10 RESX manual GB
Contents
1. Hardware system for residential garage overhead doors Built in height 73mm springs in rear INSTALLATION MAINTENANCE USAGE All rights reserved FlexiForce 2009 fl i f innovations for overhead doors RES X R MANUAL GB 2009 13 i 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 e This manual has been written for use by experienced fitters and as such is not suitable for purposes or for use by trainee fitters e 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 e Before starting read this manual carefully e Certain components may be sharp or have jagged edges As such you are advised to wear safety gloves e All 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 ha2. i SHAFT SYSTEM INSTALLATION DOOR W gt 3000mm Cable drums With key way FF 4 13 FF05NL 12 etc RHW RH Central shaft suspension With coupler and 2 bearing plates 310CL CR or USA MINI kan a Torsion springs with spring fittings and spring break devices With key way tube key wayed shaft FFO5NL12 FF 4 13 p 711A etc i Ln m 2 x T02GBL etc 705GB etc CENTRAL SHAFT SUSPENSION W gt 3000mm Traditional installation Super Click installation USA MINI flexifo rce RES X R MANUAL GB 2009 www flexiforce com 12 13 i FIXATION TO TRACKS 1070B35 Traditional installation SuperClick installation CLICK Ga flexifo rce RES X R MANUAL GB 2009 www flexiforce com 13 13 i PANEL lt gt HARDWARE INSTALLATION lt O M Q 1055BV or ka 8 alternative O AG 7 E GG 24 10 581 582CEN flexifo rce RES X R MANUAL GB 2009 www flexiforce com oors 14 581CEN lorange 582CEN black NG 4 GG VR flexifo rce RES X R MANUAL GB 2009 www flexiforce com 19 manual INSTALLATION TOP PANEL TOP ROLLER CARRIER A Close the door and secure the door panel Loosen the two self tapping screws 1055BV secur ing the top roller holder 418SL R so that it can be displaced with a slight tick Press the top panel against the side upper seal an
3. 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 Min 110 NB E operation Horizontal track extra lenght to create space for E operator bracket So combinations RXV10 RXH30 RXV20 40 RXV30 RXH50 RXVAO RXH60 RXV50 RXH60 RXV60 RXH70 4 flexifo rce RES X R MANUAL GB 2009 www flexiforce com 23 manual OPTIONAL TANDEM ROLLERS fo rce RES X R MANUAL GB 2009 24 13 i PANEL ASSEMBLY INSTALLING END CAPS 40ES500L etc or alternatives POSITIONING OF END CAPS PER PANEL BRAND Kingspan panel Tecsedo panel Metecno panel 40ES500L R 40ES610L R 40TS500L R 40TS610L R 40FS500L R 40FS610L R 40ES500WL R 40ES610WL R RAL9010 40TS500WL R 40TS610WL R 40FS500WL R 40FS610WL R 40EM500L R 40EM610L R 40TM500L R 40TM610L R 40FM500L R 40FM610L R 40EM500WL R 40EM610WL R RAL9010 40TM500WL R 40TM610WL R 40FM500WL R 40FM610WL R flexifo rce RES X R MANUAL GB 2009 www flexiforce com innovations for overhead doors 29 13 i W 45mm W Day
4. GB 2009 www flexiforce com innovations for overhead doors Panel overlay 10 5 mm INSTALLING VERTICAL TRACK SET flexifo rce RES X R MANUAL GB 2009 www flexiforce com innovations for overhead doors 7 HORIZONTAL TRACK SET long side short side lt __ 1062M 4x gt WWW flexiforce com flexiforce RES X R MANUAL GB 2009 8 13 i PULLEY SYSTEM INSTALLATION 1062M 2x Oo L o68M RX60L R 1006B 2x NB Optional installation of RX80L R and 570 80 pulley CONNECTION HORIZONTAL TRACKS E operation 10628 9 Aa 2 gt 1070835 v 1070B35 L 1068M 8 4 v 1070B35 v 1062M e 1062M DAYS OPENING WIDTH 134MM flexifo rce RES X R MANUAL GB 2009 www flexiforce com 9 13 i SUSPENSION HORIZONTAL TRACK TO CEILING flexifo rce RES X R MANUAL GB 2009 www flexiforce com innovations for overhead doors 10 13 i SHAFT SYSTEM INSTALLATION DOOR w 3000mm Cable drums No key way FF4X8 400 8 5 FF0402 BLACK ba Torsion springs tube shaft Without key way with spring fittings and spring break devices 656 or 656T USA MINI aR M BOLTS NUTS PRE ASSEMBLED flexifo rce RES X R MANUAL GB 2009 www flexiforce com 11 4
5. Loosen the bolts in the tensioning plug and remove the key Turn the 1st tensioning iron in the direction required Insert the 2nd tensioning iron fully into the next tensioning aperture Take over the tensioning of the spring from the 1st tensioning iron with the 2nd tensioning iron Remove the 1st tensioning Iron from the aperture Turn the 2nd tensioning iron a quarter turn in the direction required 9 Insert the 1st tensioning iron fully into the tensioning aperture 10 Take over the tensioning of the spring from the 2nd tensioning iron with the1st tensioning iron 11 Repeat steps 4 through 10 until all tension is released 12 Remove the last tensioning iron pero pL pa 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 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 halv
6. a w Natl T ub Y M 2 RH 77 LH B gt m O FlexiForce spring gauge WGD10 flexifo rce RES X R MANUAL GB 2009 www flexiforce com 28 13 i DISMANTLING THE OVERHEAD DOOR 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 CAUTION Torsion springs and bottom brackets are under high tension Exercise at all times great caution Use properly fitting and maintained tension irons see drawing Start dismantling of the door by closing the door and securing its movement with a clamp on the vertical track First the tension on the torsions springs and cable has to be released Do this by fol lowing these instructions 1 Insert the 1st tensioning iron fully into the tensioning aperture Take over the tension of the spring with this tensioning iron
7. d 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 fo rce RES X R MANUAL GB 2009 16 13 i CABLES amp TORSION SPRINGS Hook in the cable end In the drum Rotate the drum for winding the cable Position the drum on the shaft flexifo rce RES X R MANUAL GB 2009 www flexiforce com 17 Tighten FF 4X8 FF0402 FF400 8 S NB See separate manual spring break device installation 656Manual GB pdf flexifo rce RES X R MANUAL GB 2009 www flexiforce com 18 13 i TORSION SPRING TENSIONING CAUTION Torsion springs are subject to considerable tension Proceed at all times with extreme caution Instal lation maintenance and repair should be carried out only by experienced and properly trained overhead door fitters Use correctly fitting and properly maintained tension levers Flexi Force code RES TB Number of turns on the torsion springs Number of turns Height H 4 panels 5 panels 2000mm 7 1 turns 6 8 turns 2125mm 7 6 turns 7 3 turns 2250mm 8 0 turns 7 7 turns 2375mm 8 4 turns 8 7 turns 2500mm 8 5 turns 9 2 turns 5 panels 6 panels 2750mm 9 4 turns 9 2 turns 3000mm 10 3 turns 10 0 turns Insert the 1st tension lever completely into the slot Turn the 1st tension l
8. es 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 flexifo rce RES X R MANUAL GB 2009 www flexiforce com 29 13 i 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 me chanics 2 Replacement of broken weared components should always be done by qualified overhead door mechanics 3 When checking the door always disconnect the electrical main power supply Make sure that it is blocked against re engaging without you knowing it REGULAR MAINTENANCE After installation 1 Grease running part of the tracks MECHANIC 2 Grease the bearings of the rollers MECHANIC 3 Grease the shafts of the rollers MECHANIC 4 Grease the bearings of the shaft MECHANIC 9 Grease the hinge pins MECHANIC 6 Grease the
9. ever a quarter turn such that the spring is tensioned Insert the 2nd lever completely into the next slot Take over the tension of the spring from the 1st tension lever to the 2nd tension lever Remove the 1st tension lever from the slot Turn the 1st ten sion 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 RES X R MANUAL GB 2009 WWW flexiforce com flexiforce innovations for overhead doors 19 manual 4 force RES X MANUAL GB 2009 innovations for overhead doors 20 manual 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 POSITION SAFETY LABELS ON THE DOOR LABEL GB etc flexifo rce RES X R MANUAL GB 2009 www flexiforce com 21 Install any additional accessories that you have ordered separately such as Handgri
10. ith inclination 4 Were modifications made afterwards check if any changes were made during the fitting or if a pass door was fitted later or any reinforcement profiles fitted etc 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 NB Also make sure to instruct the user about this 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 isa 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 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 carri ers rollers etc SPRING IDENTIFICATION RHW Red RHW Red LHW Black X LHW Black k
11. 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 or wear and tear USER 3 Check bottom seal on damage or wear and tear USER 4 Grease all above mentioned points USER 9 Clean the panels USER 6 Clean the windows only water wash do not use cloth USER 7 Remove dirt and waste from the door or its surroundings USER Every 12 months 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 RES X R MANUAL GB 2009 www flexiforce com 30 13 i 7 Check the panels on damage wear and roust MECHANIC 8 Check the spring breaking device acc to instructions in manual MECHANIC 9 Check and test the safety edge system with operator MECHANIC 10 Check the manual operation of the door MECHANIC 11 Grease the springs MECHANIC After two year
12. ook 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 This door can only be installed according to the CE certificate if all parts are according to the parts lists of the SP certificate See www flexiforce com Flexi Force 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 ITT REPORT 0402 CPD 402201 NB This garage door cannot be equipped with a pass door wicket door All CE approvals are not valid when a pass door is installed If you want to include a pass door a new Initial Type Testing should be arranged under your responsibility RECOMMENDED ADDITIONAL MANUALS ddmanuar ddmanuat CG product specs 696 _ Sup FlexiForce inside erClick k spring breaking device stallatior residential garage overhead doors system for INSTALLATION MAINTENANCE CE RES Overview panel hardware combinations flexiforce flexifo rce RES X R MANUAL GB 2009 ww
13. p lock etc See separate instructions in product packaging AN ne A lock may not be fitted to an electrically driven door NB A manually operated door should always be equipped with a hand grip installed at a safe location on the door NB Do NOT INSTALL a pull rope with a power operated door at any time This can cause serious injuries or danger to the user of the door Place your CE identification plate on the door mandated together with any warning labels required Hand over necessary documents to the end user 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 RES X R MANUAL GB 2009 www flexiforce com 22 13 i OPTIONAL E OPERATION When you have selected an electrical opera tor drive LIFTMASTER LM60K R or other then this should be assembled in conformity with the handbook supplied with this opera tor and above displayed instructions You should clearly follow the instructions for electrical operation in this handbook In order to maintain the closing peak force of the door within the CE standards the attach ment point of the drawbar should be fixed at the proper position
14. ravelling expenses over distances of 1 hour away at most For large scale projects we strongly advise you to first install 1 door completely before installing the other doors In this way any errors can be detected early on and rectified comparatively cheaply This manual does not confer any rights Technical modifications may be made without written notice FlexiForce has endeavoured to design and put together this hardware set in conformance with the applicable CE norms However we recommend to check our configuration against any local national specification flexifo rce RES X R MANUAL GB 2009 www flexiforce com innovations for overhead doors 2 13 i INTRODUCTION Flexi Force has developed a completely new hardware set for residential garage overhead doors Designed for all built in situations depending on the available space The set includes the following features Suitable for single and double garages to W x H 5000mm x 3000mm max 160 kg Spring package behind the horizontal tracks needed head room 75 100mm Fitted with cable within the tracks and spring breaking device meeting CE standards Restricted installation sizes CE approved when selecting the proper Flexi Force components In this handbook we shall restrict our instructions for the proper assembly of the complete door For installation of not mentioned products or parts including any components added by the supplier as well as for a user handb
15. s or after every 3000 cycles 1 Grease all the above mentioned points MECHANIC 2 Check or test the fixation of the springs to the fittings MECHANIC 3 Check the balance of the door and adjust if needed MECHANIC 4 Check the cables for damage or wear and tear MECHANIC 9 Check the cable connection points on drums and bottom bracket MECHANIC 6 Check the roller on wear and free moving space MECHANIC 7 Check the hinges on breaking MECHANIC 8 Check the panels on damage wear and roust MECHANIC 9 Check the spring breaking device acc to instructions in manual MECHANIC 10 Check and test the safety edge system with operator MECHANIC 11 Check the manual operation of the door MECHANIC 12 Grease the springs MECHANIC 13 Check side seals on damage or wear and tear MECHANIC 14 Check top seal on damage or wear and tear MECHANIC 15 Check bottom seal on damage or wear and tear MECHANIC 16 Check the shaft on wear and tear or damage MECHANIC 17 Check the bottom bracket on wear and tear and damage MECHANIC 18 Check the connection of the drum to the shaft keys MECHANIC 19 Check and re fix the bolt of the coupler MECHANIC 20 Check the connections of the track system MECHANIC 21 Check the suspension of the door to the lintel and ceiling MECHANIC Use for greasing PTFE SAE20 or WD40 Use for cleaning Soft soap with water Do not use aggressive soap or cloth flexifo rce RES X R MANUAL GB 2009 www flexiforce com 31
16. s Opening Width 1031RES6090 or alternatives INSTALLING BOTTOM ALU SEAL 1031RES6090 or alternatives Lt flexifo rce RES X R MANUAL GB 2009 www flexiforce com innovations for overhead doors 26 13 i CUTTING FINISHING TOP PANEL NB Make sure that the bottom panel will not be cut for adjusting the panel or door height This AX shout be done with the top section only The attachment of the bottom bracket which is hold ing the complete door weight is relying on the construction of the panel Danger can occur if the panel is cut at this point Total door panel height Days Opening Height H 15mm 1038TOP 6090 etc flexifo rce RES X R MANUAL GB 2009 www flexiforce com 27 13 i 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 instance by the application of different panels glass pass door with heavy profiles 2 Are the correct parts supplied and fitted especially the drums and springs are important are the correct dimensions supplied Is the door properly installed horizontal tracks really horizontally and not w
17. s been granted to this door will be cancelled when components are changed or installation is not done according to this manual Installer is responsible for this e 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 condi tions free of charge A copy may also be downloaded from our website www flexiforce com FlexiForce strives to deliver 100 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 incon venience 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 t
18. w flexiforce com innovations for overhead doors 3 13 i IN THIS MANUAL E Attention general warnings 2 Guarantee terms and conditions 2 Application range 3 Recommended additional manuals 3 Tools for correct and rapid assembly 5 Applied fixation materials 9 RES X System overview 6 Installing vertical track system 7 Installing horizontal track system 8 Shaft system installation 11 Panel lt gt Hardware installation 14 Cables amp Torsion springs 17 Finishing the door 20 Optional E operation 23 Panel assembly 25 Troubleshooting 28 Dismantling instructions 29 Maintenance and replacement parts 30 flexifo rce RES X R MANUAL GB 2009 www flexiforce com 4 13 i 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 10mm Plug 13 mm 4 mm 8mm 1 10 mm 13 mm 15 mm 17 mm with 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 Alternatives 10550 screw 6 3
19. x25mm with drill point Max torque 10Nm key 10 2 V i O P t 18771777 1070 35 bolt M8x25 1068M nut M8 Max torque 13Nm key 13 25 t 1068M H M8 1053BV screw 6 3x3bmm 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 cap RAL9010 Optional 1055 10 white 1 9010 cover for screws key 10 1006B press bolt 1062B bolt M x16 1062M nut M6 1062M nut M6 Max torque 9 1Nm key 10 Max torque 5 3Nm key 10 16 25 10628 6 1062M H B M6 1071BC bolt M8x12 SuperClick secure bolt NB Fixation material for Installing to wall and Max torque 10Nm key 13 flexiforce innovations for overhead doors ceiling is not included in this manual RES X R MANUAL GB 2009 WWW flexiforce com 5 13 i RES X SYSTEM OVERVIEW Pulley system Leading the cables to the drums at the rear end of the horizontal double track RXH10etc Horizontal double track set RXR L R Pre assembled curve set Shaft system with torsion springs spring break devices drums spring fittings cables etc Door panels sections With end caps hinges bottom brack ets bottom astragal and seal top roller carriers windows etc RXV10etc Vertical set with track side seal and vertical angle Top view flexifo rce RES X R MANUAL
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