Installation Manual - Doco International
Contents
1. 24740 eres EN V1 3 11 e o da Installation manual FEET Fixings for vertical track sets The fixing materials needed for mounting this track set to the wall or construction are included in this fitting set The installer 1s responsible for ensuring that the mounting place 15 structurally strong enough to carry this industrial door The installer 15 also responsible for the correct fixings for the relevant structure brick concrete steel wood The value used for measurement depends on the wind load class and door size If class 2 620 Pa N m break load If class 3 965 Pa N m break load If class 4 1375 Pa N m break load Example door size 5000x4000 20m Wind load class 3 Force against door panel F PxA 20 620 19300N Refer to appendix 3 for wire strength and number of fixings for vertical track sets EN V1 3 12 abu 4 6 1 Standard system ST The standard system is distinguished by the fact that when opened the door panel immediately goes onto the horizontal section of the track set The track set comprises 2 sections that are welded bolted or riveted together For the correct connecting method see 3 6 Connections The length of various items such as guide tracks and L angles and associated item numbers is obtained using the DOCO 2000 programme Installation The vertical section comprises the L angle with seal and guide track Assembly using 4 6 T2. EN V1 3 36 a o dao Installation manual abu 4 12 4 Bottom section pre assembl Important Never cut the bottom panel to adjust the overal door panel height always cut the top panel see also appendix 4 Cut the panel 1 to the correct length Fit the end covers 2 to the panel 1 using blind rivets Slide the aluminium profile 3 onto the entire length of the panel 1 and secure using blind rivets Cut aluminium profile to size at end cover Slide the rubber seal type see 4 16 3 4 into the aluminium profile 3 Rubber seal length panel size 30mm Now position the Fraba OSE S 1101 type optical sensors transmitter receiver in the rubber seal Connect these sensors according to the drive installation manual Slide the OSE D B 55 8 2st type end stop 6 into the aluminium profile 3 and secure it Fitthe cable break protection in accordance with Spring break protection manual 25450 or 25455 Cable break protection 25450 TUV certified up to 900 kg door weight Cable break protection 25453 TUV certified up to 900 kg door weight Always ensure the rotation module with blade rotates freely at all times Fit the side hinges 5 and the centre hinges 8 divide the centre hinges 8 over the length of the panel See 4 11 1 for the correct number of centre hinges EN V1 3 37 a alqda Installation manual 4 12 5 Intermediate
3. Installation area see system diagram Vertical fitting 7 5m max width Height 8 4m max Door surface 36m2 max Weight 600kg max Installation area see system diagram EN 13241 1 classification see appendix 5 This manual describes the installation of a sectional door using only DOCO International parts The installation of parts not specified or other parts not described in this manual is the responsibility of the end producers of the garage port They are also responsible for the correct CE certification of the sectional door EN V1 3 5 TI HOAD T V NORD CERT 5 eee sl DOCO International has had the product testing of these fitting sets carried out by the TUV Nord cert institute in Germany registered as Notified Body No 0032 Documents of this product testing may be requested from DOCO This product testing does NOT include any access door If you DO install an access door additional product testing is needed This is the responsibility of the garage door manufacturer 4 2 Scope of supply The fitting set supplied by us includes the following parts the details of which depend on the door dimensions and the type of lifting system Track set Vertical track set assembled Horizontal track set assembled Side seals Power unit and bearing plates Side bearing plates Shaft Cable drums Steel cables Spring break protection devices Coupling
4. maximum top panel overlap 15mm See figure on the right udo Figuur 9 Note If a different seal system is used the classifications according to EN 13241 1 are invalid EN V1 3 33 oul T o o dao Installation manual Pe 4 12 Panels general As our track sets with hardware can be used UNIVERSALLY in combination with various panel manufacturers here 1s a general description of the installation of the panels Always ask your panel manufacturer which additional measures if any are needed to ensure finger pinch safety In general when using sandwich panels steel plates with PUR foam 4 5mm holes need to be drilled However check with your panel manufacturer about the actual drill size The complete door panel including aluminium profiles and bottom seal stop should comply with the following measurements W 40 E 1 u C4 L gt d am 9 4 12 1 Hardware Refer to appendix 4 for the correct selection of hinges for the panel The distance between the centre hinges should be divided equally over the length of the panel see table 1 The recommended maximum torque for the various parts 1s detailed in table 2 Table 1 Table 2 Bottom console 0 2749 Side hinge 2749 3999 Centre hinge 3999 4999 Top roll holder 5000 5999 6000 7500 EN V1 3 34 4 12 2 Rollers 35 kg unit 6200 ZZ precision 100 kg
5. 1005 HL 1006 HL 1007 HL 1008 HL 1004 HL 1009 FL 1010 FL 1012 FL provided it is also attached to C track _ F j mm 166 8 14022 fm y M C 225 4 4 24620 14021 Ch o 25016 ae 4 10 3 Shafts i de Choice of Hollow shaft with key way 25018 Solid black shaft 25016 Solid galvanized shaft 25516 25 4 For sectional doors with a clear width of gt 4000mm and or gt 200 kg you should select a solid shaft EN V1 3 26 ofoga Installation manual haia 4 10 4 Keys The purpose of the key is to transmit drive power Depending on the selected shaft the correct key should be selected For the hollow shaft with key way 10 5 key height 25064 straight version 25073 bent version For the solid shaft 6 35 key height 25048 straight version 25062 bent version 25073 25064 10 5 25018 6 35 4 10 5 Spring break protection 25449 For detailed installation and maintenance instructions see Spring break protection manual 25449 4 10 6 Centre support consoles Centre support consoles are designed to give the shaft adequate support bearing so the shaft can turn freely without noticeable sagging General guideline 1 centre support console per 1500mm bearing point PS spring break protections also count as bearing points Centre support consoles with fixed o
6. 220 mm with use 11005 HL 250 mm with use 11006 HL 320 mm with use 11004 11104 11007 11008 11108 EN V1 3 8 abwr 4 4 3 System drawing Vertical lift 3 ppet Track 30 mm m 1 owwer Track 12 mm fim n 11009 11010 11012 11112 Vertical Lift Industrial 2x H 250 mm F2 53 mm 38 mm F1 L1 83 mm F2 L2 33 mm H 250 mm H 250 mm H 500 mm with use 11009 H 550 mm with use 11010 4 4 4 System drawing Vertical lift with central power unit D2 Erz all 11009 i 11010 11012 OH E 214112 12 mm m 6 EN V1 3 Full Vertical 2x H 250mm 500 mm F2 100 mm F1 L 83 mm A H 250 mm a o da Installation manual abu 4 4 5 System drawing Standard roofline lift OH 7 Use above 45 a full vertical drum A 12 mm m Standard lift pitch Industrial H H 235 mm 753 mm A B mm H 650 mm cos a D cosa 38 mm F1 H 83 mm 420 with use 11014 11002 500 with use 11003 11103 1 4 4 6 System drawing High roofline lift 11005 11006 11007 11008 11108 11004 11104 OH L nel 12 mm m Use above 45 a full vertical drum HI Lift Pitch Industrial H H HL mm 753 mm A B mm H HL 650 cos a mm 38 mm F1 H 83 m
7. Installation Manual for industrial sectional doors with torsion springs 2 c T V NORD CERT i A La d Contents 1 Symbols and or warning signs 4 2 General 4 21 Safety requirements regarding installation and use 4 3 Directives and standards 5 3 1 Warranty and liability D 4 Mounting 5 4 Application 5 41 1 Specifications 5 42 Scope of supply 6 4 3 Installation tools and accessories fi 4 4 Systems and system drawings 7 441 System drawing Standard lift ST 8 4 4 2 System drawing High lift HL 8 4 4 3 System drawing Vertical lift VL 9 444 System drawing Vertical lift with central power unit 9 4 4 5 System drawing Standard roofline lift ST pitched 10 4 4 6 System drawing High roofline lift HL pitched 10 4 5 Installation details 11 4 6 General installation of vertical track sets 11 4 6 1 Standard system 13 4 6 2 Standard roof line system ST pitched 14 463 High lift HL 15 4 6 4 High roof line lift HL pitched 16 4 6 5 Vertical lift FL 17 4 6 6 Vertical lift with central power unit VL mid 18 Connections between guide tracks and vertical angles 18 47 1 Spot welding 18 4 7 2 Bolting 19 4 7 3 Riveting 19 4 8 Drop down of the horizontal track set section 20 4 8 1 Drop down points 20 4 8 2 End separator profile for doors lt 5499 22 4 8 3 separator profile for doors wider than gt 5550 22 4 9 Spring buffers 25 4 10 Spring set power unit 25 4
8. LN FEET 4 3 Installation tools Here is a minimum list of the necessary tools Level hose Drill Battery drill Jigsaw Tensioning rods Flexible steel rule A Ratchet and cover 10mm 13mm Ring open ended spanner 10 11mm 12 13mm Gripper 2x A Blind rivet pliers Ladder or scaffolding cherry picker file Allen keys Drill bits O9 010 Working gloves Safety goggles Always wear safety goggles and gloves when drilling Use stable and safe ladders or scaffolding 4 4 Systems and system drawings We use the following 5 systems lifts Standard system ST see 4 4 1 Standard roof line system ST pitch see 4 4 2 High system HL see 4 4 3 High roof line system HL pitch see 4 4 4 Vertical system VL see 4 4 5 Vertical system with central power unit VL mid see 4 4 6 The following pages feature system drawings for the systems mentioned EN V1 3 ofoga Installation manual abu 4 4 1 System drawing Standard lift ncl 12 mm m H Standard lift Industrial 235 mm 753 mm H 650 mm 38 mm 1 H 83 mm 420 with use 11014 11002 500 with use 11003 11103 F1 4 4 2 System drawing High lift 11005 11006 11007 11008 11108 11004 11104 12 mm m HI Lift Industrial H H HL mm 53 mm A B mm H HL 650 mm 38 mm Fi H 83 mm HL
9. max 750mm 24860 24860 EN V1 3 22 a o do Installation manual sl Now check the following the horizontal sections should be perpendicular to the door panel and or wall construction surface and X should be 90 degrees Measure C and D and ensure they are equal If not correct the angles Measure A and B and ensure they are equal If not correct the angles Your track set is now aligned lt 4 L kaj 4 9 Spring buffers Fix the spring buffers using 2x 14021 24620 and 2x nut 14022 The next consecutive items are installed in a similar way 25026 short version pair vertical angle installation 25026 short version pair C track installation 25330 25326 universal short version unit C track or angle installation 25330 25341 universal short version unit C track or angle installation 25041 long version pair vertical angle installation 25041 C long version pair C track or angle installation Short version is approx 350mm long Long version is approx 500mm long See figures on next page EN V1 3 23 24620 14021 7 14022 25326 350 mm 25341 500 mm 25330 25341 EN V1 3 24 FEET ofoga Installation manual 4 10 Spring set power unit Depending on the size and weight of your sectional door the configuration of the power unit may look different Before starting the final installation we will first discu
10. Riveting 4 7 1 Spot welding Spot welds should be fully welded through in accordance with the spot weld equipment instructions manual Vertical angle The following applies for spot welding Winkezarge 1 weld 25 metre refer to figure on the right hand side 250 250 Guideline for spot welding coupling sleeves T g 2 spot welds on the guide track and sleeve and 3 spot welds divided over vertical angle and sleeve see figure below a Track Laufschiene Looprails Vertical Angle Spot welding Winkelzarge Punkt schweissung Hoekkozijn Puntlas Sleeve Muffe Mof Track Laufschiene Looprails Holes for bolt connection Locher fur Bolz verbindung Gaten voor bout verbinding The spot welds should be finished using a Zinc Spray restoring the parts galvanic protection layer EN V1 3 18 ofoga Installation manual abu 4 7 2 Bolting If you choose to bolt the track set then use the following guideline Use an 8 bolt 14010 or 14023 and nut 14022 or 14013 every 5 metre See figure 8 combination drill 9mm M6 combination drill 7mm Guideline for bolting coupling sleeves ee 2 bolts between the guide track and sleeve and 3 bolts spread out over vertical angle and sleeve see figure 3 6 1 29 read about spot weld bolting 4 7 3 Riveting Should you decide to rivet the track set follow the same procedure as for spot welding Refer to 4 8 1 Rivets must be fixe
11. ail TI IH Y 14010 ui 7 Vertical part V 44022 1 1 14010 5 29 EN V1 3 16 o o da Installation manual 4 6 5 Vertical lift VL A vertical system 15 characterized by the fact that the door panel goes up vertically The track set only comprises 1 section that is welded bolted or riveted For the correct connecting method see 3 6 Connections The length of various items such as guide tracks and L angles and associated item numbers is obtained using the DOCO 2000 programme Installation The vertical section comprises the L angle with seal and guide track Assembly using 4 6 Depending on the height of this system it may be necessary to interconnect the L angles and guide tracks EN V1 3 17 A A o o dao Installation manual 4 6 6 Vertical lift with central power unit VL mid The track set section is the same as 1n 4 6 5 4 7 Connections between guide tracks and vertical angles For connections between L angle and construction wall see 3 3 General installation of vertical track sets To make sure the track 1s stable the connections between guide tracks L angle or inter connections between guide tracks or L angles need to be fixed in such a way as to comply with EN 12424 wind force The guide tracks and or L angles can be connected using three methods Spot welding Bolting
12. 10 1 Configurations 25 4 10 2 Side bearing plates 26 4 10 3 Shafts 26 4 10 4 Keys 27 4 10 5 Spring break protection 25449 27 4 10 6 Centre support consoles 27 4 10 7 Coupling 28 4 10 8 Torsion springs 29 4 10 9 Creating your own torsion springs turning plugs 30 4 10 10 Creating your own torsion springs impact plugs 31 4 10 11 Cable drums 32 4 10 12 Spring set installation power unit 33 4 11 Lintel seal installation 33 4 12 Panels general 34 4 12 1 Hardware 34 4 12 2 Rollers 35 4 12 3 Panel assembly 36 4 12 4 Bottom section 37 4 12 5 Intermediate sections 38 4 12 6 Positioning the bottom panel and intermediate sections 38 EN V1 3 2 ajo do LN FEET 4 12 7 Positioning the top panel 4 13 Fitting the cable and positioning the cable drum 4 14 Tensioning the spring set 4 15 Correcting spring tension 4 16 Controls 4 16 1 Rope operation manual operation 4 16 2 Chain operation 1 4 item 25025 4 16 3 Electric drive slip on motor and control 4 16 3 a Control Pulse control 4 16 3 b Control Dead man control 4 16 3 c Control Automatic or remote control 4 17 Options 4 17 1 Windows 4 17 2 Locks and bolts 4 17 1 Lock 25226 25228 4 17 3 Handles 5 Commissioning 6 Troubleshooting 7 Disassembly 7 1 Removal 8 Appendices Appendix 1 High lift cable drums Appendix 2 Vertical lift cable drums Appendix 3 Fixing vertical track sets Appendix 4 Hardware panels Appendix 5 EC declaration off co
13. 2 16 Aandraaimoment 27 34 Nm D opsleutel i Kabelbevestiging blank Schroef 16 0 Aandraaimoment 13 Nm Dopsleutel Kabeltrommel Verticale heffing Asbevestiging rood Schroef AE UNC Aandraaimom ent 27 34 Nm Dopsleutel t Kabelbevestiging blank Schroef 16 0 Aandraaimoment 13 Nm Dopsleutel amp High lift 152mm 127mm Vertical lift 11012 8534 mm b 1000 kg 178 mm EN V1 3 32 A Kimi 4 10 12 Spring set assembly power unit Assemble the two shaft halves on the ground as in 4 10 1 ofe do Installation manual Slide the assembled shaft half 1 into the bearing of the side console see detail A and fit the spring break protection console to the steel construction or concrete Ensure the shaft is level Fit both shaft halves together using the coupling Use SUITABLE plugs screws or bolts nuts for the relevant base Use plugs of 8 or 10mm with hexagonal screws for wall mounting Use a minimum of 8 bolts and nuts for mounting to a steel construction not included 1 35D MAX 350 MAX 2 3 i E m A i 4 11 Lintel seal installation Slide the rubber seal 24740 or 24250 550 onto the seal profile 24710 24710 Fit the seal profile 24710 onto the lintel at the length of the clear _ width Fit the seal profile 24710 at 60mm above the lintel Attention
14. 21 Closing speed Closing speed Closing speed Closing speed Closing speed cm sec cm sec cm sec cm sec cm sec Installation of electric drive and control The installation of the electric drive and control must be carried out in accordance with the installation manual provided by the supplier of the electric drive and control Ensure the shaft protrudes approx 150mm at the electric drive side Then fit the slip on motor support plate and slide the slip on motor onto the shaft and fit the key supplied GFA SE GFA nr 30002685 4 16 3 a Control Pulse control This control performs one complete opening and closing movement of the door panel Always make sure you can see the door panel when using this control 4 16 3 b Control Dead man control This control will only operate the door panel as long as the activating button 15 pressed As soon as the activating button 15 released the door panel stops EN V1 3 45 4 16 3 c Control Automatic operation or via remote This control can be used to operate the door panel without having the door panel in sight If the control is switched this way or is changed to this mode later an additional photoelectric cell needs to be installed This photoelectric cell can be a reflection type or a one way photoelectric cell protection It should be positioned no more than 200mm from the door and no more than 300mm from the ground inside Reflection type photoelectric cell sh
15. 68 5 180 10 1 63 4 180 12 4 77 9 180 11 69 1 187 5 10 2 64 1 187 5 12 5 78 5 187 5 111 69 7 195 10 3 64 7 195 12 6 79 1 195 11 2 70 3 202 5 10 4 65 3 202 5 12 7 79 8 202 5 11 3 71 0 210 10 5 65 9 210 12 7 79 8 210 114 71 6 217 5 10 6 66 6 217 5 12 8 80 4 217 5 11 5 72 2 225 10 7 67 2 225 12 9 81 0 225 11 5 72 2 232 5 10 8 67 8 232 5 13 81 6 232 3 11 6 72 8 240 10 8 67 8 240 13 81 6 240 11 7 73 5 247 5 10 9 68 5 247 5 13 1 82 3 247 5 11 8 74 1 255 11 69 1 255 13 2 82 9 255 11 9 74 7 262 5 111 69 7 262 5 13 3 83 5 262 5 12 75 4 270 11 2 70 3 270 13 3 83 5 270 121 76 0 2413 11 3 71 0 211 3 13 4 84 2 277 5 12 2 76 6 285 11 4 71 6 285 13 5 84 8 285 12 2 76 6 292 5 11 4 71 6 292 5 13 5 84 8 292 5 12 3 77 2 300 11 5 72 2 300 13 6 85 4 300 12 4 77 9 305 11 6 72 8 305 13 7 86 0 307 5 12 5 78 5 315 12 6 79 1 322 5 127 79 8 330 12 7 79 8 337 5 12 8 80 4 345 12 9 81 0 352 5 13 81 6 360 13 1 82 3 367 5 13 2 82 9 375 13 2 82 9 382 5 13 3 83 5 390 13 4 84 2 397 5 13 5 84 8 405 12 5 78 5 412 5 13 6 85 4 415 13 6 85 4 EN V1 3 93 e e do i 11009 M216 3350 VLVL Door height cm EN V1 3 s Circum ference cm 11010 M280 5500 VLVL Door height cm 330 337 5 345 352 5 360 367 5 375 382 5 390 397 5 405 412 5 420 421 5 435 442 5 450 457 5 465 472 5 480 487 5 495 502 5 510 517 5 525 532 5 540 547 5 555 Circum fe
16. After installation check whether the CE mark has been affixed and completed This manual should be carefully stored reserve the right to modify specifications without written notice 2 1 Safety requirements regarding installation and use The garage gate may only be installed connected and commisioned by skilled personnel When working on the electrics always ensure the power is and remains isolated Never bypass safety features Some parts have sharp edges use safety gloves Never operate the sectional gate if you see that the safety features are damaged During installation maintenance of the garage gate wear at least gloves safety shoes and when drilling safety goggles Always ensure a stable footing when working Secure the installation maintenance site using appropriate safety devices to keep others children at distance Maintenance should only be performed by a specialist firm and or qualified personnel Provide adequate lighting Only use suitable tools especially for tensioning torsion springs EN V1 3 4 mg 3 Directives and standards The following directives and standards were used during the design production and installation of these tracks 98 79 EEC Machine Directive 89 106 EEC Construction Equipment Directive 89 336 EEC EMC Directive 2006 95 EG Low Voltage Directive EN 12604 2000 Mechanical aspects requirements and classification EN 12605 2000 Mech
17. Assembled torsion springs part 21xxx 2369X 2x 25240 2x 4x part 22 0 1 248xx 2 part 2274x part 1300x part 25016 xx depends on various See 4 10 11 part 25110 4mm 295kg part25111 xx 5mm lt 463kg part 25112 xx lt 600kg part 25449 2x 4x 25448 2x 4x part 25042 via DOOR PROCESSING computer programme See 4 10 8 Hardware and panel related products Cable break protection base console Side hinges Centre hinges End covers Stiffening profiles Rollers Aluminium bottom profile Aluminium top profile Bottom seal Top seal Spring buffers Self tapping screw without drill head Self tapping screw with drill head Lintel seal profile Optional extras Lock Handle Chain hoist Drop down profiles Drive and control unit GFA Closing side sensors Fraba set Fraba end stop set EN V1 3 part 25453 a lt 450kg part 25450 600kg panel dependent see appendix 4 panel dependent see appendix 4 panel dependent see appendix 4 part 24701 xx gate width gt 5000mm depends on gate size see 4 12 2 part 80041 part 80041 part 80045 part 2274x part 25330 2x 25341 2x part 14017 part 14027 part 24710 2474 part 25226 part 25093 part 25025 depends on gate size see 4 8 depends on various 4 16 3 fraba part OSE S 1101 fraba part OSE D B 55 8 o o da Installation manual
18. in the drawing I zu 10 TT EN V1 3 49 4 17 3 Handles Handle 25093 1 3 EN V1 3 50 Installation manual aue 5 Commissioning This industrial gate should be commissioned by an experienced fitter Commissioning must be recorded in writing The person responsible for the installation should complete the certificate of conformity and affix the CE label Affixing the CE label certifies compliance with EN directives Affix CE lable item 80310 NL FR bottom left or right to an end cover of the 2 section 6 Troubleshooting Check points for a defective unbalanced sectional gate Applicable to all lift systems Check 1 Check the weight of the door panel Check 2 Have the correct cable drums been supplied Check 3 Are the cable drums fitted correctly Check the following from inside to outside Left drum coded red and fitted on the left Right drum coded black and fitted on the right 5 the cable positioned in between construction wall and shaft Check the position of the cable going in Check 4 Check the correct torsion springs have been supplied and fitted Check the wire thickness Check the spring diameter Check the spring length excluding spring heads Check 5 When the door panel is closed there should not be too much friction The rollers should still turn Check 6 Are there any obstructions durin
19. kg use 4 drop down points min 8 steel quality 8 8 301 450 kg use 6 drop down points min 8 steel quality 8 8 45 600 kg Use 8 drop down points min 8 steel quality 8 8 Important observations Make sure that the spring buffers for the last drop down point are mounted Refer to 4 9 For the last separator construction refer to 4 8 2 Use an M8 MIO 8 8 steel quality self tightening hexagonal nut with a synthetic DIN 985 ring ISO 10511 Make sure the angle of the triangular construction is Approx 30 NEVER weld the suspension points 301 450 kg l 451 600 kg EN V1 3 20 EN V1 3 999 90 69294 24607 _ M10 2s P Se eee ee s 100 M10 nutlock ISO 10511 M10 8 8 8 nutlock ISO 10511 4 8 2 End separator profile for doors lt 5499 ALL industrial doors must be equipped with an end separator profile 24860 This serves to limit the extent to which the track with the strengthening profile bends Refer to details B and C detail B on page 21 4 8 3 End separator profile for doors wider than gt 5550 For doors 75001 a double C rail construction must be used The C rails are linked using 8 bolts 14010 and M8 nuts 14022 every 500 mm refer to the figures below gt 5500 mm 24860
20. should be determined using table 1 Speed revs sec Speed revs min Cable drum Cable drum Highest arm moment lt gt cm circumference cm Standard lift 11014 5 3 33 3 11002 6 9 43 3 11003 10 5 65 9 Extended lift 11005 depends on extended lift 11006 depends on extended lift 11007 depends on extended lift 11008 depends on extended lift 11004 depends on extended lift see table appendix 1 Vertical lift 11009 depends on extended lift 11010 depends on extended lift 11012 depends on extended lift see table appendix 2 Thus the closing speed S becomes See table appendix 1 See table appendix 1 See table appendix 1 See table appendix 1 See table appendix 1 See table appendix 2 See table appendix 2 See table appendix 2 S cable drum circumference cm X speed revs sec Example Drive GFA SE 9 24 Door 4000x4000 vertical lift Drum 11010 gt according to table at top of this page 0 25 revs sec gt according to table 2 at 400 72 8 cm circumference Closing speed 72 8 cm x 0 25 revs sec 18 2 cm sec The table on the next page can now be used to check whether this closing speed complies with the certification This is the case for our example 5 types of closing edge protection have been certified for this application EN V1 3 44 Installation manual adbur ite eee GFA GFA GFA GFA GFA Drive type SE 9 15 SE 9 20 SE 9 24 SE 9 30 SE 14
21. such a way as to tension the spring 4 Hold the 1 tensioning rod secure and now position the 2 tensioning rod in the next hole of the tensioning head 5 Turn the 2 tensioning rod a quarter turn 6 Hold the 2 tensioning rod secure taking over the tension and remove the 1 tensioning rod 7 Repeatstep 3 4 5 6 until the correct tension is reached 8 Secure the tensioning head to the shaft by tightening both bolts the tensioning head to 27 34Nm 9 Now remove the last tensioning rod 10 Now check the number of turns by counting the number of lines on the spring Remove the block on the shaft and vertical guide tracks and your sectional door is finished Ensure the door is properly balanced If not follow the instructions in 4 15 correcting the spring tension 4 15 Correcting the spring tension Block the shaft and the door panel Secure the door if necessary so it cannot rise for instance by fitting clamps to the vertical guide tracks IMPORTANT Tensioned springs carry a high tension always be very careful especially when adjusting and make use of the right size and well maintained tensioning rods 12025 The maximum adjustment to the springs is 1 turn per spring Ensure both springs are adjusted equally 1 Insert the 15 tensioning rod in the tensioning head 2 Turn the tensioning rod in the desired direction 3 Carefully undo the bolts in the tensioning head and take over the spring tension 4 Ho
22. unit 6200 ZZ precision 100 kg unit Roller selection Door panel weight 15 kg m2 Door panel width lt 5000mm selection 25010 E 25008 25066 Door panel weight lt 15 ke m2 Door panel width gt 5000 lt 6000mm selection 25011 E 25251 Door panel weight lt 15 ke m2 T Door panel width 26000 lt 7500mm selection 25251 Fit a finger guard 25700 to each roller except at cable break protection units Note the position of the roller with finger guard in the track Parts marked A should be positioned in the guide section of the track EN V1 3 35 a o do Installation manual 4 12 3 Panel assembl In general a door width of lt 4999 requires the use of single side hinges and end covers you don t need to use stiffening profiles A Ask your panel manufacturer what the maximum panel width is before stiffening panels are required Panel assembly using single side hinges up to doors lt 4999 0 4999 Panel assembly using twin side hinges gt 5000 7500 door width gt 5000 requires fitting twin side hinges adjusted extended end covers and reinforcing profiles on A every intermediate panel d 4 a P F 222 a c P A m i ra F a git f ai rr i Rae S P m 3 J P a mere Lea q 4 lt YO AES a Ss 3 E p 24701 a 25438
23. 3 3 4 34 133 35mm 5 1 4 35 152 40mm 6 36 Checking the wire thickness a The best way 15 to count 10 windings b when unloaded and measure them Then divide this measured value by 10 the result a gives you the thickness of the wire See figure Custom ordered torsion springs should be identified by a label attached to it This label will state the following left or right handed spring spring diameter d wire thickness wd spring length L number of windings of the spring turns order number sectional door dimensions DMW x DMH your reference comm see label EN V1 3 29 4 10 9 Create your own torsion springs turning plugs This example shows you how to make a 95 25mm spring with spring heads Method of operation Determine the correct spring length Cut the spring to the correct length Take item 12001 universal L R spring head and screw it into the torsion spring Turn the spring head to the point where the spring end is half way down the spring head opening 12001 S 12001 W Heat the ends and bend the spring ends approx 90 round using a hammer and punch to secure them properly Repeat the above procedure for the other side fi j j IH I 3 K W Your torsion spring 15 now complete 12001 5 EN V1 3 30 4 10 10 Creating your own torsion sp
24. Rahmen Innenseite Spacer met plastic glas Spacer with plastic glass Abstandhalter mit Glass EN V1 3 47 4 17 2 Locks and bolts General Electrically operated doors may not be fitted with locks or bolts 4 17 2 1 Lock 25226 25228 Specifications Lock 25226 with black outer plate Lock 25228 with chrome outer plate Stroke approx 80mm Heavy duty version fitted to end cover Euro cylinder keys a Euro cylinder b Outer plate c Screws to fix outer plate d Lock screws don t undo Installation A Screws coded D should NOT be undone 1 Install the lock at approx 850mm from the ground just above the side hinge of the bottom section 2 Using a jigsaw cut a 62mm hole in the panel and drill O11mm holes as in drawing _ E 2 5 Lock 25225 Shootbolt 25226 f J d X 39 L U E E m E a ri EN V1 3 48 3 Place the lock 1 in the hole cut at 2 and mark the fixing points using a marker pen Drill 4 5mm holes at these points 4 Attach the lock to the end cover using the 4 x No 2 Parker screws to 15Nm Then tighten the 1 x No 3 Parker screw to 10Nm 5 Fitthe outer plate to the outside and secure the outer plate to the lock using the crosshead screws 5 6 Next drill two 210 holes in the L angle with guide track and remove the remaining material using a file as
25. anical aspects testing methods EN 12445 2000 Safety for powered gates testing methods EN 12453 2000 Safety for powered gates requirements EN 13241 1 2003 Door and gate product standard 3 1 Warranty and liability Unprofessional installation unauthorized alterations other parts to the sectional gate or alterations to the drive that are not in compliance with this manual will invalidate the warranty and thus will release the manufacturers from any liability This also includes damage resulting from incorrect operation failure to follow the instructions in this manual and or poor maintenance and or care 4 Installation 4 1 Application DOCO International have developed fitting sets designed for installation industrial entrances exits to be used safely for vehicles and or people These sets contain the following features Steel fitting sets with front torsion springs fully balanced Compliance with the CE standard provided only DOCO International parts are used unless stated otherwise f the gate is switched to automatic or remote control extra measures need to be taken to guarantee safety See paragraph 4 16 3 c Control Automatic operation or via remote 4 1 1 Specifications Standard lift High lift 7 5m max width 7 5m max width Height 9 8m max Height 9 9m max Door surface 36m2 max High lift 4 15m max Weight 600kg max Door surface 36m2 max Installation area see system diagram Weight 600kg max
26. ated materials EN V1 3 92 a o dao Installation manual 5 al we eee d Appendix 1 High lift cable drums 11005 11006 11007 11008 11004 M102 1375 HL M134 1375 HL M146 3050HL M203 3050HL M162 4165HL Circum Circum Circum Circum Circum Extended ference Extended ference Extended ference Extended ference Extended ference lift cm cm cm lift cm cm lift cm cm cm lift cm cm cm lift cm cm cm 0 7 6 47 7 0 10 5 65 9 0 8 4 52 8 7 5 7 7 48 4 7 5 10 6 66 6 7 5 8 5 53 4 15 7 8 49 0 15 10 6 66 6 15 8 6 54 0 22 5 7 9 49 6 22 5 10 7 67 2 22 5 8 8 55 3 30 amp 50 2 30 10 8 67 8 30 8 9 55 9 37 5 8 2 51 5 37 5 10 9 68 5 37 5 9 56 5 45 8 3 52 1 45 11 69 1 45 9 1 57 1 52 5 8 4 52 8 32 5 11 1 69 7 52 5 9 2 57 8 600 8 5 53 4 600 11 2 70 3 600 9 3 58 4 67 5 8 6 54 0 67 5 11 2 70 3 67 5 9 5 59 7 75 8 7 54 6 75 11 3 71 0 75 9 6 60 3 82 5 8 8 55 3 82 5 11 4 71 6 82 5 9 7 60 9 90 8 9 55 9 90 11 5 72 2 90 9 8 61 5 97 5 9 56 5 97 5 11 6 72 8 97 5 9 9 62 2 105 9 1 57 1 105 117 73 5 105 10 62 8 112 5 9 2 57 8 112 5 117 73 5 112 5 10 1 63 4 120 9 3 58 4 120 11 8 74 1 120 10 2 64 1 127 5 9 4 59 0 127 5 11 9 127 5 10 3 647 135 9 5 59 7 135 12 75 4 135 10 4 65 3 142 5 9 6 60 3 142 5 12 1 76 0 142 5 10 5 65 9 150 9 7 60 9 150 12 1 76 0 150 10 6 66 6 157 5 9 8 61 5 157 5 12 2 76 6 157 5 10 7 67 2 165 9 9 62 2 165 12 3 77 2 165 10 8 67 8 172 5 10 62 8 172 5 12 4 77 9 172 5 10 9
27. d in accordance with the instructions manual of the Rivet equipment Minimum rivet size 5 mm EN V1 3 19 o o dao Installation manual abu 4 8 Drop down of the horizontal track set section The necessary fixing materials needed for mounting this track set to the wall or construction are included in this fitting set The installer is responsible for ensuring that the mounting place is structurally strong enough to carry this industrial door The installer is also responsible for the correct fixings for the relevant structure brick concrete steel wood Therefore you must take the weight of the door blade into account and the fact that the door blade causes a dynamic load Once the vertical track set section has been mounted against the wall or construction the horizontal track set section can be mounted Paragraph 4 7 provided information about connecting the vertical and horizontal track set sections This paragraph gives information on how to fix the horizontal track set section to the roof construction Position the horizontal track set section and fix it to the vertical track set section already done at 4 7 Detail A Support the end of the horizontal track set section by temporarily hanging it from the roof construction using a rope see figure Now fix the drop down construction to the horizontal track set section and then to the roof construction see figures 4 8 1 Drop down points 0 300
28. es long Key Mounting bracket Chain holder Adjusting rings 2x Fixing bolt EN V1 3 42 Fixing the hand chain hoist Ensure the chain runs freely in its housing Ensure the shaft protrudes approx 120mm at the mounting side Slide one adjusting ring onto the shaft Slide the housing onto the shaft Fit the mounting bracket to the housing and then to the wall or construction Fitthe key Slide the other adjusting ring onto the shaft and secure both adjusting rings Attach the chain holder to the wall or construction at a height of approx 1200mm A Distance to bottom of chain approx 900mm If the chain 15 too short or too long it should be lengthened or shortened This is achieved by simply opening and closing a link Extra chain DOCO item 25020 1 Link DOCO item 25220 2809 1200 300 EN V1 3 43 ojolda 5 eee d 4 16 3 Electric drive slip on motor and control Our fitting sets have been certified for the drives specified in the table below fitted with the specified bottom edge protection switch lists in combination with GFA controls TS 961 TS 970 TS 980 Fraba sensors OSE S 1101 transmitter and receiver or Gelbau switch list In accordance with RWTUV Gutachten Nr 2674 04 vom 5 11 2004 The closing edge speed is determined by the cable drum and the number of windings of the drive For extended lift and vertical lift the closing edge speed
29. ffset see figure on the right 13013 offset 86 max load 130kg st M 254 13014 offset 111 max load 120kg st 13015 offset 127 max load 110kg st 13016 offset 152 max load 100kg st Offset Adjustable support console see figure below Max load 150kg st AISI 304 F 14021 I T SS ses deed 13027 14022 EN V1 3 27 o o dao Installation manual 4 10 7 Couplings The purpose of couplings is to create a connection between two shaft sections There are two types available namely fixed couplings and adjustable couplings Fixed coupling item 25017 item 25034 Adjustable coupling item 25042 Recommended torque is 32 36Nm 32 36 Nm lt E d _ _ 25034 32 36 Nm A qx 25017 Lam l 25042 EN V1 3 28 a o da Installation manual 4 10 8 Torsion springs Calculation using DOOR PROCESSING computer programme Torsion springs are available in left handed and right handed versions A left handed spring can be identified as follows Follow the end of the spring back to its centre If it turns anti clockwise then it is a left handed spring If it goes in clockwise it 1s a right handed spring This 1s clarified in the figures below LWV RWV Springs are available in the following sizes d item series 50 8mm 2 67mm 2 5 8 33 d 95 25mm
30. g opening closing of the door panel Check 7 Check the clearance between door panel and guide track it should be approx 30mm and the cable should run freely Check 8 Are the guide tracks parallel in both vertical and horizontal direction Measure distance and height Additional to high and vertical lift systems Check 9 Check the cable exit point at the drum For high lift systems this should be checked by tracing the course of the cable As soon as the first roller goes round the bend the cable should be at the flat section of the cable drum also see 4 13 EN V1 3 91 a o do Installation manual 5 al we eee d 7 Disassembly A CAUTION DANGER A A Disassembly should only be performed by qualified installation disassembly personnel Ensure only installation disassembly personnel is present at the disassembly area and keep others away if necessary by using appropriate safety devices Ensure no electric components are live Ensure adequate light when disassembling Especially when releasing the springs ensure the use of correct tools and stable footing For details and drawings of the various parts to be dismantled please refer to the installation instructions in this manual Procedure Step 1 Release the torsion springs IMPORTANT Tensioned springs carry a high tension always be very careful and use the right size and well maintained tensioning rods 12025 1 Insert the 1 tens
31. he horizontal section comprises a bend guide track and a stiffening profile These two sections are connected using a sleeve See figure Horizontal part Vertical part EN V1 3 13 a o do Installation manual LN FEET 4 6 2 Standard roofline system _ ST pitched A standard roofline system 15 identified by the fact that when opened the door panel immediately goes onto the horizontal section of the guide track under the roof edge The track set comprises 2 sections that are welded bolted or riveted together For the correct connecting method see 3 6 Connections The length of various items such as guide tracks and L angles and associated item numbers is obtained using the DOCO 2000 programme Installation The vertical section comprises the L angle with seal and guide track Assembly using 4 6 The horizontal section comprises a bend guide track and a stiffening profile These two sections are connected using a sleeve See figure Horizontal part 2g 14022 A X 3 NS lt 08 A 5 b 14023 J 14022 a i af 14010 f Vertical part V 44022 29 14010 EN V1 3 14 o o da Installation manual abu 4 6 3 High lift HL A high lift system 15 characterized by the fact that when opened the door panel goes up first before it follows the horizontal section of the track The track set compr
32. ioning rod into the tensioning head 2 Keep a good grip on the 1 tensioning rod and carefully undo the bolts on the tensioning head and transfer the spring tension 3 Now place the 2 tensioning rod in the next hole of the tensioning head and carefully release the spring The spring 15 released from top to bottom 4 Again fit the 15 tensioning rod to the tensioning head and release 5 Repeat steps 3 4 until the spring is released 6 Repeat steps 1 4 for the other spring springs Step 2 Remove the drive following the drive supplier s instructions Step 3 Undo the bolts in the cable drums and remove the steel cables from the cable drums Be careful for any residual tension in the cables check the cables are slack Step 4 Remove the power unit Do this by first removing the coupling and then carefully sliding both shaft halves out of the bearing plates Be aware that components may slide along the shaft Step 5 Remove the panel sections from top to bottom Achieve this by removing the roller holders and centre hinges Step 6 Remove the horizontal section of the track set including the ceiling brackets Step 7 Remove the vertical track set section 7 1 Disposal parts of this industrial gate can be easily identified and recycled Separate the parts after dismantling Note Materials can only be recycled if they are returned separately Deliver the materials to the relevant body responsible for processing the separ
33. ises 2 sections that are welded bolted or riveted together For the correct connecting method see 3 6 Connections The length of various items such as guide tracks and L angles and associated item numbers is obtained using the DOCO 2000 programme Installation The vertical section comprises the L angle with seal and guide track Assembly using 4 6 The horizontal section comprises a bend guide track and a stiffening profile These two sections are connected using a sleeve See figure Horizontal part Vertical part 14023 14010 1 EN V1 3 15 a o do Installation manual LN FEET 4 6 4 High roofline lift HL pitched A high roofline system 15 characterized by the fact that the door panel first goes up vertically before it follows the horizontal section of the track set below the edge of the roof The track set comprises 2 sections that are welded bolted or riveted together For the correct connecting method see 3 6 Connections The length of various items such as guide tracks and L angles and associated item numbers is obtained using the DOCO 2000 programme Installation The vertical section comprises the L angle with seal and guide track Assembly using 4 6 The horizontal section comprises a bend guide track and a stiffening profile These two sections are connected using a sleeve See figure Horizontal part Fo 4022 2 WF 2 f 1 E a L U J n
34. ld the 1 tensioning rod secure and now position the 2 tensioning rod in the next hole of the tensioning head 5 Turn the 2 tensioning rod a quarter turn in the desired direction 6 Hold the 2 tensioning rod secure taking over the tension and remove the 1 tensioning rod 7 Repeat step 4 5 6 until the desired tension is reached 8 Secure the tensioning head to the shaft by tightening the bolts in the tensioning head to 27 34Nm max 9 Now remove the last tensioning rod Remove the block on the shaft and vertical guide tracks and your sectional door is finished EN V1 3 41 Installation manual 4 16 Operation Your sectional gate may be operated using the following methods 1 Rope operation manual operation 2 Chain operation 1 4 3 Electric drive slip on motor and control a Control pulse operation b Control dead man operation c Control automatic or remote operation 4 16 1 Rope operation manual operation Attach the rope to the cable break protection and to a point approx 1600mm from the bottom Rope length door height 1000mm 4 16 2 Chain operating 1 4 item 25025 The hand chain hoist 25025 may not be used for doors heavier then 600kg provided the sectional door is perfectly balanced Maximum allowed pulling force 16 kg Maximum allowed torque on the shaft 39 N mm The hand chain hoist 25025 comprises the following components Housing and transmission Hand chain approx 8 metr
35. m HL 250 mm with use 11005 HL 280 mm with use 11006 HL 350 mm use 11004 11104 11007 11008 11 108 EN V1 3 10 adbur 4 5 Installation details OH Make sure the location for the track sets to be installed 15 level and that the construction is strong i enough to carry the track sets Res 1 Ensure the floor is level and devoid of irregularities If not fill in Before starting on the installation assess whether the mounting place fulfils the minimum requirements figure right and system drawings W clear width H clear height 2 Le W 7 clearance above x side clearance D installation depth for each system minimum 100mm excl slip on drive 4 6 General installation of vertical track sets 1 2 Mark line 1 on the wall Then draw line 2 using a spirit level Then add markings 3 and 4 for the bottom alignment 3 4 Mount the side seal to the already assembled vertical track set L angle and guide track and 1f necessary cut to size Mount both vertical track set sections against the wall or construction ensuring they are level at point 3 and 4 Make sure they run parallel and are level in both directions See figures 2 and 3 Ensure both L angles are parallel and at right angles with line 3 4 The bottom offset depends on the cable break protection used see 4 12 3 For type 25450 OFFSET 34 mm For type 25453 OFFSET 34 mm
36. nformity EN V1 3 39 40 41 41 42 42 42 44 45 45 46 46 46 48 48 50 51 51 52 52 53 54 55 55 56 Installation manual Kas 1 Symbols and or warning signs 2 General This Installation Manual was written specifically for use by qualified personnel and is therefore not suitable for apprentices or DIY ers General DANGER symbol ATTENTION symbol Carefully read the text when you see this symbol Symbol Risk of personal injury Carefully read the text when you see this symbol If anything regarding installation and or maintenance is not clear please contact DOCO International To prevent serious personal injury all directions and instructions in this manual should be carefully read and observed This manual describes the installation of industrial fitting sets with torsion springs but it may be necessary to consult other installation manuals such as the one for the drive if fitted Your fitting set is designed in accordance with the latest European standards however you should check whether it complies with your local national standards Adding or removing parts may have an adverse effect on the operation and thus the safety of the final sectional gate All indications regarding right left installation are seen from the place of installation 1 from the inside looking out Unless stated otherwise all measurements are in millimetres
37. o determine the exact point where the cable exits the drum when the sectional door 15 closed at the high lift section conical section of the cable drum follow the procedure below Take a piece of rope of the exact high length Take the rope and start from the conical section at the bottom and begin winding it towards the top Where the rope ends is the correct exit point for the cable Mark this point Guide the cable through the cable break protection and behind the roller shafts to the cable drum slide the cable end through the cable fixing hole and wind the cable up to the mark allowing for a minimum of 0 5 safety winding being left on the cable drum Vertical lift To determine the exact point where the cable exits the drum when the sectional door 1s closed at the conical section of the cable drum follow the procedure below Take a piece of rope of a length that is equal to the door height Take the rope and start from the conical section at the bottom and begin winding it towards the top Where the rope ends is the correct exit point for the cable Mark this point Guide the cable through the cable break protection and behind the roller shafts to the cable drum slide the cable end through the cable fixing hole and wind the cable up to the mark allowing for a minimum of 0 5 safety winding being left on the cable drum Equal to 2 windings TUV approved Ref TUV BB FTA MUCZre sc 30604 Besch to
38. own 1 GFA Item 40005048 photoelectric cell max 7 5m range 2 GFA Item 40005241 reflector max 300 mm 4 17 Optional extras Optional extras for installation Windows Locks bolts Handles 4 17 1 Windows DOCO windows have been approved in accordance with the EN 12600 standard of the EU and comply with Class 2 Approved windows 85102 ovalclick window black window size 725x325 cutting size 695x295 R70 85600 oval screw window black window size 665x345 cutting size 638x320 R100 85603 PC rectangular screw window black window size 637x332 cutting size 610x305 85606 rectangular screw window white window size 488x322 cutting size 466x300 85616 PC rectangular screw window black window size 488x322 cutting size 466x300 EN V1 3 46 Window installation Cut out the relevant cutting size as specified on the relevant window s data sheet using a jigsaw First position the window section to the outside using sealant then position the spacer with plastic glass and finally position the inner frame Screw or click the window together NOTE Depending on the model the window will either screw or click together and the spacer part may already be sealed to the outside frame Example Window 85606 Zaagmaat Cut out dimension Schneidemass Buitenframe Outside frame Rahmen Au enseite Schroeven A Screws Schrauben 0 e Binnenframe Inside frame
39. pp Motors GfA SE series Closing edge safety device Various Fraba and Gelbau models all of them in accordance with RWTUV Certification no 2674 04 Manufacturer Doco International BV Nusterweg 96 NL 6136 KV SITTARD NL Tel 31 46 4200666 Fax 31 46 4526894 Relevant EU Directives applied Machinery Directive 98 37 EC Construction Products Directive 89 106 EEC EMC Directive 89 336 EEC Low voltage Directive 73 23 EEC Harmonised Standards applied EN 13241 1 Doors Product Standard Part 1 EN 12604 Doors Mechanical aspects EN 12453 Safety in use of power operated doors Requirements EN 12635 Doors Installation and use EN 12978 Doors and gates Safety devices EN V1 3 96
40. rence cm 11012 Appendix 2 340 8500 VLVL Vertical lift cable drums Circum ference cm Extended lift cm 555 562 5 570 577 5 585 592 5 600 607 5 615 622 5 630 637 5 645 652 5 660 667 5 675 682 5 690 697 5 705 712 5 720 727 5 735 742 5 750 757 5 765 772 5 780 787 5 795 802 5 810 817 5 825 832 5 840 94 Appendix 4 Hardware Panels 80612L 610 80617L 488 80041 80045 25734 80612L 610 80613L 488 80041 80045 25333 118438 118449 80045 80612L 610 80617L 488 80041 80045 25333 80612L 610 80617L 488 80041 80045 25634 25633 EN V1 3 xil di Appendix 5 EC MANUFACTURER DECLARATION EC DECLARATION OF CONFORMITY We hereby declare that the products described below conform to the relevant fundamental requirements of the applicable EU directives both in its basic design and construction as well as in the version marketed by us Inspection bodies TUV Nord Cert 0032 and SP 0402 This declaration will cease to be valid if any modifications are made to this product without our express approval or if a door operator or panel other than those indicated below or other products than those described by Doco International are used Product Description Manually or electrically driven sectional overhead door DOCO SL HL VL Panels in finger safe execution ThyssenKrupp Hoesch Ryterna Bremet Apco Kingspan Tekla Teckentru
41. rings impact plugs This example shows you how to make a 152 4mm spring with spring heads Method of operation Determine the correct spring length Cut the spring to the correct length bad 12006 57 4 Take item 12006 universal L R spring head and tap it into the torsion spring Do this by placing tabs A 1 behind the second winding B 2 and then tapping the plug into it using a rubber hammer at C 3 images as i k N NA NA MS NN I 3l 1 HII if ur L m um ru T Iie LM WW Es atn Jf Iya i f Wh if rj Keep tapping until the spring head is positioned halfway down the spring head opening 4 Heat the ends and bend the spring ends approx 90 round using a hammer and punch to secure them properly 5 6 Repeat the above procedure for the other side EN V1 3 31 o o dao Installation manual abwr 4 10 11 Cable drums All Cable drums are based on 0 5 safety windings Equal to 2 windings TUV SUD approved Ref TUV BB FTA MUC re sc 30604 Besch torque doc Kabeltrommel Standaard heffing Asbevestiqing rood Schroef 16 UNC NS andraaimomen m AN S Dopsleutel Kabelbevestiging blank Schroef 8 16 UNC Aandraaim oment 13 Nm D opsleutel i Kabeltrommel hoge heffing ASbevestiging road Schroef
42. rque doc THIS ONLY APPLIES TO DOCO INTERNATIONAL CABLE DRUMS Secure the cable by tightening bolt blank Then secure the cable drum including key onto the shaft by tightening the bolts red See 4 10 11 Once again Ensure the position of the left and right cable drum is the same and that the cable tension of both cables is equal EN V1 3 40 a o do Installation manual LH NET 4 14 Tensioning the spring set Secure the door if necessary so it cannot rise for instance by fitting clamps to the vertical guide tracks Tension the springs according to the procedure below The number of turns for the spring 1s specified on the labels of the assembled spring After tensioning secure the tensioning head to the shaft using 27 to max 34Nm this applies to both tensioning head 12002 W and tensioning head 12003 W Procedure for tensioning a spring IMPORTANT Tensioned springs carry a high tension always be very careful especially when adjusting and make sure the tensioning rods 12025 are the right size and are well maintained Tension the springs from bottom to top Tensioning the spring will make it thinner and longer the number of turns x wire thickness if this is not the case then the left and right springs have been swapped 1 Mark the spring by drawing a straight line 2 Insert the 1 tensioning rod into the tensioning head 3 Turn the 1 tensioning rod a quarter turn in
43. section pre assembly Cut the panels to the correct length Fitthe end covers 2 to the panel 1 using blind rivets Fit the side hinges 5 and the centre hinges 8 divide the centre hinges 8 over the length of the panel See 4 11 1 for the correct number of centre hinges 4 12 6 Positioning the bottom panel and intermediate sections Remove the cable break protection on one side Position the roller without finger guard 25700 on the side of the cable A break protection Position the bottom section between the L angles Now fit the cable break protection including roller to the other side but without finger guard 25700 Make the bottom section level see figure the right A Position the intermediate sections 2 3 4 etc on top of the bottom sections and join them together using the hinges Adjust the rollers such that the nylon wheel runs in the curve of the track and that play between panel and side seal is minimal 24740 It should be possible to rotate the nylon roller wheel by hand See figure below right Pay attention to the installation of the finger guard EN V1 3 38 4 12 7 _ Positioning the top section Cut the top section to the correct height see 4 11 for the correct height measurement Slide the aluminium profile 3 onto the entire length of the panel 1 and secure using blind rivets Position the top section onto the intermediate
44. sections and install the top roll holder 25001 25005 in the correct position The correct position is determined by pressing the panel against the lintel seal Now take the top roll holder with roller including finger guard and measure the distance X Mark the positions for the Parker screws and secure See figures top roll holder 25005 shown Adjust the top roll by pressing the panel against the lintel seal and securing the screws in the roll holder Detail 14017 EN V1 3 39 k mg 4 13 Fittine the cable and positioning the cable drum General Ensure the shaft is level Guide the cable see table through the cable break protection and behind the roller shafts to the cable drum Slide the cable end through the cable fixing hole of the cable drum and ensure the position of the right and the left cable drum is the same When installing the cables ensure the cable tension for the right and left cable is the same Tensile strength Diameter Minimum break force Max door weight including 6 x safety 1770 N m 499 kg 166 kg max 1770 N m 887 kg 295 kg max 1770 1390 kg 463 kg max 1770 Nim 2000 kg 666 kg max Determining the correct cable length Standard lift Guide the cable through the cable break protection and behind the roller shafts to the cable drum slide the cable end through the cable fixing hole and wind a minimum of 0 5 safety winding onto the cable drum High lift T
45. ss the various components needed to assemble the power unit First we will discuss the configurations followed by the various components 4 10 1 Configurations Shaft with one torsion spring Shaft with two torsion springs Shaft with four torsion springs Use the figures below to assess which 15 applicable to you Shaft with torsion spring Shaft with two torsion springs Shaft with four torsion springs General description 1 2 3 4 5 6 EN V1 3 25 Side bearing console Spring break protection units with or without offset plate Couplings fixed or adjustable Centre support consoles Right Wound Torsion Springs RWV Left Wound Torsion Springs LWV Installation manual 13001 or 13025 25017 25034113013 or 13025 13026 27 25449 or 25042 13026 27 RWV LWV 13002 or 13025 25017 25034113014 or 13025 111 13026 27 25448 25449 25042 13026 27 RWV LWV 13003 or 13025 25017 25034113015 or 13025 127 13026 27 25448 25449 25042 13026 27 RWV LWV 13004 or 13025 25017 or 25034113016 or 13025 152 13026 27 25448 25449 25042 13026 27 RWV LWV 4 10 2 Side bearing plates Choose the correct side bearing plate for the table this depends on the drum or offset X used Installation is carried out using paro plates 24620 with bolts 14021 and nuts 14022 14015 see figure 1014 ST 1002 ST 1003 ST
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