HZ 10RES 450HZ 10 450H304
2. by placing 33 nail into hole 0 2 Ifelecticallyoperated install switch R and check iflip activates 5980 mis 3 Place the torsion spring B with stationary spring fiting D and the spring device with pawl wheel L on the door shaft 4 EN the stationary fitting D with help of the bolts and distance rings on the blocking Please note The stationary fiting D has 0 turn freely around the bearing If necessary widen the hole of the fit ting 63 b The spring fitting D and blocking plate J ha ve a play of2 mm which is created by distance rings and have 0 be free of the cente plate For cerkain statonary fitings e g FF 2 63TAl one dis tance ring per hole has to be deleted because that type of fitting is already provided with cast rings 5 Install the central plate the door frame where normally he cente bearing plate is installed If the centeline is over 86 mm utilise he adjusting plate 5 In case ofa cente line of 152 mm apply reinforcing angle U on the models 675LH RH and 675LH RH 5 4 6 Take care thatlip M is placed above the door shaft 7 the pawl wheel L with help of the setscrew s and a 1 4 key 0130 minimumlengh 8 Wind the torsion spring B in the prescribed usual way Alltorsion springs on one door mustbe given an equal number ofturns Remove emporary blocking of the pawl
3. 553106 A IEstra Addit 10828 HANDLEIDINGENMND manual GB no3 74 Hexiforce MANUAL 685CH 553HING 6416 NEN Extra Addit 1062B M HANDLEIDINGENMND manual GB no3 T5 Hexiforce MANUAL HANDLEIDINGENMND manual GB no3 76 Hexiforce MANUAL up 687 Normal system N Y HANDLEIDINGENMND manual GB no3 77 Hexiforce MANUAL 21 SPRING BUMPERS HANDLEIDINGEN IND manual GB no3 78 Hexiforce MANUAL 22 HORIZONTAL CONNECTION TRACK ZO lt gt XD HANDLEIDINGENMND manual GB no3 79 Hexiforce MANUAL 23 BREAK AWAY 24 HORIZONTAL SPRING CONSTRUCTION HANDLEIDINGEN IND manual GB no3 80 Hexiforce MANUAL HANDLEIDINGEN IND manual GB no3 81
4. HANDLEIDINGENMND manual GB no3 39 10 BOTTOM CONSOLES AND VERTICAL TRACK SET rce 10 1 Vertical track set The distance between the vertical angles is determined the type of bottom console or cable break safety device Basic criteria for application ofthe table below 1 panel width C ear width 45 mm 2 oscillation 10mm The latter is the free laeral movement that a door panel is able to make between the vertical tracks required for smooth operation withouttoo much friction 2 2 X Z Fill with Fill with mm Spacer bush pacer bush 42500 75 2066 10 10mm 87 2066 05 5mm 2066 10 10 2066100001 428 71 24291611 43080 65 871 2066 05 5mm 42 437 011 AXVERS 641 43 015 64 20660559 440600 72 MoREGL 76 440410 74 4403 9 HANDLEIDINGENMND manual GB no3 MANUAL 10 2 Bottom console 427S X The bottomconsole 4275 consists ofthe following parts Consol 4275X Self tapping screws Bearing roller holder 4412 Spacer bush 10mm 2066 10 Eye bolt with cable 427000 10508 FlangednutM10 1058F Order ofassembl Position the bottom console on the panel such that the side and underside are flush with the panel Secure the console with 5 self tapping screws See figure a cm m KC i
5. Tighten all bolts Depending on the cable drumuse 1 or2 bolts to secure the horizontal tracks to the vertical comer line em m amp m A i A WA UB E IN x HANDLEIDINGENMND manual GB no3 21 lexi 3 OPERATION rce 3 1 Rope operation Fitthe cord supplied using the clip and coupling to the bottom console ata pointon the corner line atshoulder height 94 16618 1046 _ 1062M 1056 1047 3 2 Chain hoist 1 1 type 722A The 722A chain hoist transmission ratio 1 1 is suitable for 1 spindles The setconsists ofthe following parts Chah guide Sprocketwheel Manual chain 8 metre Chain stop Adjustmentring Key Order of assembly see figure Check whether the chain of the chain hoist to be fitted can run freely and whether the chain stop can be fitted Slide the adjustment ring onto the spindle Then slide the chain guide and the sprocket wheel with the chain onto the spindle Tighten the adjustment ring and slide the guide wih sprocket wheel against it Apply the key between sprocket wheel and spindle and tighten the securing screw of the sprocket wheel Now secure the chain stop on the edge of the vertical corner line or elsewhere on the strucure Height indication 1250mm HANDLEIDINGEN IND manual GB no3 MANUAL Depending on the height of the spindle the chain should be shortend or an extra separate length of chain supplied th
6. When the cable is autthe shaftshould be tumed such that the keyways in shaftand drum correspond to each other Fitthe key and tighten the setscrewsin drum 10 Nm Block the shaft with for example a clamp Place a locking pin in the spring break device such that the is free of the pawl wheel Secure the other cable in the same fashion Both cables should be under equal tension while the door panel is perfectly level Protectthe door fromrising This can be achieved for example by placing clamps on the vertical track Tension the springs by the number of tums prescribed see label Springs and packaging listin the box pull spring 5 mm apart 0 reduce friction and secure the spring shaftusing sere wsof the en so n plug UN 12 CAUTION Torsion springs are under hightension Exercseatall times greatcaution Installation maintenance and repair should be carried out only by experienced and properly trained overhead door fitters Use properly fitting and maintained tension irons see drawing Tensioning the spring 1 Ensure thatthe brand strip on the spring forms a straightline 2 Insertthe 1 tensioning iron fully into the tensioning aperture 3 the 1 tensioning iron a quarter turn so that the spring is tensioned 4 Insertthe 270 tensioning fully into the next tensioning aperture 5 Take over the tensioning ofthe spring fromthe 15 tensioning iron with the 2
7. 450CZ 45062410 4506304 41562 417 45052 4470008 1055BV 1055BV RVS 1053BV 1053BV RVS 1052BV 9VB and 1085 9 and 1094 40 9ZR and 1090 9K and 1085 629VER 630D 632 637 4050 668 4081 638 40 56 640T 642BL 634 639BL 643BL Pg 7 Pg 15 Pg 22 Pg 26 Pg 29 Pg 29 Pg 30 Pg 31 P 9 38 10 Bottom brackets Bottom bracket Bottom bracket Bottom bracket Bottom bracket Bottom bracket Bottom bracket Bottom bracket Cable break device Cable break device Cable break device Cable break device Bottom bracket RVS Bottom bracket RVS 11 Botipm bracket switches Simple switch astic cover with switch earing plates ixed side bearing plates 1 ixed side bearing plates 1 ixed intermediate bearing plates 1 ixed intermediate bearing plates 1 Fixed side bearing plates 1 and1 Universal bearing plates Baseplae Bearing plate exd bearing Bearing plate incl 1 bearing Wall plate Bearing 1 Bearing 1 Bearing retainer 13 Shafts Black solid shaft1 Keywayed 1 tube shaft Galvanised solid 1 shaft Galvanised solid 1 shaft 14 Spring breaking devices Spring breaking device 1 Spring breaking device 1 incl switch Reinforced spring breaking device 1 Reinforced spring breaking device 1 ind switch Reinforced spring breaking device 1 Reinforced spring breaking device 1 4 incl switch Spring breaking device plate Spring break
8. Ee 57 Hexiforce MANUAL Installation spring system non adjustable bearing plates 8 Non adjustable bearing plates Cable inside inside vertical angle 5 tematthe lintel zc 4 Determine fromthe diagram which situation which is valid Size 2 7 Situation X mm 86 30548 31548 E or675 i sms sage 6754322BAS USA 8 USA B 6754674 HOEK 40 152 308 48 318 48 or 675 or 670 6754322BAS Non 7045 adjustabld 152 3084CP 3084C 675 2 7065 100 only for 6 spring and or W 25000 AN ATTENTION Installation method torsion springs from the middle stationary plug to the side winder plug HANDLEIDINGENMND manual GB no3 10 Hexiforce MANUAL ATTENTION Installation method torsion system adjustable A Springs partly from side stationairy plug Adjustable bearing plates winder ping cabk inside Spring systematthe lintel 1 and 1 shaft 4 Determine from the diagram which situation which valid af Ba es USA B FH 675 322BAS 70557100 323taG 8 675 85 674 322BAS 308 4 2 675 5 4 3228 5 1 70657100 m 323LAG
9. gt 10538 10558 1062 1062 these articles are selected by option and therefore be missing in the set ATTENTION Adding other components or using different fxing materials can influence the safety and quality of our configured set We take no responsbillity for sets which differ on the level of components from our original configuration packing list lexiforce NIMAL NEEDED TOOLS AND EQUIPMENT Effective and safe assembly requires that the proper tools be used Below a list of the tools required at a minimum Cord rope tension irons as per drawing grip or gluing clamp to block the door grease and oil CE plate and waming labels spirit level or transparent hose chain punch for 721A measuring tape protractor for roofline matching system screwdriver with straightblade screwdriver with crossed blade pliers for split pin iron file jigsaw socket open end ring spanners size 55 8 10 13 14 916 15 17 24 for 440REGL socket keys size 3 and 4 drilled hole diameters HANDLEIDINGEN IND manual GB no3 MANUAL 05 07 010 013 015 016 pliers for systemplugs E transmission article code 97030 cable clamps 511C and 531 notrequired for standard set Tension irons to use with Flexi Force spring fittings INSTALLATION GENERAL Checking dimensions Before assembling the set the details below should be checked the basis of this fi
10. Position the CBD on the panel such that the side and underside are flush with the panel Secure the CBD with 11 self tapping screws See figure Secure the cable to the CBD by successively placing a ring the cable eye and again a ring on the screw thread and to bck with a self locking nut See figure The cable canbe secured to the cable ductby squeezing together the lips of the cable duct A Indien de kabel geborgt wordt met een splitpen niet meegeleverd dient men er zich van te overtuigen dat de werking van de beveiliging niet belemmerd wordt VERWIJ DER DE GEPLAATSTE HANDLEIDINGENMND manual GB no3 MANUAL 51 10 13 440 3 cable break device icm 441BR 3HD Assembly exterior bracket Exterior bracket 441 BR 3HD consists of the following parts Exterior bracket 441BR 3HD INK Locking bolts 8 25 1070B 3 5 Flangednuts M8 1068M Clip 1044 See also separate handbook CBD Order of assembly Fitthe exterior bracketto the console with 6 bolts and nuts See figure Then fitthe cable to the bracket with the clip supplied HANDLEIDINGENMND manual GB no3 MANUAL 52 lexiforce MANUAL 1014 427S RVS bottom console Bottom console 427S RVS consists of the following parts Console RVS 421S RVS Self tapping screws 1 Bearing roller holder 447 304 3 Spacer bush 10mm 2066 10 eh Eyebolt with cable 2530RVS
11. 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 fromour website www flexiforce com e strives to deliver 100 in conformance with the order In practice in spite ofall our controls this is not always possible However we willrectifyanyerrors asquicklyas possible inorder to minimise the inconvenience caused 0 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 delivery and give us the opportunity to 016 suitable solution e FlexForce willonly reimburse third party costs if we have givenexplidtpermission Dr this in advance The reimbursement is basedon normal rates and travelling expenses overdistances of1 hour away at most e This manual does notconfer any rights Technical modifications maybe made withoutwritten notice e Flex Force has endeavoured 0 design and this hardware setin conformance with the applicable laws and CE norms However please checkour interpretation with your local national spedfications body Flexi Force B V 37 3770 AA Barneveld The Netherlands Tel 13140 342 427777 Fax 3140 342 414679 E mail ff flexiforce nl Internet www flexiforce com HANDLEIDINGEN IND manual GB no3 2 Hexiforce MANUAL e
12. The pawl 9 must be pushed to the lip the blocking plate by the smal double torsion spring T 10 Ifelectricallyoperated the wiring of the switch must be connecidin sucha way thatafter shorttouch the dooroperator stops 11 Ifthe centreline is 152 mmthe reinforcing angle 0 should be installed on models 675STR and 675STR 5 4 WHAT TO DO AFTER BLOCKING OF THE DEVICE AFTER SPRING BREAKAGE 1 Theinstallerhas 0 preventthe door from falling by Supporting he bottomsecton e g by placing he forks ofa forklift tuck under the section 2 Remove te spring break device and the adjusting plate if installed and remove the broken spring 3 Instal anew spring anda new spring break device and ifapplied an adjusting plate according to installation instruction 4 Ifa tubular key way shaftisinstalled this should also be replaced ATTENTION If the s pring break device has been activated due to spring breakage the device and or its parts may not be usedagain HANDLEIDINGEN IND manual GB no3 MANUAL MALFUNCTIONING In case of malfunctioning ofthe spring break device the cause has to be determined and solved If necessary the spring break device has to be replaced and send to he manufacturer indicating 1 of malfunctioning 2 door leaf panel weightapplied 3 cable drum 7 4 The fling distance if nown The manufacturer wil research the reason ofthe malfunctoning TESTS A skilled
13. door installer has to check he tension of the during the regular6 months maintenance chec of the door If the double brsion spring is broken ithas to be replaced MAINTENANCE In principle the spring break device does notneed maintenance However itis advisable to prevent dirt entering or to remove this regularly 677 67 SWITCH INSTALLATION The setconsists of 677 67 Switch 1024SCHROE Scew M3x16 2513M0E Nut M3 The switch has to be mounted inside of the SBD The lever 1 ofthe switch must touch the lip of the blocking plate 2 The cables may not hinder the functioning of the device Check if the activation of the SBD also activates the switch Connect according to the schedule on the next pages 64 MANUAL 949 65 HANDLEIDINGENMND manual GB no3 MANUAL N 0 T e 66 HANDLEIDINGENMND manual GB no3 lexiforce MANUAL 15 COUPLERS 7035 7045 USTABLE COUPLER HANDLEIDINGEN IND manual GB no3 67 Hexiforce MANUAL 70557100 70657100 FIXED COUPLER 708 90 FIXED COUPLER HANDLEIDINGENUND manual GB no3 68 lexiforce MANUAL RHW Black RHW Black LHW Red X LHW Red d y 10 VK LL fl 2 545678692 11 EE EES 14144413 C UNE PDP PDP DP pr oD PAD A
14. tensioning iron 6 Remove the 19 tensioning iron fromthe aperture 7 Turn the 2 tensioning iron a quarter tum so that the spring is tensioned 8 Repeatsteps 2 through 7 for as long as ittakes for the spring to make the prescribed number oftums 9 Secure the spring plug to the shaftby fitting the key and tightening the bolts in the tensioning plugon the shaft 10 Remove the lasttensioning iron 11 Check the number ofturns by counting the number ofturns thatthe brand strip has made Remove the blocking of the door in the track and fromthe shaft and check that the door is balanced Should this notbe the case then correctby de ensioning and or tensioning of the springs by at most 1 turn per spring Ensure thatboth springs are corrected equally Correction of the spring tension 1 Insertthe 1 tensioning iron fully into the tensioning aperture 2 Takeoverthe tension ofthe spring with this tensioning iron 3 Loosen the bolts in the tensioning plug and remove the key 4 the 15t tensioning iron in the direction required 5 Insertthe 27 tensioning iron fully into the next tensioning aperture 6 Take over the tensioning ofthe spring fromthe 155 tensioning iron with the 27 tensioning iron 7 Remove 15 tensioning iron fromthe aperture 8 the 2 tensioning iron a quarter tum in the direction required HANDLEIDINGEN IND manual GB no3 MANUAL 9 Insertthe 15 tensioning iron fully int
15. to the console by inserting the pin through the console and the loop in the cable Secure the pin with the splitpinand bend the extremities of the split pin 000 See figure 10 66 10 66 437VERS 437 bottom console The cable adjustment bracket 437VERS consists of the following parts Bracket 437VERS EyeboltM10 10508 Nuts M10 1058F Order ofassembly Secure the bracket to the consok by inserting the pin through the console and the aperture of the bracket Secure the pin with the splitpinand bend the extremities of the split pin out The cable should be seared to the bracketwith an eyebolt Firsttighten an M10 flanged nut as far as possible on the eyebolt Insert the eyebolt from above through the bracketand tighten the 279 nut on the eyebolt See figure HANDLEIDINGEN IND manual GB no3 MANUAL M IP 82 A 1 gt 1 9 Bc 1 e d d Le 44 Hexiforce MANUAL 10 7 Bottom console 425HD 10 8 Bottom console 430HD HANDLEIDINGEN IND manual GB no3 45 10 8 440 600 Cable break device The cable break device 440 600 consists ofthe following parts 440 600 Self tapping screws See for area of application and other information also our Separate handbook CBD download from www flexiforce com Order of assembly Move the hinged section of the CBD ag
16. 2 Perforated angle 50x50 50830 3000 5 Perforated angle 40 40 40B25 3000 S Perforated angle 30 30 30B25 3000 S Perforated angle 30x30 en 50x50 30825 3000 and 50830 3000 Perforated SU profile 48x 48503000 Perforated SU profile 48x en 50 48503000 and 50503000 19 Triangular plate Pg 73 Triangular plate for tack suspension 3010 Triangular plate for installation 100K box beam 355CONS 20 Tension set Pg 74 Tension with plastic pulleys 685CH NP LHR Tension setwith steel lever 687 NP LHR 21 Spring bumpers Pg 78 Shortspring bumpers 718 Long spring bumpers 719 Extra long spring bumpers 719EP 750 22 Horizontal connection tracks Pg 79 5C profile at the rear of horizontal track 5C and 2602 etc 5C profile in middle of horizontal track 5C and 2602 etc 23 Breakaway Pg 80 24 Horizontal connection spring Pg 80 100K beam for installation spring system 100K and 355CONS etc 25 Panelproduction sections 81 Metaalunie Conditions Attachments A In this manual we limit ourselves to the instructions for proper installation of our hardware set parts the installation of the complete door with added components and for a proper user manual we put the responsibility to the supplier of the complete overhead door The installer supplier is also responsible for the proper CE marking of the door This manual has been written for use by experienced fitters and as such is not suitable for d i y purposes or for us
17. 23 5 D HANDLEIDINGENMND manual GB no3 42 lexiforce MANUAL 10 5 432 Bottom console Bottom console 432 consists of the following parts Console 432 Self tapping screws Splitpin Pin Order of assembly Insertthe bearing roller into the bottom console Rotate the bearing roller with console in the verticalguide tracks One ofthe two bottomconsoles may be fitted beforehand on the panel Position the bottomconsole on the panel such thatthe side is flush with the panel The underside ofthe console should be level with the underside ofthe panel Secure the console with 6 self tapping screws See figure Secure the cable 0 the console by inserting the pin through the console and the loop in the cable Secure the pin with the splitpin and bend the extremities ofthe split pin 000 See figure HANDLEIDINGENMND manual GB no3 43 10 60 437 bottom console 437VERS Bottom console 437 consists ofthe following parts Console 437 Self tapping screws Splitpin 2107 Pin 1042 Order of assembly Insertthe bearing roller into the bottom console Rotate the bearing roller with console in the verticalguide tracks One ofthe two bottomconsoles may be fitted beforehand on the panel Position the bottom console on the panel Such thatthe side and underside are flush with the panel Secure the console with 6 selftapping screws See figure Secure the cable
18. A A A A AAAS Ah CX xa xl m 727222 2 Wize TY s Mf WG OW d W Mii 77 WI I 07 222 Wl Me 4 WZ WMG 4 MG 22 MAH 17 7 WM E WI Mi 7 72222238 WME Au il 2 2 Wi 774 Mu 7 201 y S Zeit 4 uli 402 IJ A WE A 22 2224 HANDLEIDINGENMND manual GB no3 69 Hexiforce MANUAL 17 CABLE DRUMS FF NL 12 FF NL 18 FF NL 32 5 4 HANDLEIDINGEN IND manual GB no3 70 MANUAL FF VL 28 FF VL 11 1 28 5 4 FF VL 18 5 4 HANDLEIDINGENUND manual GB no3 71 Hexiforce MANUAL x 30820 30 25 SPS EN ay lis 40825 40 25 25 20850 4850 5050 1068 1070B 5 5 48SU 48 5080 50 4850 5050 HANDLEIDINGEN IND manual GB no3 72 Hexiforce MANUAL 19 TRIANGULAR PLATE 555CONS HANDLEIDINGENMND manual GB no3 73 lexiforce MANUAL 20 CABLE TENSIONING SETS 685CH 553D0 UB 907 503 15 lt 3500 15 1 503 20 H gt 3500mm 20m1 1 25 Extra Addit 19798 3 5 1068 combinatian with cable break device install special bracket 2605 Bei Verwendung von Seilbruchsicherung brauchen Sie sonder Bugel 2605KBB En combination avec parachute de cable il faut installer suppart 2605 2605KBB 2
19. FlangednutM8 2535M RVS e ah A 2 Order of assembly ar Position the bottomconsole on the panel such thatthe 4 3 side and underside are flush with the panel Secure the ES 54 d consok with 5 self tapping screws See figure Fitthe spacer bush to the bearing roller Fit the bearing LA roller holder to the spindle of the bearing roller See figure 80 Place the bearing roller in the vertical guide tracks at the level of the console Secure the bearing roller holder with 2 selftapping screws The cable is secured to the console with an eyebolt First tighten as far as possible an M8 flanged nuton the eye bolt See figure Guide the cable around the reverse pulley ofthe console insertthe eyebolt from below through the console and tighten the 2 nuton eyebolt See figure AN a gt 9 8 In order to prevent deformation or breaking of the cable the cable may only be set more loose HANDLEIDINGENMND manual GB no3 10 15 437RVS bottom console Bottom console 437RVS consists of the following parts Console RVS 437 RVS Self tapping screws RVS BoltM8x35 RVS 2535B RVS NutM8 RVS 2535M RVS Spacer bush 2066 05 Order of assembly Place the spacer bush on the bearing roller Insert the bearing roller inb the bottomconsole Rotate the bearing roller with console in the vertical guide tracks Position the bottomconsole on the panel such thatthe side is flush with the panel S
20. H 675LH RH and 675LH RH 5A can be applied on industrial sectional overhead doors which are chain or electrical operated Model670LH RH and 675LH RH are suitable for industrial overhead doors having a 1 254 mm key way shaft Model 675LH RH 5A is suitable for industrial overhead doors having 1 14 3175 mm key way shaft We advise you to apply the reinforced version model 675LH RH on heavy springs especially on 6 152 mm springs This reinforced version can withstand larger axial forces thanks to the fanges The combination of weight and length of the spring as wel as the distance between the shaft supports bearing plates influence he amount of axial force the distance ofthe shafttowards the door installation Surface and the number of turns on spring are also of influence The maximum moment of rotation per spring break device is 210 Nm Newton Meter Fora specificdrum the minimum number of spring break devices per door can be determined as follows Maximum moment of rotation 0 5 x drum diameter x g Drum diameter in meters measured from the point where the cable peels off the drum when door is closed Example FF NL 18 drum for normal lift ha ving 5 mm cable gives adiametrof 1384 mm 210 e 303 kg 3034 N 0 5x 01384x 10 HANDLEIDINGEN IND manual GB no3 MANUAL So for a door weight as lifted by the cables up to 303 kg you mayapply the minimum of 1 0r more spring break devices Ove
21. IND BS hardware setfor industrial commercial overhead doors INSTALLATION MANUAL lexiforce MANUAL ATTENTION GENERAL WARNINGS To assemble instal and use this hardware set safely anumber of precautions must be taken For the safety of all concerned pay heed 0 the warnings and instructions given bdow 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 instalation of hardware for overhead doors and as such mustbe supplemented with instructions for any additional components Before starting read this manual carefully Certain components may be sharp or have jagged edges As such you are advised 0 wear safety loves All the components which have been supplied are designed for use with this specific overhead door Including additiona components may have an adverse effecton the safety of and the guarantee on the door Ensure that thereis sufficient light during installation Rem ove obstacles and dirt Make sure that there is no one else present other than the fitters Other people children getin the way endanger themselves during the instalation GUARANTEE CONDITIONS ANDTERMS 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
22. SA A See Picture Bearing 1 USA B See Picture Retainer 325 See Picture 308 48 3086 48 507 468 308 48 305 4 etc HANDLEIDINGENMND manual GB no3 MANUAL EI 111 315 4B etc 318 4CP 315 48 75 46 515 48 515 48 86 111 57 rce MANUAL 318 4Cetc el 320 4 etc 7 dl 1 d T D ri HANDLEIDINGENUND manual GB no3 58 MANUAL 323LAG B 60 HANDLEIDINGENMND manual GB no3 MANUAL USA 8 fitting USA 8 325 HANDLEIDINGEN IND manual GB no3 61 13 SHAFTS de M HANDLEIDINGEN IND manual GB no3 MANUAL 321WAL4323LAG SY 322 5 KEY WAYED TUB E 1 Article code 70568 KEY WAYED SOLID 1 Article codes 702K black 702 2 galvanised KEY WAYED SOLID SHAFT 1 Article code 699 2 62 rce 14 SPRING BREAKING DEVICE SBD 670L 675LH RH 675LH RH 5 4 A ATTENTION GENERAL WARNING Torsion springs are under high tension Do not try to remove adjust or withoutrekasing the tension Always be careful during instalation Installation maintenance and repairs only can be done by qualfied and experienced overhead door mechanics APPLICATION RANGE The Flexi Force spring break devices 670LH R
23. TICAL ANGLE 7 1 928 and 1090 2 track 1 2 72 9VB and 1085 2 track ZC A li 08 IK AE A i HANDLEIDINGEN IND manual GB no3 MANUAL 73 9 8 and 1094 40 2 track 1094 40 7 4 96 and 1085 3 track 1 _ 30 LOCKS Slide bolt629 VER Slide bolt630D Slide bolt632 Cilinder lock 635 Cilinder lock 637 40 50 Cilinder lock 638 40 56 Cilinder lock 668 40 LH RH 1 0 5 2 BY rce See Picture See Picture See Picture See Picture See Picture See Picture See Picture 1053 8 5 2 MANUAL 31 Hexiforce 6300 MANUAL LH RH 1052 10538 105S5Bv RVS _ SY w ES d VN 100 HANDLEIDINGENMND manual GB no3 32 Hexiforce MANUAL 1052BV 1053BV RVS 1055BV RVS HANDLEIDINGENMND manual GB no3 33 Hexiforce MANUAL HANDLEIDINGENMND manual GB no3 34 Hexiforce MANUAL 637 40 50 HANDLEIDINGENMND manual GB no3 35 Hexiforce MANUAL 638 40 56 BK LH HANDLEIDINGENMND manual GB no3 36 pm MANUAL force 668 40BL HANDLEIDINGENMND manual GB no3 MANUAL 9 GRIPS HANDLEIDINGEN IND manual GB no3 38 MANUAL
24. USA A Size Situation X mm 67 5 5 1 1 With 56152 321WAL Wall p late HANDLEIDINGENMND manual GB no3 11 Fitthe bearing plates 1 to the wal Trace centre line spiritlevel between the two side bearing plates in order to be able to fit the remaining bearing plates and the shaftin proper alignment Fit he remaining parts to the shaft See assembly spring package bearing plates and spring break device Secure a rope with loop to the structure to support the shaftduring assembly Fitthe spring package to the wall Assembly door panels For fiting purposes the assumption has been made that the panels are already fitted with end caps top and bottom profile and top bottomrubber Remove the protective foil from the panels See 4 Hinges roller holders Fitbase of the side hinges to the panels The position will in many instances be determined by the holes in the end caps For doors gt 5000 clear width double side hinges will be used as standard Fit the lower hinge blades of the intermediate hinges at equal intervals to the panel The number of intermediate hinges to be fitted to one panel is determined as in the table below unless ordered otherwise Intermedate hinges mm pieces 0000 2149 1 5000 5999 4 7000 7999 6 Place the lower panel in the clear width and support it with a pair ofblocks See 10 Bottombrackets Place the rollers where necessary bef
25. ainst the spring resistance and inserta locking pin in the through which this is fixed relative to the base plate Insertthe bearing roller in the CBD and rofate this in the vertical guide tracks One ofthe two bottomconsoles may be fitted beforehand on the panel Position the CBD on the panel such thatthe side and underside are flush with the panel Secure the CBD with 6 self tapping screws See figure Secure the cable to the CBD by placing one after the other a ring the cable eye and once more a ring on the screw thread and securing it with the self locking nut See figure The cable canbe secured to the cable ductby squeezing together the lips ofthe cable duct When the cable is secured with a split pin not supplied make sure that the operation of the safety device is not impeded REMOVE THE LOCKING PIN FITTED HANDLEIDINGENMND manual GB no3 MANUAL 46 7 MANUAL 109 Cable break device 440 600 icm P dn 441 en 4418 2HD See also separate handbook Assembly exterior bracket 441HBR The exterior bracket 441HBR consists ofthe following parts Exterior bracket 441HBR INK Locking bolts M8x25 1070B 3 5 Flangednuts M8 1068M lip 1044 Order of assembly Remove the 4 locking bolts with which the angles are secured to the U bracket Mountthe exterior bracket with these 4 bolts and with the two extra bolts to the console see dwg Then fitthe ca
26. all bolts Depending on the cable drumuse 1 or2 bolts to secure the horizontal tracks to vertical comer line 1 HANDLEIDINGEN IND manual GB no3 19 lexiforce MANUAL 26 FLH Following The Roof System Low 2 Distinguishing feature With FLH systems the door turns through the bend directly above the clear height and then tracks the angle ofthe roof The horizontal section consists of a double track See figure i Tracks The track system of the FLH System consists of a vertical and a horizontal section Vertical trackset This is made up ofa lefthand and righthand assembled corner lines with a guide track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track setconsists of a left hand and right hand section a double bend straight tracks and a reinforcement profile The bends and the straight guide tracks are fitted to each other by connection plates and a side plate The side plate is fitted with a return pulley Assembly vertical track set Slide the side seal onto the corner line and shorten this where necessary Secure the vertical track set level to the pendent See 1 General Ensure that the side seal cannot be displaced When necessary deform the rim of the corner line above the side seal Assembly horizontal track set Secure a piece of cord 0 the ceiling or roofstucture See figure Adjustthe horizontal track lining with he roof Tighten all bolts Depe
27. andbook Order of assembly Move the hinged section of the CBD againstthe spring resistance and inserta locking pin in the aperture through which this is fixed relative to the base plate Insertthe bearing roller in the CBD and rofate this in the vertical guide tracks Position the CBD on the panel such thatthe side andunderside are flush with the panel Secure the CBD with 6 self tapping screws See figure Secure the cable to the CBD by successively placing a ring the cable eye and again a ring on the screw thread and to bck them with a self locking nut See figure The cable canbe secured to the cable ductby squeezing together the lips of the cable duct When the cable is secured with a split pin not supplied make sure that the operation of the safetydevice is not impeded REMOVE THE LOCKING PIN FITTED In order to prevent deformation or breaking of the cable the cable may only be set more loose HANDLEIDINGENMND manual GB no3 MANUAL 50 10 12 440 3 Cable break device Cable break device CBD 440 3 consists of the following parts CBD 440 3 Self tapping screws See also separate handbook Order of assembly Move the hinged section of the CBD against the spring resistance and inserta locking pin in the aperture through which this is fixed relative to the base plate Insertthe bearing roller in the CBD and rofate this in the vertical guide tracks
28. atcan be inserted This can be arranged simply by bending a link open and then shut Height indication floor to underside chain 750mm Ensure thatthe manual chain is not distorted 3 3 Chain hoist 1 3 type 721A The 721A chain hoist transmission ratio 1 3 is suitable as standard for 1 spindles The setconsists ofthe following parts Frame with sprocketwheeland gear wheel small Manual chain 8 metre Chain stop Sprocket wheel large Bicycle Chain Key Order of assembly see figure Check wheter the chain of the chain hoist to be fitted can run freely and whether the chain stop can be fitted Slide the large sprocket wheel onto the spindle Determine the positon of the frame Then fit the frame hand tight to the wall Place the bicycle chain on the gear wheels and connect both ends with the connecton link Apply the key between gear wheel and spindle and tighten the securing screws ofthe gear wheel Tension the bicycle chain by sliding the frame int the Slotted holes and secure the frame Depending on the position of the frame the bicycle chained 50000 be Shortened or lengthened See for further instructions italicized text at 722A 3 4 Chain hoist 1 4 type 724 The 724A chain hoist transmission ratio 1 4 is suitable as standard for 1 spindles The setconsists ofthe following parts Casing with sprocket wheel Manual chain 8 metre Chain stop Connector Key Order of assembly see figure Check whet
29. ble to the bracketusing the clip See figure Assembly exterior bracket 441HBR 2HD The exterior bracket 441HBR 2HD consists ofthe following parts Exterior bracket 441HBR 2HD INK Locking bolts M8x25 1070B 3 5 Flangednuts M8 1068M Clip 1044 Order of assembly The assembly procedure is the same as for exterior bracket 44 1HBR See figure HANDLEIDINGEN IND manual GB no3 47 lexiforce MANUAL 10 10 Cable break device 440REGL Cabk break device CBD 440REGL consists of the following parts CBD 440REGL NutM16 1040M Hollow adjustment bolt 1040REGL Self tapping screws See also separate handbook Order of assembly Remove the M16 nuts fromthe hollow adjustment bolt Insertthe cable through the largestaperture ofthe adjustmentboltso thatthe end pressure clamps ofthe cable disappear inb the hollowadjustmentbolt supplied this way as standard See figure Insertthe adjustment bolt with the cable through the bush on the CBD Tighten both nuts on the adjustment bo It See figure When the cable has been finally setthe 270 nutshould be secured as locking nut Move the hinged section of the CBD against the spring resistance and inserta locking pin in the aperture through which this is fixed relative to the base plate Insertthe bearing roller the CBD and rofate this in the vertical guide tracks Position the CBD on the panel such that the side and underside are flush with the panel Secu
30. e 2 Lead the cable 6 free through the cable break device with attention to preventing thatafter installation ofthe Cover itcan obstruct the functioning or damaging the cable With side mounted cable under the cover the cable mustbe positioned flat on the panel and a hole mustbe created in the cover 3 Shift depending on the installation side a cap 1 in HANDLEIDINGENMND manual GB no3 MANUAL the rightor lefthole ofthe cover The free hole is needed for guiding the vertical track 4 Shift the cover 2 with the foreseen guidance over the balanced mounted plate 8 of the switch mechanism When the cover is mounted to weakly remove the cover and tighten the nuts 10 more heavily With cable breaking the lip 3 in the cover is pushed away by means ofthe tuming U bracket 45 thus activating the switch 1052BV 1053BV RVS 1055BV RVS 56 12 BEARING PLATES 12 1 Non adjustable bearing plates Side bearing plates 305 4B etc See Picture Side bearing plates 218 7 See Picture Side bearing plates 315 4B etc See Picture Sice bearing plates 318 4C See Picture Bearing pates 320 4 See Picture 122 Adjustable bearing plates Base plate 322 5 See Picture Bearing plate 323LAG See Picture 323LAG B See Picture 12 3 Universal bearing plates Interm Bearing plate USA 8 retainer See Pict Interm Bearing plate USA 8 100 See Picture 124 Several Wall plate 321WAL See Picture Bearing 1 U
31. e by trainee fitters The article codes are mentioned between brackets We wish you smooth installation of this set If you have any questions or remarks please contact us Flexi Force B V HANDLEIDINGEN IND manual GB no3 6 lexi 1 GENERAL rce SPEC IFICATION OF DELIVERY HARDWARE SET With the Flexi Force supplied hardware set for industrial doors depending on selected door dimensions and lift Systems the next mentioned articles are included in the standard delivery Check before starting the installation if your set has been delivered according to the packing list The setcontains cable drums side bearing plates intermediate bearing plates spring breaking device shaftwith key way roller bearings vertical track set with angle side seal horizontal track set with reinforcementand curve coupler rollers assembled torsion springs black orpowder coated suspension profiles chain hoistwith chain or rope intermediate hinges side hinges toprolerbracket bottom bracketor cable break device lock or slide bolt grip springbumpers cables keys triangular plate cable tension set box 7 fixing material Notsupplied in the set windows top bottom profile with seal needed material for fixing to the wall endaps struts HANDLEIDINGEN IND manual GB no3 MANUAL Fixing material o T 1006B 1062M 027 68B 1047 1044 O7 1026 688 1045 __20178 10708 3 5
32. ecure the console with 6 self tapping screws See figure Secure the cable 0 the console by inserting the bolt M8x35 from within through the console and the 000 in the cable Then tighten the nuton the bolt See figure HANDLEIDINGENMND manual GB no3 MANUAL 54 11 BOTTOM CONSOLE SWITCHES 111 69015 11 2 440SWL R On electricaly operated doors install a switch 440SW on both devices Make sure thatthe Ubracket 5 activates the switch The switch needs wiring to the operator in order to stop the operator when activated 1 Release the nut 3 and shiftthe bracket 4 with the open slotted hole under the nutand then fixen the nut handtight The Switch has to be mounted on the non busted flange ofthe base plate The wire 1 ofthe switch mustpoint upwards 2 Adjust the lip 6 ofthe switch in such a way thatitis activated through tuming the U bracket 2 by contacting the flange 5 of the base plate When using model 440 3 the switch first has to be slided in the slotted holes 7 ofthe bracket 3 Fasten the nut 3 now definitively HANDLEIDINGEN IND manual GB no3 MANUAL gt 55 6 11 3 440 Cover with switch The 440KAP 2 covers a mounted 2 cable break device with intemal cable fixing code 440 600 440 en 440HD completely This is according to CE norms 1 Install the switch mechanism 9 with two screws in the upper holes 11 ofthe base plate ofthe devic
33. gure Clear width packing list B Clear height packing list Side area see 10 Bottom brackets D area see 2 Liftsystems Bases for further instructions are Panelwidth including end caps A 45 mm Panelheightstapled incl bottomrubber 2 B 25 mm NB The material used for mounting the track set and the spring system to the wall roof is nota partofthe delivery Use proper material for this conform the norms and proper for the material in which you mount Checking built in depth Check if there is sufficientspace available for the track set see 2 Liftsystems Checking section width When the section length door panel width differs from the above mentioned data all sizes related to the side Space change Checking vertical track set First mark on both piers using a spirit evel or water level hose and then mark C picture Fit both vertical tracks with the lower surface on mark line picture The two bearing tacks should be parallel to one another Forsloping floors one of the bearing tacks may be compensated Or example with a wedge Size X Picture is being determined by the bottom brackettype delivered to the set See 10 Bottom brackets Installation track set The table below refers to see 2 Liftsystems the equivalent page of the manual belonging to the actual lift system HANDLEIDINGEN IND manual GB no3 MANUAL fasten 17 11 7
34. her the chain of the chain 150 be 1120 can run feely and whether the chain stop can be fited Allow the spindle pro tude circa 60 mm fro m the bearing plate Slide connector 000 the spindle of the chain ho st and ft the key supplied Slide chain hoist wih the 0 0 010 spindle and secure the entire assembly 0 the bearing wih a bolt see drawing Secure the 00 0 by tightening both screws See for further instructions italicized text at 722A 22 MANUAL 721A Ze WA b x 1 a Tideri Ki 1 dB P EE ERE Ben dun Ge 23 HANDLEIDINGEN IND manual GB no3 Hexiforce MANUAL 3 5 Chain Hoist 1 4 direct 725 Ps 1 6 gt 50 168 00 0 00 16 11 2001 gt HANDLEIDINGENMND manual GB no3 3 6 Option Reducing socket 1 gt 114 When 0 door is produced with 1 spindle and 1 chain hoista reducing socket setis supplied with the spindle The setconsists ofthe lowing pars 702ST 12 Coupler 1 1 700438 Key 2 pieces 702 0250Z Galvanized spindle length 25 cm Assembly Slide connecor onb the 17 spindle ft he key and tighten securing bolts Insert the 1 spindle in the other socket half also f
35. ide seal See 7 Vertical corner lines For large clear heights and or large high lift the vertical track setis supplied in two sections Horizontal track set The horizontal track setconsists of a left hand and right hand bend and a reinforcement profile that is secured to the bend and the straight guide track Assembly vertical track set Slide the side seal onto the corner line and shorten this r 1 1 where necessary Secure the vertical track set level to the pendent See 1 General Ensure that the side seal cannotbe displaced When necessary deform the rim of the corner line above the side seal Assembly horizontal track set Se cure a piece of cord 0 the ceiling or roofstucture See figure Adjustthe horizontal track 5610 1 degrees rising h Tighten all bolts Depending the cable drum use 1 or 2 bolts to secure the horizontal tracks to the vertical corner line HANDLEIDINGEN IND manual GB no3 17 24 VL Vertical lift 2 Distinguishing feature With Vertical systems the door rises straightupward See figure Tracks The track systemofthe Vertical system consists only ofa vertical section Vertical trackset This is made up ofa lefthand and right hand comer line with a guide track and side seal See 7 Vertical corner lines For large clear heights the vertical track setis supplied in two sections Assembly vertical track set Slide the side seal onto the corner line Sec
36. ighten as far as possible an M10 flanged nut on the eye bolt Guide the cable around the reverse puley of the consok insert the eyebolt from below through the console and tighten the 2 nuton the eyebolt Now insert the splitpin as perdrawing into the aperture designed for thatpumoseand bend its endsout The aperture next to the eyeboltserves to secure when required a cord for manual operation See figure 4 To preventthe console distorting or breaking the cable may only beset looser adjust eye downwards 41 lexiforce MANUAL 104 429 Bottom console Bottom console 429 consists of the following parts Console 429 Self tapping screws Splitpin Pin Order of assembly Secure the cable to the console by inserting the pin from the interior through the console and the loop in the cable Secure the pin with the splitpin and bend the extremities ofthe splitpinout Insert the bearing roller in the bottom Consol See figure Now rotat the bearing roller with console in the vertical guide tracks One of the two bottom consoles may be fitted beforehandon the panel Position the bottom console on the panel such that the side and underside are flush with the panel Secure the console with 6 self tapping screws See figure s E 2 Ay Su A 5 NS 22 e 9 EM A X 27 9 64 M y
37. ing device Base plate Spring breaking device Base plate reinbrcement 15 Couplers Fixed aluminium coupler for 1 shaft Adjustable caststeel coupler for 1 shaft Fixed caststeel coupler for 1 shaft Adjustable caststeel coupler for 1 4 shaft Fixed caststeel coupler for 1 shaft Ug v 12 TT HANDLEIDINGEN IND manual GB no3 MANUAL 4215 428 425HD 2 en 3 429 432 437 437VERS 430HD 2 3 440 600 441 HBR 441BR 2HD 440 REGL 441HBR REGL 440 HD 440 3 441BR 3HD 421S RVS 437RVS 6901SCHA 440SWL R 440KAP 305 4B etc 318 4CP 315 4 etc 318 4 320 4 USA 8LH RH 322BAS 323LAG 323LAG B 321WAL USA A USA B 325 T02K 10508 702 2 699 7 670 670 and 677 67 675 675 and 677 67 675 5 4 675 5 4 and 677 67 670 661 675 322BAS 675 674 32245 708 90 70351 10551100 1045 10651100 Pg 40 Pg 55 Pg 57 Pg 62 Pg 63 Pg 67 lexiforce MANUAL 16 Springs Pg 69 Powder coated torsion springs XCALPS Natural black torsion springs XCALNS 17 Cable drums 70 Normal lift cable drum FF NL 12 Normal lift cable drum FF NL 18 Normal lift cable drum FF NL 32 54 High lift cable drum FF HL 54 High lift cable drum FF HL 120 High lift cable drum FF HL 164 5 4 Vertical lift ca ble drum FF VL 11 Vertical lift ca ble drum FF VL 18 6 4 Vertical lift ca ble drum FF VL 28 6 4 18 Suspension profiles Pg 7
38. mal Syste m consists of a vertical and a horizontal section Vertical trackset This is made up ofa lefthand and righthand assembled corner lines with a guide track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track setconsists of a left hand and right hand bend and a reinforcement profile that is secured to the bend and the straight guide track Assembly vertical track set Slide the side seal onto the corner line and shorten this where necessary Secure the vertical track set level to the pendent See 1 General Ensure that the side seal cannot be displaced When necessary deform the rim of the corner line above the side seal Assembly horizontal track set Secure a piece of cord 0 the ceiling or roofstructure See figure Adjustthe horizontal track 5610 1 degrees rising Tighten all bolts Depending on the cable drumuse 1 or2 bolts to secure the horizontal track to the vertical comer line HANDLEIDINGENMND manual GB no3 MANUAL 15 7 MANUAL 2 2 LHR Low Head Room System 2 Distinguishing feature A With Low systems the door turns through the bend Le gt directly above the clear heightand the horizontal section 1 consists double track See figure Tracks The track systemofthe Low System consists ofa vertical and ahorizontal section Vertical trackset This is made up ofa lefthand and righthand assembled corner line with a guide
39. nding on the cable drumuse 1 or 2 006 0 secure the horizontal tracks the vertical comer line HANDLEIDINGEN IND manual GB no3 20 lexiforce MANUAL lt gt 2 7 FHL Following The Roof System High 2 P 2 Distinguishing feature a With FHL Systems the door first rises directly above the Clear height and then after turning through the bend tracks the angle of the roof The FHL track section consists of one single track See figure Tracks The track system of the FHL System consists of a vertical and a horizontal section Vertical trackset This is made up ofa lefthand and righthand assembled corner line with a guide track and side seal See 7 Vertical corner lines For large clear heights and or large high lift the vertical track setis supplied in two sections Horizontal track set The horizontal track set is constructed from a lefthand and a right hand bend and a reinforcement profile that is secured to the bend and the straight guide track Assembly vertical track set Slide the side seal onto the corner line and shorten this where necessary Secure the vertical track set level to the pendent See 1 General When the vertical set consists of two sections then assemble as depicted the figure For a few vertical sets only the lower fastener is present Assembly horizontal track set Secure a piece of cord 0 the ceiling or roofstucture See figure Adjustthe horizontal track lining with the roof
40. not included in this handbook since Flexi Force does not supply panels For this we refer you to the supplier of the panels or to other sources in the market HANDLEIDINGEN IND manual GB no3 MANUAL TROUBLESHOOTING What should check if the door is not balanced properly When a door is notwell in balance then itis necessary to check firstthe following details Is the given information correct weight ofthe door leaf including hardware is the division of the weightequal 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 Were the correctparts supplied and fitted Especially the drums and springs are important correctdimensions supplied 5 the door properly installed horizontal tacks realy horizontally and notwith inclination for High Liftdoors shafton the correctheight Otherwise the cable length is notcorrectand door is badly balanced Were modifications made afterwards checkifany changes were made during the fitting or ifa pass door was fitted latr or any reinforcement profiles fitted etc 14 lexiforce 2 BUILD IN SYSTEMS 2 1 NL Normal lift 2 Distinguishing feature With Normal systems the door tums through the bend directly above the clear heightand the horizontal section consists ofa single rail See figure Tracks The track system of the Nor
41. o the tensioning aperture 10 Take over the tensioning of the spring fromthe 2nd tensioning iron with 1 tensioning iron 11 Repeatsteps 4 through 10 until the correction required has been made 12 Secure the spring plug to the shaft by fitting the key and tightening the bolts in the tensioning plugon the Shaft 13 Remove the lasttensioning iron Fitting spring bumpers See 21 Spring bumpers Fitthe spring bumper in accordance with the appropriate instruction Suspension horizontal track set Setthe door in the opened position so that the horizontal track that can still move freely is able to adjustto the door panels Ensure thatthe bearing rollers on left and right have the same play so thatrail and door panel run parallel Conducta cross measurementas per the figure to check the adjustment Secure further in this position the suspension of the horizontal track set 13 Completing the door Cord Chain operation See 3 Controls Handgrip Foot pedal See 9 Handgrips Lock See 8 Locks Lubricate all hinges and bearing rollers with one drop of oil Grease the cables Grease the bearing roler shafts The torsion springs are already lightly oiled Place your CE identification plate on the door together with any warning labels required Option electrical operator This should be assembled in accordance with the handbook supplied with the opera br A ATTENTION The assembly of door sections is
42. orehand type dependent in the bottom brackets and fit the bottom brackets with secured cables to the panel in such fashion thatthe rollers are already located in the track Remove the blocks and fit the slides with roller on the hinge blocks Place the first intermediate panel on the lower panel such thatthe edges are aligned Secure for the time being with a glue clamp or similar Fitfirst the side hinges and then the intermediate hinge Repeat this procedure with the other intermediate panels HANDLEIDINGEN IND manual GB no3 MANUAL Place finally the top panel Secure this also temporarily with a glue clamp or similar Fitthe side hinges and then the intermediate hinges Fit the accompanying top roller holder as specification See 4 Hinges op roller holders Fitting cable and tensioning the spring package Align the shaft Roll out the steel cables until all he kinks have disappeared already secured to he bottom bracket Guide the first cable from the botom bracket behind the bearing roller Shafts to the cable drum See figure Feed the cable into the drum secure itwith he the drum The cable should protrude fom the dum see 17 cable drums or download the specification sheets from our site www iforce com Slide the cable drum 30815 the bearing and rotate the drum such thatthe windings min 2 safety windings restnext to each other in the grooves ofthe drum
43. r 303 kg you need a minimumof2 or more spring break devices ATTENTION Never exceed the maximum weight per pair of drums as given by your drum supplier Apply one spring break device per torsion spring The spring break device model 670LH RH has approval number94073 ofthe BG Berufs Genossenschaft Bauliche Einrichtungen at Bonn Germany and has been tested by the TUV Technische Uberwachungs Verein Bayem at Munich The spring break devices model 67 5LH RH and 615LH RH 5 4 have approval number 98098 of the BG The numberof spring break devices must be equal 0 the number of springs METHOD OF OPERATION When tensioning the counter balancing torsion spring B the blocking plate J tums about5 degrees and the lip blocks the pawl The smal double torsion spring pushes the pawl to the lip M The pawl wheel L which is fixed 0 the door shaft A by means of a key can um freely and he door can be opened and closed case of a spring breakage the moment of the balandng spring is no longerappearing and so the blocking plate can tum The small torsion spring and gravity push the pawl N away and the pawl catches into the pawl wheel L by which the fallofthe dooris blocked Ifelectically operated the P will buch the switch R rendering motor inoperable which will avoid overload by the motor on the safety device and other door parts INSTALLATION INSTRUCTIONS 1 Block temporarily the
44. re the CBD with 6 self tapping screws See figure The cable canbe secured to the cable ductby squeezing together the lips of the cable duct When the cable is secured with a split pin not supplied make sure that the operation of the safety device is not impeded REMOVE THE LOCKING PIN FITTED In order to prevent deformation or breaking of the cable the cable may only be set more loose HANDLEIDINGEN IND manual GB no3 lexiforce MANUAL 1011 440REGL cable break device with 441HBR REGL Exterior bracket441HBR REGL consists of the following parts Exterior bracket 441HBR REGL INK Locking bolts 8 25 10708 35 Flangednuts M8 1068M NutM16 1040M Hollowadjustmentbolt 1040R EGL See also separate handbook CBD Order of assembly Remove the 4 locking bolts thatsecure the angles to the 5 U bracket exteriorbracketto the CBD with these 4 bolts and the two extra bolts See figure 2 Then fitthe cable to the bracketas specified for 440REGL When the cable is secured with a split pin not supplied make sure that the operation of the safetydevice is not impeded REMOVE THE LOCKING PIN FITTED In order to prevent deformation or breaking of the cable the cable may only be set more loose HANDLEIDINGENMND manual GB no3 49 10 12 440 10 cable break device Cable break device CBD 440 HD consists ofthe following parts CBD 440HD Self tapping screws See also separate h
45. s KA Je 2 3 S I a 1 KE Fit the spacer bush to the bearing roller Fitthe bearing roller holder to the spindle of the bearing roller Place the bearing roller with spacer bush and bearing roler holder in the vertical guide tracks at the level of the console Secure the bearing roller holder WI 2 self tapping screws See figure c 40 The cable is secured to the console with an eyebolt First tighten as far as possible an M10 flanged nut on the eye bolt Guide the cable around the reverse pulley of Consol insert the eyebolt from below through the console and tighten the 2 nut on the eyebolt See figure To prevent the console distorting or breaking the cable may only beset looser adjust eye downwards 103 428TAI bodemconsole Bottom console 428 consists of the following parts Console 428 Self tapping screws Eye bolt with cable 4217006110508 FlangednutM10 1058F Splitpin 2107 Order of assembly Insert the bearing roller into the bottom console and turn this in the vertical guide tracks One of the two bottom consoles may be fitted beforehand to the panel Position the bottom console on the panel such that the side and underside are flush with the panel Secure the console with 6 self tapping screws See figure HANDLEIDINGENMND manual GB no3 MANUAL The cable is secured to the console with an eyebolt First t
46. ting the key here and tighten the securing bolts Where necessary shorten spindle The exta bearing that may need 0 be fited 0 support or secure the spindle chain hoistis notin duded in the delivery See also assembly instuctons fr chain hoist 37 Extra Chain When spindle is placed atgreater heights an exta separate chain is supplied fr extension of chain Extension insertion can be realized easily by opening and then dosing link The 31106 invo ved is 723A manual chain HANDLEIDINGENMND manual GB no3 MANUAL 25 Hexiforce 4 HINGES 41 Intermediate hinges galvanised 450HZ See Picture 447DOUB See Picture A420HZ 10RES See Picture 450HZ 10 See Picture 42 Intermediate hinges RVS 450H304 See Picture 43 Side hinges galvanised 45062 See Picture A420CZ 10RES See Picture 45062410 See Picture 44 Side hinges galvanised 450C304 See Picture 450H304 iud HANDLEIDINGENMND manual GB no3 MANUAL 420HZ 10RES 450HZ 10 105389 26 MANUAL 420 2 10 5 10RES 420RZ 447DOUB 27 HANDLEIDINGENMND manual GB no3 MANUAL 450C304 450CZ410 28 HANDLEIDINGENMND manual GB no3 Hexiforce MANUAL 5 SCREWS Max torque L Nm TYPE mn 10 0138 138175 55 00 tic hkness mm 2 00 3 00 3 00 4 00 HANDLEIDINGEN IND manual GB no3 29 Hexiforce VER
47. track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track setconsists of a left hand and right hand section a double bend straight tracks and a reinforcement profile The bends and the straight guide tracks are attached to one another by junction plates and a side plate The side plate is fitted with a cable pulley 1 Assembly vertical track set Slide the side seal onto the corner line and shorten this where necessary Secure the vertical track set level to the pendent See 1 General Ensure that the side seal cannotbe displaced When necessary deform the rim of the corner line above the side seal Assembly horizontal track set Se cure a piece of cord 0 the ceiling or roofstucture See figure Adjustthe horizontal track set0 1 degrees rising A Tighten al bolts Depending on the cable drum use 1 or 2 zw bolts to secure the horizontal tracks to the vertical Come gt line HANDLEIDINGENUND manual GB no3 16 7 MANUAL 2 3 HL High lift 2 Hh un Distinguishing feature Tn With High Systems the door rises vertically first above the clear heightbefore the upperpanel tums through the 1 bend See figure 1 d Tracks 11 The track system of the High System consists of a vertical and a horizontal section Vertical track set This is made up ofa lefthand and right hand comer line with a guide track and s
48. ure the vertical track setlevel to the pendent See 1 General When the vertical set consists of two sections then assemble as depicted in the figure For a single vertical setonly the lower fastener is present HANDLEIDINGENMND manual GB no3 MANUAL 18 lexiforce MANUAL 2 5 Following The Roof System Normal 2 1 W Distinguishing feature p a With FTR Normal systems the door turns through the pc bend directly above the clear height and then tracks the angl of the roof The horizontal section consists of a i single track See figure Tracks The track system of the FTR System consists of a vertical and a horizontal section Vertical trackset This is made up ofa lefthand and righthand assembled corner line with a guide track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track setconsists of a left hand and right hand bend and a reinforcement profile that is secured to the bend and the straight guide track Assembly vertical track set Slide the side seal onto the corner line and shorten this where necessary Secure the vertical track set level to the pendent See 1 General Ensure that the side seal cannot be displaced When necessary deform the rim of the corner line above the side seal Assembly horizontal track set Secure a piece of cord 0 the ceiling or roofstucture See figure Adjustthe horizontal track lining with the roof Tighten

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