Hardware system for residential (garage) overhead doors
Contents
1. manual 88 RS70 C Hardware system for residential garage overhead doors Built in height 86mm springs rear INSTALLATION MAINTENANCE USAGE All rights reserved FlexiForce 2009 manual 88 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 1 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 the safety of and the guarantee on the door Also the CE approval which has been granted to this door will2. RETO top view HH ROM Side view B H 70mm for manual operated doors B H 0mm for e operated doors NB See Chapter E operation Mna flexifo rce RS70 manual GB 2009 innovations for overhead doors manual 8 Panel overlay 10 5 mm INSTALLING VERTICAL TRACK SYSTEM flexifo rce RS70 manual GB 2009 www flexiforce com innovations far overhead doors manual 88 VERTICAL TRACK SET gt PULLEY SYSTEM INSTALLATION NB Optional installation of RX80L R and 570 80 pulley flexi fo rce RS70 manual GB 2009 www flexiforce com innovations overhead doors manual 88 CONNECTION HORIZONTAL TRACKS R s 1070835 STE uc e E 1070 35 days opening width 134mm SUSPENSION HORIZONTAL TRACK CEILING flexifo rce RS70 manual GB 2009 innovations for overhead www flexiforce com 13 manual 85 SHAFT SYSTEM INSTALLATION DOOR W 3000mm Cable drums No key way FF4X8 FFA400 8 S FF0402 Central shaft suspension Without key way tube shaft BLACK p Torsion springs LH with spring fittings and spring break devices CENTRAL SHAFT SUSPENSION 2 ALTERNATIVES USA MINI 312R Ms BOLT STS pA asti US R NI flexifo rce RS70 manual GB
3. 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 f lexifo rce RS70 manual GB 2009 jiii innovations for overhead
4. 1 1 flexifo rce RS70 manual GB 2009 innovations overhead doors 13 manual 88 Install any additional accessories that you have ordered separately such as Handgrip lock etc See separate instructions in product packaging P P NB Alock may not be fitted to an electrically driven door installed at a safe location on the door NB Amanually operated door should always be equipped with a hand grip A NB DoNOT 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 O O O O User manual Dismantling instructions included in this manual Maintenance instructions included in the user manual Service log book Declaration of conformity lla declaring the door is according to EN 13241 1 Visit www flexiforce com for the most recent update of information on your obligations towards handing over a safe to use door flexifo rce RS70 manual GB 2009 innovations for overhead www flexiforce com 21 13 manual 88 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 instruct
5. conditions 2 Application range 3 Recommended additional manuals 3 Tools for correct and rapid assembly Applied fixation materials RS70 System overview 6 nstalling vertical track system 7 nstalling 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 Troubleshooting 27 Dismantling the overhead door 28 Maintenance and replacement of parts 29 CU er d a Li E Fa mu t P innovations overhead doors rce RS70 manual GB 2009 www flexiforce com 4 M 13 manual 85 TOOLS FOR CORRECT AND RAPID ASSEMBLY Battery drill with Hexagonal key Socket screw spanner Ring open ended spanner Ring open ended spanner Ring open ended spanner Ring open ended spanner Socket wrench Wrench Gluing clamp Cord Water level hose Bit 4 0 mm Bit 4 5 mm Bit 6 5 mm Plug 10 mm Plug 13 mm 4mm 8mm 10 mm 13mm 15 mm 17 mm with 1 4 square 2 blocks of ca 20 en 40mm in height Measuring equipment APPLIED FIXATION MATERIALS The applicable fixation material is described in the drawings of this manuals Below an overview of the applied fasteners and optional alternatives 1055BV self tapping screw Max torque 10Nm key 10 1070B35 bolt M8x2
6. 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 FlexiForce spring gauge WGD10 flexifo rce RS70 manual GB 2009 www flexiforce com innovations for overhead 13 manual 85 DISMANTLING IHE 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 tensioning 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
7. tension on the torsions springs and cable has to be released Do this by following these instructions Insert the 15 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 1st 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 15 tensioning iron with the 279 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 Noa MA ROUN 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 tension 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
8. turns Humber of turns Turn the 1 tension lever a quarter turn such that the spring is tensioned 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 15 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 innovations for overhead www flexiforce com flexifo rce RS70 manual GB 2009 manual 85 innovations overhead doors manual 9 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 there 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 SAFETY LABELS ON THE DOOR J LABEL GB etc 1 H at 1 n ig h 1 m l J 1
9. 0WL R RAL9010 4OTM500WL R 40TM610WL R flexi fo rce RS70 manual GB 2009 innovations far overhead doors Metecno panel 40FS500L R 40FS610L R 40FS500WL R 40FS610WL R 4OFM500L R 40FM610L R 40FM500WL R 40FM610WL R www flexiforce com 24 Tj manual 88 1031RES6090 or alternatives INSTALLING BOTTOM ALU SEAL HAES DAN A erm ea Erin flexi fo rce RS70 manual GB 2009 innovations overhead doors manual 88 CUTTING FINISHING TOP PANEL 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 15mm TUGETOP 5560 elc 1224 20 ec flexi fo rce RS70 manual GB 2009 www flexiforce com innovations for overhead doors 13 manual 85 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 correct 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 insta
10. 2009 innovations overhead doors manual 88 SHAFT SYSTEM INSTALLATION DOOR W gt 3000mm double doors Cable drums With key way FF 4 13 FFO5NL12 etc Central shaft suspension With coupler and 2 bearing plates 310CL CR or USA MINI 4 A BLACK 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 bL flexifo rce RS70 manual GB 2009 www flexiforce com innovations for overhead Tjmanual 9 FIXATION TRACKS 1070B35 Traditional installation SuperClick installation 1071 flexifo rce RS70 manual GB 2009 www flexiforce com innovations for overhead 13 manual 85 PANEL HARDWARE INSTALLATION gt O MEH flexi fo rce RS70 manual GB 2009 e E innovations for overhead manual 88 5S 1L EH flexi fo rce RS70 manual GB 2009 MEUM innovations for overhead dd Manual 98 INSTALLATION TOP PANEL ROLLER CARRIER Close the door and secure the door panel Loosen the two self tapping screws 1055BV securing the top roller holder 418SL R so that it can be displaced with a slight tick Press the top panel against t
11. 5 1068M nut M8 Max torque 13Nm key 13 25 I socom Alternatives 10550 screw 6 3x25mm with drill point 1053BV screw 6 3x35mm 1053D screw 6 3x35mm with drill point 1054 25 1054 35 screw with socket hex cap drill point 1054W 25 1054W 35 screw with socket hex RAL9010 Optional 1055 10 white RAL9010 cover for screws key 10 1006B press bolt 1062B bolt M6x16 1062 nut M 1062 nut M torque 9 1Nm key 10 Max torque 5 3Nm key 10 16 10628 M6 1006B ME 1062M ME 1062M M6 1071BC bolt M8x12 SuperClick secure bolt NB Fixation material for installing to wall and Max torque 10Nm key 13 13 2 is 6 z TN i j 7 VA 1 1 1 5 r m I 1 W pU 2 a a w ka ceiling is not included in this manual flexifo rce RS70 manual GB 2009 innovations for overhead manual 88 RS70 SYSTEM OVERVIEW Pulley system Leading the cables to the drums at the rear end of the horizontal double track RS70H10etc Horizontal double track set Shaft system with torsion springs spring break devices drums spring fittings cables etc 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
12. TENANCE 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 9 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 6 months or after every 750 cycles 1 Check side seals on damage or wear and tear USER 2 Check top seal on damage wear and USER Ji 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 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 flexifo rce RS70 manual GB 2009 ii innovations for overhead Tjmanual 88 7 Check the p
13. anels 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 allthe 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 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
14. 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 permission for this in advance The reimbursement is based on normal rates and travelling expenses over distances o
15. f 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 f lexifo rce RS70 manual GB 2009 www flexiforce com innovations for overhead manual 88 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 Suitable for single and double garages Wmax 5 000 mm Hmax 3 000 mm The horizontal track set is standard reinforced with side plate RX560L R with pulley system Advised max door weight is 165 kg Each spring break device is approved to 125kg CE approved when selecting the proper FlexiForce comp
16. he 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 419S series exifo rce RS70 manual GB 2009 innovations for overhead doors manual 8 flexifo rce RS70 manual GB 2009 www tlexiforce com innovations for overhead doors manual 88 MR x Tighten FF 4X8 FF0402 FF400 8 S NB See separate manual spring break device installation 656Manual GB pdf flexi fo rce RS70 manual GB 2009 www flexiforce com innovations for overhead doors A Tj manual 88 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 trained overhead door fitters Use correctly fitting and properly maintained tension levers FlexiForce code RES TBJ Number of turns on the torsion springs Height H 2000mm 2125mm 2250mm 2375mm 2500mm 2750mm 3000mm Insert the 15 tension lever completely into the slot 4 panels 7 1 turns 7 6 turns 8 0 turns 8 4 turns 8 5 turns 9 panels 9 4 turns 10 3 turns 9 panels 6 8 turns 7 3 turns 7 7 turns 8 7 turns 9 2 turns 6 panels 9 2 turns 10 0
17. ions 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 NB E operation HB Horizontal track extra lenght to create space for E operator bracket char So combinations RSV10 RS70H30 RSV20 570 40 RSV30 RS70H50 RSV40 570 60 RSV50 RS70H60 RSV 0 RS70H70 flexi fo rce RS70 manual GB 2009 www flexiforce com innovations for overhead manual 85 OPTIONAL TANDEM ROLLERS g axifo rce RS70 manual GB 2009 53 innovations for overhead doors 134 manual 9 PANEL ASSEMBLY INSTALLING END CAPS amp 5001 etc er alternalives Kingspan panel Tecsedo panel 40ES500L R 40ES610L R 40TS500L R 40TS610L R 40ES500WL R 40ES610WL R RAL9010 40TS500WL R 40TS610WL R 4OEM500L R 40EM610L R 4OTM500L R 40TM610L R 40EM500WL R 40EM61
18. nce 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 3 Is the door properly installed horizontal tracks really horizontally and not with inclination 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 D 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 bearing 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
19. onents 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 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 1115 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 ad product epoce FlexiForce inside 11 13 656 SuperClick Col P RES Li yerview haraw Ira CE moins 101154 Hexilarce flexifo rce RS70 manual GB 2009 innovations for overhead 7J manual IN THIS MANUAL Attention general warnings 2 Guarantee terms and
20. 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 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 in an environment kindly way Check with your local authorities where and how you can leave this as garbage f lexifo rce RS70 manual GB 2009 innovations for overhead Tj manual 8 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 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 MAIN
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