manual - Sezam doors
Contents
1. WWW FLEXI FORCE COM Flexiforce 2 4 VL Vertical lift 2 Distinguishing feature With Vertical systems the door rises straight upward See figure Tracks The track system of the Vertical system consists only of a vertical section Vertical track set This is made up of a left hand and right hand corner line with a guide track and side seal See 7 Vertical corner lines For large clear heights the vertical track set is supplied in two sections Assembly vertical track set Slide the side seal onto the corner line Secure the vertical track set level 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 set only the lower fastener is present FF MANUAL I ND HWS 19 manual 1062M WWW FLEXI FORCE COM 2 5 FTR Following The Roof System Normal 2 Distinguishing feature With FTR Normal systems the door turns through the bend directly above the clear height and then tracks the angle of the roof The horizontal section consists of a single track See figure Tracks The track system of the FTR System consists of a vertical and a horizontal section Vertical track set This is made up of a left hand and right hand assembled corner line with a guide track and side seal See 7 LB Vertical corner lines Horizontal track set The horizontal track set consists of a left hand and2. A 2 ge 7 AT Wem d 4 0 ex Ex 3 u e FF VL 28 FF VL 11 FF VL 28 5 4 FF VL 18 5 4 FF MANUAL IND HWS 69 WWW FLEXI FORCE COM manual 30 20 3000 35 40B25 3000 S 20830 000 5 30B20 40B25 20850 1026 688 1068 4850 5050 1068 1OZDB 9 5 4850 4850 Si FF MANUAL IND HWS 70 WWW FLEXI FORCE COM Hexilorce 19 TRIANGULAR PLATE SITAS FF MANUAL I ND HWS 71 WWW FLEXI FORCE COM exiforce manual 20 CABLE TENSIONING SETS 685CH 553DOUB 907 T 593 15 H lt 3500mm 18m1 501 20 H gt 3500mm 70m1 Extra Addit 553000UB 907 1x HRS 25 Extra Addit 70 1 5 1068 GESKEP In combination with cable braak device install special bracket 7605K BB Bei Verwendung van Seilbruchsicherung brauchen Sie sonder Bugel 2605 DB En combination avec parachute de cable d faut installer support 7695KBB ax M x l Extra Addit 1962B H gt 553HING FF MANUAL I ND HWS 72 WWW FLEXI FORCE COM manual 685CH HMR EI Extra Addit ae _ 553HING A cover to protect the bracket 2600 is required eX 16 Extra Addit 1062B H FF MANUAL I ND HWS 73 WWW FLEXI FORCE COM 687 springs at the rear FF MANUAL I ND HWS 74 WWW FLEXI FORCE COM manual 687 Normal system FF MANUAL I ND HWS
3. FF MANUAL IND HWS 21 WWW FLEXI FORCE COM 2 7 FHL Following The Roof System High 2 Distinguishing feature 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 track set This is made up of a left hand and right hand 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 set is supplied in two sections Horizontal track set The horizontal track set is constructed from a left hand 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 in the figure For a few vertical sets only the lower fastener is present Assembly horizontal track set Secure a piece of cord to the celling or roof structure See figure Adjust the horizontal track lining with the roof Tighten all bolts Depending on the cable drum use 1 or2 bolts to secure the horizontal tracks to the vertical corner line F
4. Tracks The track system of the FLH System consists of a vertical and a horizontal section Vertical track set This is made up of a left hand and right hand assembled corner lines with a guide track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track set consists of a left hand and right hand section with 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 m Following Low Headroom Sturz mit dachfohge Lintedu qe permis nna H TETI ID 20 28 CDOE H ak H LB 4180 ren De ri AM dul men Ci 33 4185 men Di 2v H TE 3815 ma bx ZW H PL 1306 mer a z57 554 25D 4 E P HLH l NN L in Ti 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 f necessary deform the rim of the corner line above the side seal Assembly horizontal track set Secure a piece of cord to the ceiling or roof structure See figure at normal system Adjust the horizontal track lining with the roof Tighten all bolts
5. 1085 5 e L o Ed WWW FORCE COM Hexilorce 8 LOCKS Slide bolt 629VER Slide bolt 630D Slide bolt 632 Cilinder lock 635 Cilinder lock 637 40 50 Cilinder lock 638 40 56 LH 1053Bw RVS 1055BW RWS 629VER See Picture See Picture See Picture See Picture See Picture See Picture 102ZEV FF MANUAL I ND HWS 32 manual Cilinder lock 668 40 See Picture Cilinder lock 632LHR See Picture Cilinder lock 6695 See Picture 1100 o F WWW FLEXI FORCE COM Fexiforce manual 630D LH RH BD ARCS 10528 e 1053BV RVS RYS c I 11100 FF MANUAL IND HWS 33 WWW FLEXI FORCE COM Fedoce manual 632 632LHR 10526 1 GEGEN RYS 55 5 1100 FF MANUAL IND HWS 34 WWW FLEXI FORCE COM 635 FF MANUAL IND HWS 35 WWW FLEXI FORCE COM 637 40 50 FF MANUAL I ND HWS 36 WWW FLEXI FORCE COM manua BE LH 638 40 56 FF MANUAL IND HWS 37 WWW FLEXI FORCE COM lexiforce A M5x55 B5 Bx B 2x Do ees 2X s 36 41 MOXOD 485 51 M565 668 40BL 637 638 and 668 40BL The T grip must be installed in such way that in case of an unlocked door the T grip is situated in the horizontal position FF MANUAL IND HWS 38 WWW FLEXI FORCE COM force manual 9 GRIPS General To minimize the
6. Hexiforce installation manual IND HWS hardware set for industrial overhead doors max 8 0m max h 6 0m max kg 700kg NL VL HL LHR FLH FHL rights reserved Flexi Force BV 2005 NEW CE LHR system patent pending FF MANUAL IND HWS 1 manua WWW FLEXI FORCE COM Flexiforce manual ATTENTION GENERAL WARNINGS To install use and maintain this door 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 v SPECIAL SAFETY WARNINGS OR REMARKS IN THIS MANUAL ARE INDICATED WITH THIS SYMBOL A READ THESE WARNINGS CAREFULLY v This manual has been written for use by experienced fitters and as such is not suitable for d i y purposes or for use by trainee fitters v This manual describes the installation of the hardware set components door sections panels and refers to installation manuals of the electrical operators 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 Certain components may be sharp or have jagged edges As such you are advised to wear safety gloves 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 effe
7. Bearing plate USA 8 retainer See Pict Interm Bearing plate USA 8 fitting See Picture 124 Several Wall plate 321WAL See Picture Bearing 1 USA A See Picture Bearing 1 USAB See Picture Retainer 325 See Picture 4 1 1 305 4B T 306 4B 111 1915 48 86 307 4B 127 215 468 1 11 1308 46 159 1315 48 127 i 4 1515 48 152 3 315 4B 3086C etc 305 48 3086 etc d 1 D e d D F 4 D d 4 4 0 H J rm d M Mm Ae e FF MANUAL IND HWS 58 WWW FLEXI FORCE COM 318 4C etc 320 4 etc FF MANUAL IND HWS 59 WWW FLEXIFORCE COM manual 5 322BAS FF MANUAL IND HWS 60 WWW FLEXI FORCE COM 323LAG B WWW FLEXI FORCE COM FF MANUAL IND HWS 61 USA 8 fittin FF MANUAL IND HWS 2 WWW FLEXI FORCE COM Hexilorce 13 SHAFTS FF MANUAL IND HWS 63 manual 321WAL 323LAG Sa M 322BAS ef KEY WAYED 1 Article code 705GB KEY WAYED SOLID 1 Article codes 702K black 702 2 galvanised KEY WAYED SOLID SHAFT 1 Article code 699 Z WWW FLEXI FORCE COM Hexilorce 14 SPRING BREAKING DEVICE SBD 670LH RH 675LH RH 675LH RH 5 4 Please s
8. base of the side hinges to the panels The position will in many instances be determined by the holes in the end Caps For doors 5000 clear width double side hinges will be used as standard Make sure that the space between panel and vertical track is no more than 10mm Bushes on the roller shafts of the top section and bottom section must be used On LHR doors do not put bushes on the 593 rollers 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 Clear width Intermediate hinges mm pieces 0000 2749 2750 3999 4000 4999 6000 6999 1000 7999 8000 8999 Place the lower panel in the clear width and support it with a pair of blocks 1 4 5000 599 6 See 10 Bottom brackets Place the rollers where necessary beforehand type dependent in the bottom brackets and fit the bottom brackets with secured cables to the panel in such fashion that the 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 that the edges are aligned Secure for the time being with FF MANUAL I ND HWS 13 manual a glue clamp or similar Fit first the side hinges and then the intermediate hinge Repeat this procedure with t
9. by qualified overhead door mechanics 3 When checking the door always disconnect the electrical main power supply Make sure that it is blocked against re engaging without you knowing it REGULAR MAINTENANCE After installation 1 Grease running part of the tracks MECHANIC 2 Grease the bearings of the rollers MECHANIC 3 Grease the shafts of the rollers MECHANIC 4 Grease the bearings of the shaft MECHANIC 5 Grease the hinge pins MECHANIC 6 Grease the lock MECHANIC 7 Protect the panels with carwax USER 8 Grease the rubbers slightly with vasaline USER After 3 months 1 Complete inspection visualy MECHANIC 2 Check balancing system and adjust if needed MECHANIC Every 6 months 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 5 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 7500 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 5 Check the roller on wear and free moving space MECHANIC 6 Check the hinges on breaking and wear and tear MECHA
10. cable around the reverse pulley of the console insert the eyebolt from below through the console and tighten the 2nd nut on the eyebolt See figure To prevent the console distorting or breaking the cable may only be set looser adjust eye downwards 10 33 bodemconsole Bottom console 428TAl consists of the following parts Console 428 Self tapping screws manual Eye bolt with cable 42700G 1050B Flanged nut M10 1058F Split pin 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 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 the console insert the eyebolt from below through the DU T console and tighten the 250 nut on the eyebolt Now insert the split pin as per drawing into the aperture designed for that purpose and bend its ends out The aperture next to the eyebolt serves to secure when required a cord for manual operation See figure A To prevent the console distorting or breaking the cable may only be set looser adjust eye ed downwards Because of
11. extremities of the split pin out See figure 10 6b 10 60 437VERS 437 bottom console The cable adjustment bracket 437VERS consists of the following parts Bracket 437VERS Eyebolt M10 1050B Nuts M10 1058F Order of assembly Secure the bracket to the console by inserting the pin through the console and the aperture of the bracket Secure the pin with the split pin and bend the extremities of the split pin out The cable should be secured to the bracket with an eyebolt First tighten an M10 flanged nut as far as possible on the eyebolt Insert the eyebolt from above through the bracket and tighten the 2nd nut on the eyebolt See figure FF MANUAL IND HWS 45 manual Because of the critical function of the bottom bracket itis not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation WWW FLEXI FORCE COM manual 10 7 Bottom console 425HD 10 8 Bottom console 430HD 10535 10556 2066 10 Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL IND HWS 46 WWW FLEXI FORCE COM Hexilorce 10 9 440 600 etc Cable break devices Download separate manual from www flexiforce com FF MANUAL I ND HWS 7 WWW FLEXI FORCE COM Fen manual 10 16 4279 RV9 bottom console Bottom console 427S RVS cons
12. 2602 etc 5C profile in middle of horizontal track 5C and 2602 etc 23 Breakaway Pg 78 24 Horizontal connection spring Pg 78 100K beam for installation spring system 100K and 355CONS etc 25 Panel production sections Pg 79 26 Dismantling instructions Pg 80 Additional information Trouble shooting Pg 81 What to do after spring break or cable break Pg 81 Hinge panel end cap overview Approved combinations Pg 86 Maintenance Maintenance instructions and replacing of parts Pg 87 User manual Enclosure on request Installation and user instructions electric operator option Enclosure on request SP Initial Type Testing Report and other approvals On request DOWNLOAD MORE MANUALS FROM WWW FLEXIFORCE COM FF MANUAL IND HWS 7 WWW FLEXI FORCE COM Hexilorce 1 GENERAL SPECIFICATION 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 set contains cable drums side bearing plates intermediate bearing plates spring breaking device shaft with key way roller bearings vertical track set with angle side seal horizontal track set with reinforcement and curve coupler rollers assembled torsion springs black or powder coated suspension profile
13. 35B RVS NutM8RVS 2535M RVS Spacer bush 2066 05 Order of assembly Place the spacer bush on the bearing roller Insert the bearing roller into the bottom console Rotate the bearing roller with console in the vertical guide tracks Position the bottom console on the panel such that the side is flush with the panel Secure the console with 6 self tapping screws See figure Secure the cable to the console by inserting the bolt M8x35 from within through the console and the loop in the cable Then tighten the nut on the bolt See figure Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL IND HWS 49 WWW FLEXI FORCE COM manual 11 BOTTOM CONSOLE SWITCHES 11 1 69015 OSUTSCHA 112 Please see separate manual cable break devices FF MANUAL IND HWS 7 WWW FLEXI FORCE COM manual Hexilorce 12 BEARING PLATES 12 1 Non adjustable bearing plates Side bearing plates 305 4B 30865 etc See Picture Side bearing plates 318 4CP See Picture Center bearing plates 315 4B 3086C etc See Picture Sice bearing plates 318 4C See Picture Bearing plates 320 4 See Picture 318 4CP 12 2 Adjustable bearing plates Base plate 322BAS See Picture Bearing plate 323LAG See Picture 323LAG B See Picture 12 3 Universal bearing plates Interm
14. 75 WWW FLEXI FORCE COM 21 SPRING BUMPERS 1062M EAS N 10648 20901 WWW FLEXI FORCE COM FF MANUAL IND HWS 76 HORIZONTAL CONNECTION TRACK 22 DMB 1 356 0 1066M S lt lt gt lt CH gt lt gt lt gt lt RC 1626 688 1 068K WWW FLEXI FORCE COM FF MANUAL IND HWS 77 23 BREAK AWAY FSOCONS FF MANUAL IND HWS 78 WWW FLEXIFORCE Hexilorce 25 PANELPRODUCTION FF MANUAL I ND HWS 79 WWW FLEXI FORCE COM Hexilorce 26 DISMANTLING OF 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 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 STEP 1 De tensioning the torsion spring s Start dismantling of the door by closing
15. HL Vertical Lift VL Following The Roof Normal Lift FTR Following The Roof Low System FLH Following The Roof High System FHL 3 Chain hoists Pg 23 Rope 10568 Chain hoist 1 1 T22A Chain hoist 1 3 721 Chain hoist 1 4 724 FF MANUAL IND HWS 4 WWW FLEXI FORCE COM Hexiforce manual Chapter Art Code Page Chain hoist 1 4 direct 725 Coupler 1 1 70251 1 2 Chain 123A Electrical operator 4 Hinges Top roller carrier Pg 27 Intermediate hinges 450HZ Intermediate hinges lengthened blade reversed pin 420HZ 10RES Intermediate hinges lengthened blade 450HZ 10 Intermediate hinges Stainless Steel 450H 304 Side hinges 450CZ Side hinges lengthened blade 450CZ 10 Side hinges Inox 450C 304 Top roller bracket adjustable 415CZ Top roller bracket for low headroom 417 Single or double side hinges and rollers 4505Z 447DOUB 5 Screws Pg 30 6 3 diameter and 25mm long 1055BV 1055BV RVS 6 3 diameter and 35mm long 1053BV 1053BV RVS 6 3 diameter and 16mm long 1052BV 6 Tracks Pg 30 2 tracks and 2H bends 2 tracks and 2G bends 3 tracks 7 Vertical angle and side seals Pg 31 Standard angle with seal on length 9VB and 1085 Standard angle with raised seal 9VB and 1094 40 Angle with short lip and roll able seal 9ZR and 1090 Special angle for 2 LHR and 3 tracks with seal 9K and 1085 8 Locks Pg 32 Slide bolt 629VER USA type slide bolt 630D Slide bolt with black knob 632 632LHR Heavy cylinder lock with slide bolt 637 40 50 668 40B
16. HL between 3 and 12 degrees To improve the connection with the horizontal 5C profile we will install an extra connection plate to the vertical angle in case of a FTR between 3 and 12 degrees The 5C profile will be shortened and will be installed to the new connection plate It is not necessary any more to produce holes in the vertical angle See drawing FF MANUAL I ND HWS 22 WWW FLEXI FORCE COM 8 1062 lexiforce 3 OPERATION 31 Rope operation Fitthe cord supplied using the clip and coupling to the bottom console at a point on the corner line at shoulder height WARNING Do not use on power operated doors 3 2 Chain hoist 1 1 type 722A The 722A chain hoist transmission ratio 1 1 is suitable for 1 spindles The set consists of the following parts Chain guide Sprocket wheel Manual chain 8 metre Chain stop Adjustment ring 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 with sprocket wheel against it 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 l
17. L 638 40 56 IGS Burglar proof lock 6695 9 Grips Pg 39 Black plastic grip foot pedal 640T 642BL Black grip 634 2 piece black grip in outside 639BL 643BL 10 Bottom brackets Pg 41 Bottom bracket 4275X Bottom bracket 428 Bottom bracket 425HD 2 3 Bottom bracket 429 Bottom bracket 432 Bottom bracket 437 437VERS Bottom bracket 430HD 2 3 Cable break device ADDITIONAL MANUAL 440etc Bottom bracket inox RVS 4275 RVS Bottom bracket inox RVS 437RVS FF MANUAL I ND HWS 5 WWW FLEXI FORCE COM Hexiforce Ch Art Code Page 11 Bottom bracket switches Pg 57 Simple switch 6901SCHA 440SWL 12 Bearing plates Pg 58 Fixed side bearing plates 1 305 4B 30865 etc Fixed side bearing plates 1 318 4CP Fixed intermediate bearing plates 1 315 4B 3086C etc Fixed intermediate bearing plates 1 4 318 4C Fixed side bearing plates 1 and1 1 4 320 4 Universal bearing plates USA 8LH RH Base plate 322BAS Bearing plate excl bearing 323LAG Bearing plate incl 1 bearing 323LAG B Wall plate 321WAL Bearing 1 4 USA A Bearing 1 USA B Bearing retainer 323 13 Shafts Pg 63 Black solid shaft 1 102K Key wayed 1 tube shaft 705GB Galvanised solid 1 shaft 702 2 Galvanised solid 1 1 4 shaft 699 7 14 Spring breaking devices ADDITIONAL MANUAL 670etc 15 Couplers Pg 65 Fixed aluminium coupler for 1 shaft 108 90 Adjustable cast steel coupler for 1 shaft 7035 Fixed cast steel c
18. MECHANIC MECHANIC MECHANIC MECHANIC device 670 675 download manual from internet WWW flexiforce com NB Do nottouch any connection or part of the door after spring break Wait until qualified mechanics arrive at the scene v Replace cable with connections v Replace cable break device v Check tracks and service or replace WWW FLEXI FORCE COM Hexiforce manua See instructions on page 33 of this manual and look into the manual of the cable break device 440 600etc download manual from internet www flexiforce com NB Do not touch any connection or part of the door after cable break Wait until qualified mechanics arrive at the scene Use for greasing PTFE or SAE 20 Use for cleaning Soft soap with water Do not use aggressive soap or cloth FF MANUAL IND HWS 89 WWW FLEXI FORCE COM
19. NIC 7 Check the panels on damage wear and roust MECHANIC 8 Check the spring breaking device acc to instructions in manual MECHANIC 9 Check the manual operation of the door MECHANIC 10 Check cable pulleys on wear and tear MECHANIC 11 Check panel sealing on wear and tear MECHANIC 12 Check cable break device on functioning MECHANIC 13 Check position of hinge pin of CBD MECHANIC 14 Check bolt and screw connections of spring break device MECHANIC FF MANUAL IND HWS 87 WWW FLEXI FORCE COM Hexilorce 15 Check connections of the pawl wheel 16 Check side seals on damage or wear and tear 17 Check bottom seal on damage or wear and tear 18 Check top seal on damage and wear and tear 19 Check cable tension set on functioning 20 Grease the springs 21 Grease bearings of rollers 22 Grease running parts of the tracks 23 Grease the bearings of the shafts After two years or after every 15000 cycles 1 Grease all the above mentioned points 2 Check or test the fixation of the springs to the fittings 3 Check the balance of the door and adjust if needed 4 Check the cables for damage or wear and tear manual MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC 5 Check the cable connection points on drums and bottom bracket MECHANIC 6 Check the roller on wear and free moving space 7 Check the hinges on breaking and wear and tear 8 Check t
20. TTENTION Installation method torsion sprinas from the middle stationairv plua to the side winder plua FF MANUAL IND HWS 11 WWW FLEXI FORCE COM Fexiforce manual ATTENTION Installation method torsion spring system adjustable A springs partly from side stationairy plug ear ng ates to the middle winder plug Adjustable bearing plates cable inside S pring system at the lintel 1 and 1 shaft valid 70357 105ST100 323LAG B Fix drums with 2 safety wraps LHW 322BAS to the black 308 4C USA A outside RHW red 675 5 4 704ST Se 322BA5 70657100 675 5 4 152 SES 322BAS 674 With 321WAL Wall plate EEN N FF MANUAL I ND HWS 12 WWW FLEXI FORCE COM mm amp D lexiforce Fit the bearing plates 1 to the wall Trace a centre line spirit level between the two side bearing plates in order to be able to fit the remaining bearing plates and the shaft in proper alignment Fit the 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 shaft during assembly Fitthe spring package to the wall Assembly door panels For fitting purposes the assumption has been made that the panels are already fitted with end caps top and bottom profile and top bottom rubber Remove the protective foil from the panels See 4 Hinges top roller holders Fit
21. about any problem with the delivery include the order number and week of production and give us the opportunity to offer a suitable solution Flexi Force will only reimburse third party costs if we have given explicit permission for this in advance The reimbursement is based on normal rates and travelling expenses over distances of 1 hour away at most For large scale projects we strongly advise you to first install 1 door completely before installing the other doors In this way any errors can be detected early on and rectified comparatively cheaply This manual does not confer any rights Technical modifications may be made without written notice Flexi Force has endeavoured to design and put together this hardware set in conformance with the applicable CE norms However we recommend to check our configuration against any local national specification Flexi Force B V P O Box 37 3770 AA Barneveld The Netherlands Tel 31 0 342 427777 ff flexiforce nl APPLICABLE CE DIRECTIVES AND RESTRICTIONS Industrial overhead doors brought into the European market must follow the EMC Directive Low Voltage Directive Machine Directive and Construction Products Directive issued by CEN only power operated doors Flexi Force has developed and constructed this hardware set according to these directives This gives a restriction to the max forces and dimensions of industrial doors Max width 8 meter Max height 6 meter Max door weigh
22. appropriate instruction Suspension horizontal track set Set the door in the opened position so that the horizontal track that can still move freely is able to adjust to the door panels Ensure that the bearing rollers on left and right have the same play so that rail and door panel run parallel Conduct a cross measurement as per the figure to check the adjustment gt SE Secure further in this position the suspension of the horizontal track set WWW FLEXI FORCE COM es 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 roller 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 operator ATTENTION The assembly of door sections is 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 FF MANUAL IND HWS 15 manua WWW FLEXI FORCE COM Flexiforce manual 2 BUILD IN SYSTEMS 2 1 NL Normal lift 2 e 210 Distinguishing feature i i D With Normal systems the door t
23. aring roller with console in the vertical guide tracks One of the two bottom consoles may be fitted beforehand on the panel Position the bottom console on the panel such that the side is flush with the panel The underside of the console should be level with the underside of the panel Secure the console with 6 self tapping screws See figure Secure the cable to the console by inserting the pin through the console and the loop in the cable Secure the pin with the split pin and bend the extremities of the split pin out See figure Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL IND HWS 44 WWW FLEXI FORCE COM 10 64 437 bottom console 437VERS Bottom console 437 consists of the following parts Console 43 Self tapping screws Split pin 2107 Pin 1042 Order of assembly Insert the bearing roller into the bottom console Rotate the bearing roller with console in the vertical guide tracks One of the two bottom consoles may be fitted beforehand on 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 Secure the cable to the console by inserting the pin through the console and the loop in the cable Secure the pin with the split pin and bend the
24. by placing clamps on the vertical track Tension the springs by the number of tums prescribed see label springs and packaging list in the box pull the spring 5 mm apart to reduce friction and secure the spring to the shaft using the screws ofthe tension plug 25Nm WWW FLEXI FORCE COM CAUTION Torsion springs are under high tension Exercise at all times great caution 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 that the brand strip on the spring forms a straight line 2 Insert the 1st tensioning iron fully into the tensioning aperture 3 the 1st tensioning iron a quarter turn so that the spring is tensioned 4 Insert the 2nd tensioning iron fully into the next tensioning aperture 5 Take over the tensioning of the spring from the 15t tensioning iron with the 2 tensioning iron 6 Remove the 1st tensioning iron from the aperture 7 Turn the 2 tensioning iron a quarter turn so that the Spring is tensioned 8 Repeat steps 2 through 7 for as long as it takes for the spring to make the prescribed number of turns 9 Secure the spring plug to the shaft by fitting the key and tightening the bolts in the tensioning plug on the shaft 10 Remove the last tensioning iron 11 Checkthe number of turns by counting the number of turns
25. ct on the safety of and the guarantee on the door Also the CE approval which has been granted to this door combination will be cancelled when components are changed or installation is not done according to this manual Installer is responsible for this v During tensioning springs can exert large forces Work carefully Use the proper equipment Ensure that you are standing in a steady position 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 v Ensure that the building is constructed strong enough to carry the overhead door construction It is the responsibility of the installing company to use fixing materials which are strong enough and equipped to fix the overhead door to the building power operated overhead door may not be equipped with a pull cord rope Be sure that this has been removed when a manual operated door is being equipped with an E operator v Environments closed by an electrical operated overhead door with operators which are not disconnectable and where the door cannot be manual operated must be equipped with a pass door v Cutting of the bottom section is not allowed The forces on cable break devices and bottom brackets are too high Cutting is weakening the construction of the door on this critical point This door ca
26. ee separate manual 670 spring breaking devices S70LHRH FF MANUAL I ND HWS 64 WWW FLEXI FORCE COM Hexilorce 15 COUPLERS 70351 70451 AD USTABLE COUPLER manua 1 7035T i 7045T j 2 3 Nm FF MANUAL I ND HWS 65 WWW FLEXI FORCE COM manual 70551100 706ST100 FIXED COUPLER 708 90 FIXED COUPLER EM 1 705ST100 Lem 1 7065 100 7004 38 m 14 FF MANUAL IND HWS 66 WWW FLEXI FORCE COM lexiforce 16 TORSION SPRINGS RAW Black LHW Red manual RHW Black LHW Red 85416 944 1 de GE 18 OE RHW e 11 AAA H 2 mm PER EEE UM M 723 40 Wi 1 2 2 207 er Uu fi HR 2225 FF MANUAL I ND HWS 67 Wa E E LHW d gt d L Lidd 7 e W IE N III 22223 Uf nh TE yi 2 Y Dag e WWW FLEXI FORCE COM 17 CABLE DRUMS FF NL 12 FF NL 18 7004 75 t P ge T 2 711A 7 N FF NL 12 FF NL 18 M as d W P p 222277 FF HL 54 FF HL 120 FF HL 54 FF HL 120 FF MANUAL IND HWS 68 manual FF NL 32 5 4 700B 110 FF NL 32 FF HL 164 FF HL 164 5 4 2222222222 12 Di T ei WWW FLEXI FORCE COM 1 15 44 FF VL 11 FF VL 18 N FF VL 18 5 4 l 2 a ka 7 17 p 3 d 8
27. emove 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 shaftconstruction 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 authoroties where and how you can leave this as carbage FOR ANY DETAILS ON THESE DISMANTLING INSTRUCTIONS WE REFER TO THE INSTALLATION CHAPTERS OF THIS MANUAL WHERE DRAWINGS AND DETAILS ARE DISPLAYED TROUBLE SHOOTING WWW FLEXI FORCE COM Hexilorce What should I check 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 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 Were the correct parts supplied and fitted Especially the dr
28. exiforce manual 4 HINGES 4 1 Intermediate hinges galvanised 450HZ See Picture 447DOUB See Picture 420HZ 10RES See Picture 450HZ 10 See Picture 420HZ 10RES 4 2 Intermediate hinges RVS 450H304 See Picture 43 Side hinges galvanised 450CZ See Picture 420CZ 10RES See Picture 450C Z0 See Picture 44 hinges galvanised 450C304 See Picture 5 450HZ 10 450H304 FF MANUAL IND HWS 27 WWW FLEXI FORCE COM 10536 105563 D 10S2EVY 420 7 10 5 MN a 5 T nd Kei e ep Eg Isl EE ca 450CZ 447DOUB WWW FLEXI FORCE COM FF MANUAL I ND HWS 28 Fexiforce manual 4500Z 10 4500304 42084410 1052M RVS Af 447 304 Ss k s 1052M 45057 i 5 Ai 35 2 10628 8 5 e 0538v RVS M T 10828 gt lt 1052BW bai 19053Bwv TOSS5BV 1055BV RVS Ka L FF MANUAL IND HWS 29 WWW FLEXI FORCE COM 5 SCREWS 1052BV 1053BV 1055BV 25 1053BV RVS 1055BV RVS 6 TRACK FF MANUAL I ND HWS 30 WWW FLEXI FORCE COM Hexilorce 7 VERTICAL ANGLE 7 1 9ZR and 1090 2 track OZR ZW 1090 7 2 9VB and 1085 2 track QVB ZW 1085 FF MANUAL IND HWS 31 manua 7 3 9VB and 1094 40 2 track 1094 40 7 4 9K and 1085 3 track 7 5 9K and 1085 2 track 9K 2V or 13155 PS
29. from www flexiforce com FF MANUALIND HWS 17 WWW FLEXIFORCE COM er Hexiforce 23 HL High lift 2 Distinguishing feature With High Systems the door rises vertically first above the clear height before the upper panel turns through the bend See figure Tracks The track system of the High System consists of a vertical and a horizontal section Vertical track set This is made up of a left hand and right hand 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 set is supplied in two sections Horizontal track set The horizontal track set consists 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 to the ceiling or roof structure See figure Adjustthe horizontal track set 0 1 degrees rising Tighten all bolts Depending on the cable drum use 1 or 2 bolts to secure the horizontal to the vertical corne line FF MANUAL IND HWS 18 Deg eg EE manual
30. gomm J 4278 8 71 2066 10 omm 71 429 y 430HD 65 97 2066 05 mm 432 ay 437 EN EE ee ANVERS 437RVS 64 2066 06 omm 440 600 440 REGL 74 9 IK profile has been used HAEL manual 10 2 Bottom console 4275 The bottom console 4275X consists of the following parts Console 4275X Self tapping screws Bearing roller holder 441Z Spacer bush 10mm 2066 10 Eye bolt with 42700G 1050B Flanged nut M10 1058F Order of assembly 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 Fit the spacer bush to the bearing roller Fit the bearing roller holder to the spindle of the bearing roller Place the bearing roller with spacer bush and bearing roller holder in the vertical guide tracks at the level of the console Secure the bearing roller holder with 2 self tapping screws See figure Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL I ND HWS 41 WWW FLEXI FORCE COM 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
31. guishing feature With CE LHR systems the door turns through the bend directly above the clear height The horizontal section consists of a double track See figure Tracks The track system of the LHR System consists of a vertical and a horizontal section Vertical track set This is made up of a left hand and right hand assembled corner lines with a guide track and side seal See 7 Vertical corner lines Horizontal track set The horizontal track set consists of a left hand and right hand section with 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 pullev mo 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 to the ceiling or roof structure See figure at normal system Adjustthe horizontal track Tighten all bolts manual 2 2 CE LHR Low Head Room System 2 Warning Power operated doors In case of installing the horizontal A track set on horizontal level a cable tension set must be installed to prevent slack cables Download detailed manual CE LHR
32. he other intermediate panels Place finally the top panel Secure this also temporarily with a glue clamp or similar Fit the side hinges and then the intermediate hinges Fit the accompanying top roller holder as per specification See 4 Hinges top roller holders Fitting cable and tensioning the spring package Align the shaft Roll out the steel cables until all the kinks have disappeared already secured to the bottom bracket Guide the first cable from the bottom bracket behind the bearing roller shafts to the cable drum See figure Feed the cable into the drum and secure it with the screw in the drum The cable should protrude from the drum see 17 cable drums or download the specification sheets from our site www flexiforce com Slide the cable drum against the bearing plate and rotate the drum euch that the windings min 2 safety windings rest next to each other in the grooves of the drum When the cable is taut the shaft should be turned such that the keyways in the shaft and drum correspond to each other Fit the key and tighten the setscrews in the drum 10 Nm Block the shaft with for example a clamp Place a locking pin in the spring break device such that the pawl is free of the wheel Secure the other cable in the same fashion Both cables should be under equal tension while the door panel is perfectly level Protect the door from rising This can be achieved for example
33. he panels on damage wear and roust 9 Check the spring breaking device acc to instructions in manual 10 Check the manual operation of the door 11 Check side seals on damage or wear and tear 12 Check top seal on damage or wear and tear 13 Check bottom seal on damage or wear and tear 14 Check the shaft on wear and tear or damage 15 Check the bottom bracket on wear and tear and damage 16 Check the connection of the drum to the shaft keys 17 Check and re fix the bolt of the coupler 18 Check the connections of the track system 19 Check the suspension of the door to the lintel and ceiling 20 Grease the springs 21 Check bolt and screw connections of spring break device 22 Check connections of the pawl wheel 23 Check cable tension set on functioning 24 Grease springs 25 Grease bearings of rollers 26 Grease running parts of the tracks 27 Grease the bearings of the shafts 28 Grease the hinge pins 29 Grease the lock 30 Grease the shafts of the rollers After spring break After cable break FF MANUAL IND HWS 88 v Replace springs and spring break device v Check the shaft on damage and replace if necessary See instructions on page XX of this manual and look into the manual of the spring breaking MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC MECHANIC
34. ine or elsewhere on the structure Height indication 1250mm Depending on the height of the spindle the chain should be shortend or an extra separate length of chain supplied that can be inserted This can be arranged simply by bending a link open and then shut Height indication floor to underside chain 750mm Ensure that the 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 set consists of the following parts Frame with sprocket wheel and gear wheel small Manual chain 8 metre Chain stop Sprocket wheel large Bicycle Chain 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 FF MANUAL I ND HWS 23 manual Slide the large sprocket wheel onto the spindle Determine the position 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 connection link Apply the key between gear wheel and spindle and tighten the securing screws of the gear wheel Tension the bicycle chain by sliding the frame into the slotted holes and secure the frame Depending on the position of the frame the bicycle chained should be shortened or lengthened See for further instructions italicized text at 722A 3 4 Chain hoist 1 4 type 724 The 724A chain hoist tra
35. ists of the following parts Console RVS 4275 RVS Self tapping screws Bearing roller holder 441 304 Spacer bush 10mm 2066 10 Eyebolt with cable 2530R VS Flanged nut M8 2535M RVS Order of assembly 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 Fit the spacer bush to the bearing roller Fit the bearing 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 self tapping screws The cable is secured to the console with an eyebolt First tighten as far as possible an M8 flanged nut on the eye bolt See figure Guide the cable around the reverse pulley of the console insert the eyebolt from below through the console and tighten the 250 nut on the eyebolt See figure AN In order to prevent deformation or breaking of the cable the cable may only be set more loose Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL I ND HWS 48 WWW FLE ME Fexiforce manual 10 17 437RVS bottom console Bottom console 437RVS consists of the following parts Console RVS 437 RVS Tm Self tapping screws RVS i dd BoltM8x35 RVS 25
36. llers etc In case of a serious damage of the bottom panel and or end caps these 2 components should be replaced as well The determination if a component should be replaced is the responsibility of the installer Please contact the supplier in case of any doubt The door should be inspected thouroughly after every accident to check if there are any other damages that should be repaired For example the following components must be replaced as well hinges track sets construction of the left and right corner plate in case of LHR WWW FLEXI FORCE COM manual Overview industrial panels lt gt Flexi Force hinges Hexilorce PANEL HINGE OVERVIEW 40440 14508268 450512 145402 ATTE RATS A50HZ Juni 43HZ Juan LL 450HZ 450CZREV 450112 Juni 450HZH0 ASOCZHOREV 450HZH0 450CZHIOREV 404 Juni FF MANUAL I ND HWS 86 WWW FLEXI FORCE COM Flexiforce manual MAINTENANCE AND REPLACEMENT OF PARTS INDUSTRIAL OVERHEAD 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
37. n only be taken into use when all instructions are followed and v theinstaller has checked the combination of hardware panel and e operator as being approved and safe Make sure to check the max peak force and the proper functioning of the safety edge system in combination with the operator v all documentation has been handed over to the end user lla Declaration of conformity User Guide Maintenance Instructions Dismantling instructions Service Log Book and this manual v aCE identification plate has been placed on the door v user has been given instructions and demonstration of the proper use and functioning of the door FF MANUAL I ND HWS 2 WWW FLEXI FORCE COM Hexiforce manua GUARANTEE CONDITIONS AND TERMS The general terms and conditions of delivery and payment issued by the Metaalunie and designated as METAALUNIE CONDITIONS are fully applicable to all our quotations contracts and their implementation We expressly reject all other terms and conditions On request we will send you a copy of these terms and conditions free of charge A copy may also be downloaded from our website www flexiforce nl Flexi Force strives to deliver 100 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
38. ng vertical track set First mark en on both piers using Spirit level or water level hose and then mark picture Size X Picture is being determined by the bottom bracket type 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 FF MANUAL IND HWS 10 1 14 Fit both vertical tracks with the lower surface on mark line picture The two bearing tracks should be parallel to one another For sloping floors one of the bearing tracks may be compensated for example with a wedge stem WWW FLEXI FORCE COM Fexiforce manual Installation spring system non adjustable NB Safety warming Doors without operator or with bearing plates operator without safety must always be equipped with Non adjustable bearing plates spring breaking device Cable inside inside vertical angle Spring system at the lintel 1 and 1 4 shaft Determine from the diagram which situation which is Size 2 X mm 86 30548 31548 f ELM 8 USA B ETES 675 322BAS 307 48 317 4B Gate With 2 safety 075 674H0EK 322BA 670 675 322 5 outside Non 7045 rm E 4CP 4 675 5 4 674 B 7065 100 1 1 4 322 5 only for 6 spring 108 90 103S T 7055 100 A A
39. nsmission ratio 1 4 is suitable as standard for 1 spindles The set consists of the following parts Casing with sprocket wheel Manual chain 8 metre Chain stop Connector 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 Allow the spindle to protrude circa 60mm from the bearing plate Slide the connector onto the spindle of the chain hoist and fit the key supplied Slide the chain hoist with the connector onto the spindle and secure the entire assembly to the bearing plate with a bolt see drawing Secure the connector by tightening both screws See for further instructions italicized text at 722A WWW FLEXI FORCE COM co 1250 OK 750 FF MANUAL IND HWS 24 WWW FLEXI FORCE COM Fexiforce manual 3 5 Chain Hoist 1 4 direct type 725 50 168 00 0 0D 186 11 2001 FF MANUAL IND HWS 25 WWW FLEXI FORCE COM Fexiforce manual 3 6 Option Reducing socket 1 gt 1 4 When the door is produced with a 1 spindle and a 1 chain hoista reducing socket set is supplied with the spindle The set consists of the following parts 70257 12 Coupler 1 1 4 700A38 Key 2 pieces 702 02507 Galvanized spindle length 25 cm Assembly Slide the connector onto the 174 spindle fitthe key and tighten the securing bolts Insert the 1 spindle in the other socket half also fi
40. oupler for 1 shaft 70557100 Adjustable cast steel coupler for 1 14 shaft 704ST Fixed cast steel coupler for 1 4 shaft 70657100 16 Springs Pg 67 Powder coated torsion springs XCALPS Natural black torsion springs XCALNS 17 Cable drums Pg 68 Normal lift cable drum FF NL 12 Normal lift cable drum FF NL 18 Normal lift cable drum FF NL 32 5 47 High lift cable drum FF HL 54 High lift cable drum FF HL 120 High lift cable drum FF HL 164 5 47 Vertical lift cable drum FF VL 11 Vertical lift cable drum FF VL 18 5 4 Vertical lift cable drum FF VL 28 5 4 18 Suspension profiles Pg 70 Perforated angle 50x50 50830 3000 5 Perforated angle 40x40 40B25 3000 S Perforated angle 30x30 30B25 3000 S Perforated angle 30x30 en 50x50 30B 25 3000 and 50B30 3000 Perforated SU profile 48x 48503000 Perforated SU profile 48x en 50x 48513000 and 505U3000 19 Triangular plate Pg 71 Triangular plate for track suspension 3010 Triangular plate for installation 100K box beam 355CONS 20 Tension set Pg 72 Tension with plastic pulleys Tension set with steel lever Tension setlow head room CE FF MANUAL I ND HWS 6 manual 685CH NP LHR 687 NP LHR 688 LHR WWW FLEXI FORCE COM Flexiforce manual Chapter Art Code Page 21 Spring bumpers Pg 76 Short spring bumpers 718 Long spring bumpers 719 Extra long spring bumpers 719 750 22 Horizontal connection tracks Pg 77 5C profile at the rear of horizontal track 5 and
41. right A hand bend and a reinforcement profile that is secured to H B 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 to the ceiling or roof structure See figure Adjust the horizontal track lining with the roof Tighten all bolts Depending on the cable drum use 1 or 2 bolts to secure the horizontal tracks to the vertical corner line between 3 and 12 degrees SE To improve the connection with the horizontal 5C pr file we will install an extra connection plate to the vertical angle in case of a FTR between 3 and 12 degrees The 5C profile will be shortened and will be installed to the new connection plate It is not necessary any more to produce holes in the vertical angle See drawing gt I FF MANUAL IND HWS 20 WWW FLEXIFORCE COM Fexiforce manual 2 6 CE FLH Following The Roof System Low 2 max b x hz 5 0x5 0m lt 300kg Distinguishing feature 10708 3 5 With CE FLH systems the door turns through the bend directly above the clear height and then tracks the angle of the roof The horizontal section consists of a double track See figure
42. risk that the end user will come close to dangerous areas for example the vertical tracks during the use of the overhead door we strongly recommend to place the grips for electrical operated doors in the middle of the door width or at least 1 5 meter from the vertical tracks Furthermore we recommend to install more than 1 grip on the door 1062B 10618 amp gt D i nn E 8 A SL 5 E n ae 1 z Pr Be p 634 25 08 s 2 N ES x 3 A e A c S 1052BV N 1053BV RNS IQSSBV RVS Ki Ce 3 Pd p 2 2 SS al e g 1 gz 0 ae E u Pd s 0 e cl oi e Er a ral Ca FF MANUAL IND HWS 39 WWW FLEXI FORCE COM 639BL WWW FLEXI FORCE COM FF MANUAL IND HWS 40 es 10 BOTTOM CONSOLES AND VERTICAL TRACK SET 10 1 Vertical track set The distance between the vertical angles is determined by the type of bottom console or cable break safety device Basic criteria for application of the table below 1 panel width Clear width 45mm 2 oscillation 10mm The latter is the free lateral movement that a door panel is able to make between the vertical tracks required for smooth operation without too much friction 2 TRACK SYSTEH 3 TRACK SYSTEH Type XxX X 4 2 Fill wit spacer Fill wit spacer tri bush bush 425HD 4278X 70 2066 10
43. s chain hoist with chain or rope intermediate hinges side hinges toproller bracket bottom bracket or cable break device lock or slide bolt grip springbumpers cables keys triangular plate cable tension set box beam fixing material Not supplied in the set windows top bottom profile with seal needed material for fixing to the wall endcaps struts FF MANUAL IND HWS 8 Fixing material 1 Sr 027 68B 1047 e 1006B 1062M E 7 e 1026 68B 1045 1017B 1070B 3 5 e 1062B 1062M 1053BV 1055BV these articles are selected by option and therefore be missing in the set ATTENTION Adding other components or using different fixing materials can influence the safety and quality of our configured set We take no responsibility for sets which differ on the level of components from our original configuration packing list WWW FLEXI FORCE COM Hexilorce MINIMAL 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 warning labels spirit level or transparent hose chain punch for 721A measuring tape protractor for roofline matching system screwdriver with straight blade screwdriver with crossed blade pliers for spli
44. t 700 kg Standard equipped with anti drop protection Cable break device and spring breaking device e Other safety accessories roller protection 580CEN 581CEN bottom safety edge system when power operated slack cable device cable inside track system Tested for CE when selecting the proper Flexi Force components and combining with tested panels and operator control unit combinations e Use of finger safe sections for door heights lt 2 75m e Cables outside the track system are not allowed unless the cables are covered 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 when truly declared conformity is done This is needed to complete your CE technical construction file according to product standard EN13241 1 The ITTR number should be placed on the CE plate on the door 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 FF MANUAL I ND HWS 3 WWW FLEXI FORCE COM Hexiforce INDEX 19 4 5 6 7 8 9 10 D Chapter Page 1 General Pg 8 Installation manual 2 Liftsystems Pg 16 Normal Lift NL Low Head Room LHR High Lift
45. t pin iron file Jigsaw socket open end ring spanners size 5 5 8 10 13 14 or 9 16 15 17 24 for 440REGL socket keys size 3 and 4 PAS FF3 75TAI 75LETAI General use FF6 00 FF2 B3T Al FAST Pb Heavy springs FF MANUAL IND HWS 9 manual drilled hole diameters 05 07 0 10 0 13 0 15 0 16 pliers for system plugs E transmission article code 97030 cable clamps 511 and 531 not required for standard set Tension irons to use with Flexi Force spring fittings WWW FLEXI FORCE COM es Checking dimensions Before assembling the set the details below should be checked on the basis of this figure A Clear width packing list B Clear height packing list C Side area see 10 Bottom brackets D area see 2 Lift systems Bases for further instructions are Panelwidth including end caps A 45 mm Panelheight stapled incl bottom rubber B 25 mm NB The material used for mounting the track set A and the spring system to the wall or roof is not a part of the 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 sufficient space available for the track set see 2 Lift systems Checking section width When the section length door panel width differs from the above mentioned data all sizes related to the side space 4 change Checki
46. that the brand strip has made Remove the blocking of the door in the track and from the shaft and check that the door is properly balanced Should this not be the case then correct by de tensioning and or tensioning of the springs by at most 1 turn per spring Ensure that both springs are corrected equally Correction of the spring tension 1 Insert the 1s tensioning iron fully into the tensioning aperture 2 Take overthe tension of the spring with this tensioning iron 3 Loosen the bolts in the tensioning plug and remove the key 4 Turn the 1st tensioning iron in the direction required 5 Insert the 250 tensioning iron fully into the next tensioning aperture 6 over the tensioning of the spring from the 1st tensioning iron with the 219 tensioning iron 7 Remove the 1st tensioning iron from the aperture 8 Turm the 2 tensioning iron a quarter turn in the direction required FF MANUAL I ND HWS 14 manual 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 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 plug on the shaft 13 Remove the last tensioning iron Fitting spring bumpers See 21 Spring bumpers Fitthe spring bumper in accordance with the
47. the critical function of the bottom bracket it is not allowed to cut A Ms the bottom section This weakens the construction and will lead to a dangerous IU situation U FF MANUAL IND HWS 42 WWW FLEXI FORCE COM Fexiforce manual 10 4 429 Bottom console Bottom console 429 consists of the following parts Console 429 Self tapping screws Split pin 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 split pin and bend the extremities of the split pin out Insert the bearing roller in the bottom console See figure Now rotate the bearing roller with console in the vertical guide tracks One of the two bottom consoles may be fitted beforehand on 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 Because of the critical function of the bottom bracket it is not allowed to cut the bottom section This weakens the construction and will lead to a dangerous situation FF MANUAL IND HWS 43 WWW FLEXI FORCE COM Fexiforce manual 10 5 432 Bottom console Bottom console 432 consists of the following parts Console 432 Self tapping screws Split pin Pin Order of assembly Insert the bearing roller into the bottom console Rotate the be
48. the door A and securing its movement with a clamp on the vertical track First the tension on the torsions springs and cable has to be released Do this by following these instructions 1 Insert the 1s tensioning iron fully into the tensioning aperture 2 Take over the tension of the spring with this tensioning iron 3 Loosen the bolts in the tensioning plug and remove the key 4 the 1st tensioning iron in the direction required 5 Insert the 274 tensioning iron fully into the next tensioning aperture FF MANUAL I ND HWS 80 manual 6 Take over the tensioning of the spring from the 15 tensioning iron with the 219 tensioning iron 7 Remove the 1st tensioning iron from the aperture 8 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 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 R
49. ting the key here and tighten the securing bolts Where necessary shorten the spindle The extra bearing plate that may need to be fitted to support or secure the spindle chain hoistis not included in the delivery See also assembly instructions for chain hoist 37 Extra Chain When the spindle is placed at greater heights an extra separate chain is supplied for extension of the chain Extension Insertion can be realized easily by opening and then closing a link The article involved is 723A manual chain In case of malfunctioning of the motor and the door is suitable for IAS manual operation the manual power necessary to open or close III ag Y the door may not be higher than 390N for industrial doors When using a E operator check if the combination of operator control unit and safety edge is approved according to EN13241 1 3 8 Electrical operation For the instructions of the electrical operator for the industrial overhead door we refer to the manual supplied with the motor In case an industrial overhead door can be manually operated as well the door must be equipped with options to make manual operation possible Options are for example grips Furthermore it must be possible to disconnect the operator to prevent electrical and manual operation atthe same time The minimum distance between the vertical track and control unit ofthe motor must be 1 5 meters FF MANUAL I ND HWS 26 WWW FLEXI FORCE COM F
50. ums and springs are important correct dimensions supplied Is the door properly installed horizontal tracks really horizontally and not with inclination for High Lift doors shaft on the correct height Otherwise the cable length is not correct and the door is badly balanced 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 WHAT TO DO AFTER SPRING BREAK OR CABLE BREAK NB Also make sure to instruct the user about this After spring breaking the door will be stopped by the 670LH RH or 675LH RH spring break device 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 with springs spring pulgs shafts and all other damaged components The door has to be inspected thouroughly We refer to the separate manual for the 670 675 spring break devices on our website www flexiforce com downloads manuals 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 the cables and CBD or bottom brackets together with all possibly damaged components such as roller carriers FF MANUAL I ND HWS 81 manual ro
51. urns through the bend i directly above the clear height and the horizontal section consists of a single rail See figure Tracks The track system of the Normal System consists of a vertical and a horizontal section Vertical track set This is made up of a left hand and right hand assembled corner lines with a guide track and side seal See 7 Vertical corner lines a T Horizontal track set The horizontal track set consists 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 1 1 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 to the ceiling or roof structure See figure Adjustthe horizontal track set 0 1 degrees rising Tighten all bolts Depending on the cable drum use 1 2 Za 2 N bolts to secure the horizontal track to the vertical corner BU line Warning Power operated doors In case of installing the norizontal track set on horizontal level a cable tension setimust be 222 installed to prevent slack cables 222 FF MANUAL IND HWS 16 WWW FLEXI FORCE COM Hexilorce max b x h 5 0 x 5 0m max kg 300 Distin
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