resl manual gb rev3 jun08

8/6/2019 Resl Manual Gb Rev3 Jun08

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RESL manual GB 08 www.flexiforce.com1

manual GB rev.3 June-08

RESHardware system forside sliding sectionalgarage doorsINSTALLATION / MAINTENANCE / USAGE All rights reserved. FlexiForce 2008


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manual GB rev.3 June-08ATTENTION! GENERAL WARNING!To install, use and maintain this door safely, a number of precautions must be taken. Forthe safety of all concerned, pay heed to the warnings and instructions given below! If indoubt, contact your supplier. This manual has been written for use by experienced fitters and as such is notsuitable for d.i.y. purposes or for use by trainee fitters. This manual describes the installation of the hardware set components, doorsections (panels) and refers to installation manuals of the electrical operator. Besure to supplement this manual if needed with instructions for any additionalcomponents not described in this manual. Before starting, read this manual carefully! Certain components may be sharp or have jagged edges. As such you are advised towear 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 adverseeffect on the safety of, and the guarantee on, the door. Also the CE-approval whichhas been granted to this door will be cancelled when components are changed orinstallation is not done according to this manual! Installer is responsible for this. 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. SPECIAL SAFETY WARNINGS OR REMARKS IN THIS MANUAL ARE INDICATED WITHTHIS SYMBOL: READ THESE WARNINGS CAREFULLY.GUARANTEE, CONDITIONS AND TERMSThe 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 theirimplementation. We expressly reject all other terms and conditions. On request we will send you a copyof these terms and conditions free of charge. A copy may also be downloaded from our websitewww.flexiforce.com.

FlexiForce strives to deliver 100 % in conformance with the order. In practice, in spite of all our controls,this is not always possible. However we will rectify any errors as quickly as possible, in order to minimisethe inconvenience caused to you or the user. As such, it is important that you inform us as soon as possibleabout any problem with the delivery (include the order number and week of production) and give us theopportunity to offer a suitable solution.FlexiForce will only reimburse third party costs if we have given explicit permission for this in advance. Thereimbursement 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.FlexiForce has endeavoured to design and put together this hardware set in conformance with theapplicable CE-norms. However, we recommend to check our configuration against any local nationalspecification.


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manual GB rev.3 June-08CHECKING DIMENSIONAL DETAILSBefore assembling the system the details below should be checked on the basis of this figure.

A = Days Opening Width = DLWB = Days Opening Height = DLHC = Side areaD = Top areaE = Side wall free space

OPW max = A max = 5.000mmOPH max = B max = 2.500mmC min = 150mm (curve side), 70mmD min = 100mm (manual operated)

142mm (power operated Liftmaster)E min = A

PARTS LISTS RESL DOOR

Article code Explanation function

Qty fordoor

2,5x2,5m

Qty fordoor

5 x 2,5m

Upper track + suspension

5060L32405060L5220

Suspension angle,horizontal, lint el. Togetherwith the RL310 and RL320,this is the suspension of the

2V running track.

11

2RL925-400 Upper curv e RESL, 2V-J-corner, made out ofstandard 2V track, bendeddifferently on special newtooling in FF HU.

1 1

= OPW

= OPH


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manual GB rev.3 June-08 2V Standard 2V track for upper

guidance at the lintel, lengthis opening width /- 370mm.

1 1 x4630mm

2V Standard 2V track for upperguidance at the wall side,length is opening width+130mm.

1 1 x5130mm

RL300 Angle bracket for tracksuspension on the wall. Incombination with RL310 andRL320.

5 10

RL310 Top bracket, together with

RL320 this carries the 2Vtrack.

9 20

RL320 Rail plate, in combinationwith the RL310, this carriesthe 2V track.

9 20

Qty for door2,5x2,5m Qty for door5 x 2,5m


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manual GB rev.3 June-08 RL330 2V-connect ion bracket, at

the point where the uppercurve and 2V track connect.

2 2

Upper roller system

DIN912

1088BN Socket capscrew, forms the"shaft" which connects thedouble roll er RL592 with thehinge on the panel.M10x140mm.

5 10

DIN125A

2050-8 Washer. Steel washer that isplaced between the bolt1068MN and the collar o f theRL592.

5 10

DIN433

2052-8 Washer. Nylon washer thatis placed between the bolt1068MN and the collar o f theRL592.

5 10

RL592 Roller system. Double rollercombination that runs in the2V track. Integrated fingerprotection.

5+ 1 for

E-power

10+ 1 for

E-power



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manual GB rev.3 June-08Seals and brushes

1030L-S6090 Alumini um bottom profile.Used as "end cap" at thebottom si de of the door. NB!For fingersafe sections, this

profile has to be cut intosection height, followingmore or less the shape ofthe panel. At this position italso holds the 1038INS2550and the sealing brus h1087B.Also used at both sides ofthe door leaf. In 1st panelwith seal 1037. In last panelwithout seal.

2 5(2pcs29901pcs

5100)

1038INS25501038INS3050

Alu profile for holding thebrush 1087B. It fits into the1030L-S profile.

1 2

1087B1 Brush. Forms the sealbetween panel and steelthreshold RLT3000.

3 m 5 m



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manual GB rev.3 June-08 91VR3015

91VR5000Alu profile that is used incombination with the newseal 1088S at the sides andlintel part of the door. At theoutside of the door thisgives a proper appearance(black line around the door).

1 1 pcs5000

or2pcs 3015

1088S-3060 Sealing, that fits on the91VR alu pro file.

3 5

1037 Seal. Standard available FFseal. Fitted at the side of thefirst panel, into the 1030L-S6090. It seals of the"locking" side of the door,against the 9VRL angle thatis fitted on the wall.

2,5 m 2,5 m

9VRL25259VRL3025

Vertical angle. On theclosing side of the door,fitted on t he wall, togetherwith 2100-15. Is standard9VR only extra holes.

1 1 pcs

Hinges and brackets on t he panels

415RL End roller bracket. Holds the447 slide with RL580 roller.Is fitted on the first panel ofthe door (so in the corner).

1 1


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447RL Slide 11mm. Roller carrierfor RL580. Used on the firstpanel in combination with415RL, on the last panelused alone (directly on thepanel).

3 3

RL580 Bottom roller. Guides thedoor through the steelthreshold RLT3000.

6 11

423FZ etc. Hinge. Standard FF hingerange 424FZ, 423FZ can beused. At top and bottom.

8 18

40ES500L/R etc. Endcap. Standard FF endcaps to cover the upperparts of the sections.

4 9

423HZ etc. Intermedi ate hinge.Standard FF hingedepending on panel choice.

4 9


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Bottom track and curves

RLB-L/R Bottom corner. "Low sideroom" corner. Connects tosteel threshold and to 2xRL15U3000 bottom tracks.

1LeftOr

Right

1LeftOr

Right

RLT3000 Thresho ld, steel. Days

opening wi dth -/- 250mm.With holes for mounting tothe floor . Guides the panelthrough the days opening.

1 2

RL15U3000 U-profi le. To be assembled 2next to each other,connected wit h 850RLplates. Length is days

opening width. Guides doorsections along the side wall.

2 4

850RL Rail fixing strip forassembling 2 x RL15U3000tracks.

4 8


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manual GB rev.3 June-08Locking / anti-burglar products

650L Lock extension. If you take astandard 650BL-etc. loc k,you can add this 650L partwith latch and st rike. One

piece is mounted on the9VRL angle. The other pieceon the panel.

option option

901 Anti-lift bracket. If the dooris mounted, 3 of thesebrackets ensure that youcannot lift the door out ofthe bottom track. So, burglarprotection. E-operation3x901 is needed. Manual

operation 2x901 and then onthe side of the panel 1 x902H/902WB.

2 or 3 2 or 3

902H Anti-lift bracket. If youmount this bracket on thedoor panel (corner panel),and you fix the 902WB to thewall, when closing the doorthese "click in" and preventthat the door can be liftedout of the threshold.

1

Onlymanual

operation

1

Onlymanual

operation

902WB Anti-lift bracket. If youmount this bracket to thewall and fix the 901H on thedoor panel (corner panel),when closing the door these"click in" and prevent thatthe door can be lifted out ofthe threshold.

1

Onlymanual

operation

1

Onlymanual

operation



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manual GB rev.3 June-08E-operation parts

RL210 E-bracket 1 1

RL220 Drive unit bracket 1 1

RL230 Draw arm 1 1

557-90Z Roller 1 1

557BUS8 Bush 2 2



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manual GB rev.3 June-08Fixation material and fasteners

ISO4017

1057B16 Hex.bolt M8x16 1 1

ISO4017

1057B60 Hex.bolt M8x60 1 1

ISO4014

1059B50 Hex.bolt M10x50 1 1

DIN985

1068MN Nyloc nut M8 6 11

DIN603

1072B Mushroom bolt 9 20

1006B Pressbo lt M6 9 9



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CALCULATION LENGTHS OF PROFILES

Article number Description Formula for length5060L L-profile suspension OPW(A)+C1+30

1038INS2550 Brush profile OPW(A)+40

1087B Brush OPW(A)+40

1088S Top seal OPW(A)

1088S Side seal OPH(B)+25(2x)

91VR Alu profile for top seal OPW(A)(1x)

91VR Alu profile for side seal OPH(B)+25(2x)

9VRL Angle OPH(B)+25

2V front Track lintel OPW(A) +C1-520

2V side Track wall OPW(A)+C1-20

RL15U3000 U-profile OPW(A)-C1+150(2x)

RLT3000 Threshold OPW(A)+C1-400

1030L-S Vertical alu profile on panel OPH(B)-17(2x)

1030L-S Bottom profile (panel) OPW(A)+100(1x)

1037 Side seal (on panel) OPH(B)-15

C1 is built-in size curve side


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MAX TORQUE FIXATION MATERIALS


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INSTALLATION 5060L ON LINTEL

OPW(A)+C1+30


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RL320

RL310

1072B


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INSTALLATION SUSPENSION SIDE WALL

RL320

RL310

RL300


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manual GB rev.3 June-08INSTALLATION OF UPPER TRACK IN SUSPENSION

2RL925-400

RL330

2V


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INSTALLATION VERTICAL ANGLE 9VRL


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INSTALLATION BOTTOM GUIDE TRACK

RLT3000


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RL15U3000 and 850RL AVAILABLE AS PRE-ASSEMBLED KITThe combination RL15U3000 and 850RL as described above is also available fromstock as a pre-assembled kit. This kit exists out of 2 RL15U profiles spotwelded with850RL. By buying a pre-assembled kit, installation of the profiles simplifies andsaves time. The article numbers and max. door width for the kits are:

Article number Description Max. door widthRLB30


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PANEL ASSEMBLY (CUTTING PANELS TO SIZE)OPW(A)+25


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PANEL ASSEMBLY: CUTTING TO SIZE OF 1030L-S60901st panel


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Intermediate panels


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Last panel


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PANEL ASSEMBLY: INSTALLATION END CAP


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PANEL ASSEMBLY (STARTING WITH 1st PANEL)

447RL

420FZ etc.

40FM500L/R etc.

(top view )


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(top of panel )

(bottom view )

(bottom of panel )

1038INS2550

1087B

1030L-S6090

1037

RL580


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PANEL ASSEMBLY: INSTALLATION LOCK 650-40RAL/ RBL and 650E

EXPLANATION INSTALLATION LOCK IN PANEL

POSITION LOCK ON PANEL (top view)

650E


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LOCK BRACKET FIXED TO 9VRL

LOCK COMPLETE INSTALLED ON RESL

GRIP INSTALLED ON DOOR RESL


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DOOR INSTALLATION

RL592

1088BN

1068MN

2050-8

2052-8


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INSTALLING THE PANELS (SECTIONS) IN THE TRACK SYSTEM

(last panel )

447RL

415RL

RL580


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FIXATION LATERAL HINGES AND INSTALLATION INTERMEDIATE HINGES

ADJUSTING PANEL POSITIONING

(position last roller inthe upper curve)

( position top of panel to 901 lift protection)

423HZ etc.


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INSTALLING 902H, 902WB ANTI-LIFT BRACKETS


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INSTALLATION SIDE AND TOP SEALS

INSTALLING END STOP IN SIDE TRACK

(top view)

2100-15


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manual GB rev.3 June-08E-OPERATION INSTALLATION

RL220

(days opening )


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(operator bracket system)

1057B60

557BUS8

RL230

RL210


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1059B50

1057B16

RL592

1068MN


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FINISHING THE DOORInstall any additional accessories that you have ordered separately such as:Handgrip, lock, etc. See separate instructions in product packaging.

NB! A lock may not be fitted to an electrically driven door.NB! A manually operated door should always be equipped with a hand grip,installed at a safe location on the door.

Oil all hinges and all bearing rollers with one drop of oil (WD40).

Let some drops of oil go into the curve of the track. This lubricates theconnection between track and nylon roller, which allows a smooth operation ofthe door.

The roller shafts are being greased during installation.

Place your CE identification plate on the door (mandated!!) together withany warning labels required.

Hand over necessary documents to the end-user:o User manualo Dismantling instructions (included in this manual)

o Maintenance instructions (included in the user manual)

o Service log book

o Declaration of conformity IIa declaring the door is according toEN-13241-1.

Visit www.flexiforce.com for more information on your obligationstowards handing over a safe-to-use door.

DISMANTLING THE RESL DOOR1. Take the power supply of the operator2. Dismantle the operator arm and brackets3. Remove the operator and draw-bar4. Remove the seals and alu profiles from the lintel5. Remove the 902 anti-lift brackets6. Disconnect the panels by loosening the hinges

7. Lift panels out of the threshold and turn them piece by piece out of the upper track8. Remove the upper and bottom track system9. Make sure that you remove all the parts and panels in an environment kindly way.

Check with your local authorities where and how you can leave this as garbage.

FOR ANY DETAILS ON THESE DISMANTLING INSTRUCTIONS, WE REFER TO THE INSTALLATIONCHAPTERS OF THIS MANUAL WHERE DRAWINGS AND DETAILS ARE DISPLAYED.


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MAINTENANCE AND REPLACEMENT OF PARTS RESIDENTIAL DOORSAn side sliding sectional garage door should be maintained and checked regularly to ensuresafe operation and use. This is described in the EN-norms.

GENERAL:1 Replacement of broken or weared components should always be done by qualifieddoor mechanics.

2 When checking the door, always disconnect the electrical main power supply. Makesure that it is blocked against re-engaging without you knowing it.

REGULAR MAINTENANCE:After installation:1. Grease running part of the tracks MECHANIC2. Grease the bearings of the rollers MECHANIC3. Grease the shafts of the rollers MECHANIC4. Grease the hinge pins MECHANIC5. Grease the lock (if present) MECHANIC

6. Protect the panels with carwax USER7. Grease the rubbers slightly with vasaline USERAfter 3 months:1. Complete inspection visualy MECHANIC2. Check height adjustment and closing and adjust if needed MECHANIC3. Grease all the above mentioned points if needed MECHANICEvery 6 months (or after every 750 cycles):1. Check side seals on damage or wear and tear USER2. Check top seal on damage or wear and tear USER3. Check bottom brush on damage or wear and tear USER4. Check seals in panels USER5. Grease all above mentioned points USER6. Clean the panels USER

7. Remove dirt and waste from the door or its surroundings USER8. Keep track of bottom rollers clean (threshold, corner and siderail) USER

Every 12 months (or after every 1500 cycles):1. Check the rollers on wear and free moving space MECHANIC2. Check the hinges on functioning and tightening of screws MECHANIC3. Check the panels on damage, wear and rust MECHANIC4. Check and test the safety edge system with operator MECHANIC5. Check the manual operation of the door MECHANIC6. Check side seals on damage or wear and tear MECHANIC7. Check top seal on damage or wear and tear MECHANIC8. Check bottom brush on damage or wear and tear MECHANIC9. Check seals in panels MECHANIC10. Grease all the above mentioned points MECHANIC11. Check bolts of coupling to operator system MECHANIC12. Check the connections of the track system MECHANIC13. Check the suspension of the door to the lintel, side wall and ceiling MECHANIC

Use for greasing : PTFE or SAE20 or WD40

resl manual gb rev3 jun08

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