Garage Door Systems ThermaRoll 55 User manual

ThermaRoll 55 Roller Garage Door
Installation Instructions
For residential doors
!
HEAVY -
LIFT WITH
CAUTION!
!
YOUR SAFETY
FIRST!
Read this booklet
carefully before
installing your door
APR 2021

2
CONTENTS
Important Information – Warnings & Safety Obligations Page 3
CE marking, Operating & Warranty Page 4
Pre-Installation Checks Page 5
Component Check / Assembly Parts / Tools / Recommended Fixings Page 6
Setting out your Installation Page 8
Full Box
Half Box
Guide Preparation Page 9
Barrel assembly attachment Page 10
Head plate Preparation Page 11
Fixing the door guides & Head plates Page 11
Installing the Manual Override Page 12
Installation of Curtain into Guides Page 12
Installation & Connection of Board, Motor Direction Page 13
Attachment of Curtain to Axle Page 18
Commissioning and Setting Somfy Motor Limits Page 19
Additional Rollixo Set Up and Connecting Additional Devices Page 20
ThermaRoll Roller Garage Door
Installation Instructions
For residential doors

3
WHO SHOULD
INSTALL THIS DOOR?
A minimum of two
people must be
available for fitting.
GDS recommend that
fitting and/or repair of
garage doors be performed by a qualified,
factory trained garage door specialist.
• Your safety, your end user’s safety and that of the general public is our primary concern. Please
read, understand and follow our advice.
• These installation instructions are intended for qualified and trained installation engineers.
• Installation, initial operation, servicing, repairs and dismantling of this product should only be
carried out by a qualified and trained installation engineer.
Failure to comply with these instructions
invalidates the warranty.
Before you begin the fitting of the door, read
and fully understand all of the instructions
thoroughly.
These doors meet all relevant safety
requirements when installed according to these
fitting instructions.
Both one and two car doors are installed in the
same manner.
Damage to the garage door due to improper
handling, installation or improper adjustment
of the electric operator is not covered by
Garage Door Systems’ warranty.
Be sure all warning labels and tags are
properly affixed to the door and that the
home owner is familiar with the door
operation.
Before removing the old door or
unpacking the door, confirm the opening
dimensions to ensure door will fit.
!
!
IMPORTANT INFORMATION
WARNINGS & SAFETY OBLIGATIONS
WARNING!
GENERAL NOTES
Goggles
Safety Shoes
Gloves
SAFETY EQUIPMENT

4
Upon completion of the installation the end
user of the door must be trained how to
operate the product safely paying particular
attention to the following points;
• The door should only be operated
when in view.
• The end user must ensure there are
no objects or persons in the opening
before and during operation.
• The end user must read and follow the
instructions given in the operating and
maintenance instructions.
• In the event of a malfunction the end
user should follow the instructions given
in the operating and maintenance
instructions and if required contact the
installer.
• It is the end users responsibility to
maintain a regular and appropriate
service and maintenance schedule.
The recommended service period for a
ThermaRoll door that will operate on average
two cycles per day is once every 12 months
or as a minimum once every 24 months to
maintain the products warranty requirements.
• The installation must be carried out by a
competent installation engineer following
these instructions.
• Only original parts are used.
• No additional objects are attached to the
door.
• Regular and appropriate maintenance
checks are performed.
• For further details on the product warranties
please contact us.
!IMPORTANT INFORMATION
CE MARKING, OPERATING & WARRANTY
GENERAL OPERATING INFORMATION RECOMMENDED SERVICE PERIOD
WARRANTY/LIFE CYCLES
CE MARKING
• To comply with the Machinery Directive both
the door and the motor and controller used
in the installation must have a Declaration of
Performance from the manufacturer.
• On completion of the installation the installer
must provide a Declaration of Conformity
and apply a CE mark giving details of the
installations to the door/motor and controller
combination, which is now classed as a
machine.
• The installer must issue to the customer a
Declaration of Conformity and operating and
maintenance instructions on completion of the
installation.
• The installer must hold copies of both
the Declaration of Performance and the
Declaration of Conformity on a technical file
for inspection by the relevant authorities.
• If any of the above requirements are not
fulfilled, the installation is illegal.

5
Tape measure
Stanley knife
Pencil
Spirit/laser level
Adjustable spanner
Riveter
Quick clamps
Spacers/wedges for frame setting
Masonry drill/bits
Electric drill
Bits
Pozidrive screw drivers
‘A’ rated steps x2
• Ensure finished floor surface is in place before
installing your ThermaRoll door.
• Ensure there is adequate sideroom and
headroom.
• The jambs and head should be on the same
plane.
• The jambs must be plumb, and the header
level for a true opening. Small irregularities in
the brickwork are acceptable as long as they
do not interfere with proper fitting of the door
guides or optional boxes.
• The surface where the door is to be fitted must
be strong enough to support the door.
• The door should be fitted only after any
plastering of the area has been completed.
Plaster splashes may damage the door finish
and interfere with proper operation.
• Before unpacking your door confirm opening
measurements as well as headroom and side
room clearance to ensure door will fit.
• Ensure that the site is clear and that all fixing
surfaces are free from loose plaster or masonry.
Ensure the opening has no irregularities that
could damage or mark the box or curtain.
!PRE-INSTALLATION CHECKS
STRUCTURAL CONDITIONS
ENSURE THAT THE AREA AROUND THE
OPENING IS STRONG ENOUGH TO SUPPORT
THE DOOR
Check:
• Structure is sound and even and can carry the
weight of the door.
• No obstacles in fitting footprint eg. no sharp
objects, pipes, cables, bumps etc. sticking
out from the pillars, lintel or header to twist
the guides, distort the fascia or catch on the
curtain.
• Floor is flat and level.
• If necessary install a sub-frame to ensure
secure, flush and level fixing (Recommended
minimum 70 X 70 PAR).
!CHECK!
RECOMMENDED FIXINGS (NOT SUPPLIED)
12 x 2.5” coach screws for wood and coach screws and
plugs for Masonry.
12 x 1” self tapping screws for steel.
TOOLS REQUIRED FOR INSTALLATION

6
THE PACKED DOOR
The door curtain will be fully packaged when
delivered. The headplates will be factory fitted to
the box and will have the curtain packed and rolled
inside.
1. The door box, endplates and curtain.
2. The barrel, guides and handcrank
Two packages.
Box, curtain, guides, barrel, override crank, control box
and instructions unwrapped and ready for installation
INCLUDES:
• Somfy Control Box
• Override label
• Power Cord
• LED Bulb
• 2 x Keygo Transmitters
• Guide Bungs
• Information Label for
Fixing to the Guide
• Cable Grip
• Screws for Mounting
Board

7
THE COMPONENTS
1
3
5
5
7
6
8
9
12
10
14 13
15
16
11
2
1. Somfy Control box
2. Crank handle.
3. Knuckle override.
4. End plate fixing nuts and bolts and guide
fixing hole bungs (in shrink wrapped pack,
attached to barrel).
5. Guide Rails 66mm with brush inserts fitted.
6. Curtain running guide inserts.
7. Curtain with bottom slat, factory fitted
wired safety edge/spiral cable and direct
connect locking straps connectors.
8. Curtain endlocks.
9. Left hand endplate.
10. Right hand end plate.
11. Barrel assembly with auto locks and motor.
12. Motor end.
13. Dummy end.
14. 90º half box - pre-fitted to end plates
15. Optional 45º full box.
16. Monkey fur
Lock strap bolts, motor headplate mounting bolts and knuckle
override and fixings pack is wrapped onto the barrel (8 bolts,
8 nuts and washers for headplate on standard ThermaRoll 77
300mm box and 4 fixings for the knuckle override).
3
4
4

8
SETTING OUT YOUR INSTALLATION
FULL BOX & HALF BOX
Your door has been supplied with either an optional Full or standard Half box pre-assembled to the
endplate - your overall size is pre-set.
Put cardboard protection down first. Place box on the floor against the opening where the door is to be
fitted, ensure overlap is equal on each side and mark a plumb line ‘A’ up each wall at the outside edge of
the box.
This is your outside edge of guide mark.
Fit base of
guide level
with the highest
point of the
floor surface
DO NOT fit
guide in recess
left by removal
of timber frame !
!
A
IMPORTANT – FLOOR IS FLAT AND LEVEL
!
Floor

Floor

GuideGuide
Guide
Gu
ide
Guide

9
GUIDE PREPARATION
The guides should be unpacked and placed either side of the opening. The guides are designed with spacing
lugs inside the box to ensure that the guide is a good fit to the head-plate. Ensure that the guides are the
correct way round. See Fig 1.
As a further aid to alignment the 25mm saw cut in the guide should be oriented as shown
GUIDE ORIENTATION
GUIDE FIXING HOLES
Face Fix Example
Reveal Fix Example
Spacing lugs
Left hand guide shown. The
spacing lugs ensure the head
plate is a flush fit against the
opening.
Inside
face
Spacing
lugs
Figure 1. Outside face (to wall)
25mm
saw cut
Splayed
guide
On 205mm head plate Drill 7mm fixing holes through the guide channel box section starting 100mm
from the bottom and space evenly thereafter, your last hole should be 100mm from the top of the guide.
Note which face of the guide is to be fitted to the wall (Spacing legs and or the saw cut away from fixing
wall). Now enlarge the fixing holes to 12mm* on the Inside face of the guide section to allow access to
the fixings and accept the hole cover grommets.
*Guides are supplied with black grommets – Drill 12mm hole.
To assist the smooth operation of the garage door a 25mm saw cut has been made at the top of both
guide sections on the internal face, and the guide should be splayed creating a funnel below the curtain
running guide insert.
Evenly spaced xing holes
Elevation 12mm Dia
100mm 100mm
15mm Long
Saw Cut
For 205mm box
Reveal
Fix Face Fix
Saw Cut
Fixing positions as illustrated right
can also be combined. You must
ensure both walls are parallel
before commencing installation.
Ensure the curtain running
guide inserts are located in
the top of each guide.

10
BARREL ASSEMBLY ATTACHMENT
Locate the 4mm rivet that is
wrapped to the barrel, used to
secure the non-drive end of the
barrel assembly.
Locate the barrel fixings wrapped to
the barrel along with the bungs for the
guide fixing holes, the knuckle override
and knuckle fixings.
Attach the motor
mounting plate
to the endplate
with the fixings
provided (nuts
bolts and
washers).
Ensure the
over-ride is at
the correct exit
angle - 45º.
Attach the non-drive end to the endplate by extending and pushing
the dummy end up tight to the endplate over the spigot. Ensure the
locking tabs push out when extending the dummy end to prevent this
retracting back into the barrel.
Attach the 4mm rivet to the
barrel to secure the dummy end
in position.
1
23
The axle can be assembled on the floor before
lifting the guides and head plates into position.
!
Correct motor position
45° over-ride position
for Somfy
1

11
FIXING THE DOOR GUIDES & HEAD PLATES
Slide the peg on the head plate into the box
channel of the guide. Note: The lugs in the
channel help to ensure the head plate rests neatly
against the head and in the correct position - see
guide orientation section on page 9. Lift into
position against the opening.
Hold guides in place using quick clamps.
Check the level of the guides, both vertically
and horizontally. If the floor is not level it will be
necessary to pack the bottom of the guide on the
low side to ensure guides are horizontally level.
IMPORTANT: It is important that your floor is
level to achieve an effective seal and ensure
proper operation of safety edge over time. The
door cannot be fitted off level to compensate for
uneven floors.
Once guides are positioned correctly secure to the wall
with fasteners using a central fixing hole. Check levels
again and when guides are level both vertically and
horizontally, secure to wall using appropriate fixings in the
remaining fixing holes.
Note: Do not over tighten to compensate for irregularities
in the wall – instead pack wall where necessary.
Secure the head plate to the wall using appropriate fixings
through the pre-drilled fixing holes. Additional fixings may
be required depending on the structural integrity!
MONKEY FUR PLACEMENT
The 90º box is being fitted it will be necessary to secure
to the head to prevent any marking of the door curtain
while in operation. Ensure any fixing used is countersunk
and that screw heads do not protrude to avoid damage
to door curtain. You have the option to fit the supplied
monkey fur at this point to cover the screw heads. Please
Note: The primary function of the monkey fur is to protect
the door curtain from the screw heads. It may also aid
draught proofing but this is not its primary function. The
monkey fur may lead to curtain marking over time, this is
not considered warranty.
ENSURE FIXINGS ARE SUITABLE FOR
THE GARAGE WALL BUILD PROPERTIES
The axle can be assembled on the floor
before lifting the guides and head plates into
position.
3
3
Opening
!
!
PREPARING THE HEAD PLATES
Head plates will be pre-drilled with 1 x fixing hole each. Head
plate will require 2 x fixings to secure via the reinforced tabs.
Use appropriate fixings to secure the head plates to the wall.
Plate peg
Fit base of guide level with
the highest point of the
floor surface
DO NOT fit guide in
recess left by removal of
timber frame
IMPORTANT –
FLOOR IS FLAT
AND LEVEL
!
Floor

Floor

ed
war
GuideGuide
Guide
Guide
Guide

12
INSTALLING THE MANUAL OVERRIDE
Correct motor position 45°
over-ride position for Somfy
ATTACH THE CORRECT MANUAL OVERRIDE CRANKING DIRECTIONAL ARROW LABELS TO
THE 45 DEGREE BOX OR DOOR GUIDE (IF HALF BOX FITTED).
!
INSTALLATION OF CURTAIN INTO GUIDES AND FITTING OF STOPS
1.Cover the barrel and rings with the protective bubble wrap from
the curtain.
2.Lift coiled curtain up level with axle (requires 2 people) and feed
the safety edge terminal block over the barrel, then feed the
bottom of the curtain over the barrel into guide.
3.Slowly unroll curtain and gently lower down to floor. NB Do not
allow the curtain to free fall over the axle as this will result in
damage to the curtain.
When you are ready to install the 45º box you will need to mark and notch out the endplate, then drill a hole
through the box to allow insertion of the knuckle override shaft to locate into the motor.
Secure the knuckle to the box with the fixings provided.
If a 45º box is not
fitted, secure the
knuckle to the
endplate flange.
Drill the box Secure the Knuckle Notch the endplate

13
INSTALLATION AND CONNECTION OF BOARD
Rollixo RTS control panel
nRemove the
courtesy light
cover.
No. Description
1Up button
2Stop button
3Down button
4Prog button
5Prog LED
6Motor & safety brake LED
7Safety edge LED
8Battery LED
9Photocell LED
3 421
Prog
STOP
Mounting the Rollixo RTS
oUnscrew
and remove the
panel cover.
pMark the
wall drilling
positions.
qSecure the
Rollixo RTS in
place.
o.
n.
p.
q.
r.
s.t.u.v.
nAlarm sounder
oPlug-in connectors for accessories
pPlug-in motor connector
qQuick plug-in mains supply cable
rCourtesy light
sLED diagnostic interface
- motor & safety brake
- safety edge
- photo-cells
- low battery
tFunctional mode setting
- standard operating mode
- auto time return mode
n
o
p
q
r
s
t
Mark the wall drilling
positions, set box aside
& drill 3 holes.
3

14
SOMFY ROLLIXO QUICK COMMISSIONING
Aditional steps must be taken to ensure the straight edge of the door meets with the straight
edge of a floor extending into the guides. Failure to do so will result in; air + light gaps, false
activations of the edge etc.
“Please refer to the Installer Guide
provided with every Rollixo, here
you will find the basic principles and
operating parameters for any CE
compliant safety edge system”
L1 L2N
M
1234
Bleu
Marron
Noir
Green/Yellow
Brown
Blue
Black
Somfy motor wiring
nConnect the motor wires into terminals 1, 2, 3
& 4 as illustrated above.
Note: The motor direction can be reversed during
the commissioning procedure.
oSecure the motor supply
cable in place with the
cable clamp.
✓✗
Additional steps must betaken to ensurethe straight edge of the door meets with the straight edge
of aoor extending into the guides, especiallywhen removing posts - holes must belled level with
the oor. Failureto do so will resultin; air + light gaps, false activations of the safety edge etc.
This quick guide provides basic installation and commissioning guidance based on the Somfy
Rollixo RTS controller and safety edge solutions. Refer to the main Rollixo RTS controller and
safety edge installation guides where more in-depth information relating to the installation
procedure of the Rollixo RTS system is required.
Rollixo RTS Solutions

15
SOMFY ROLLIXO QUICK COMMISSIONING
Sec
Safety EdgeStop
K
56 7 8 9 1
Sec
Safety EdgeStop
K
56 7 8 9 1
Safety brake
bmeh]j
oConnect the electrical safety brake
i i l 5&6
nUse the link provided to
connect terminals 5 & 6
OR
The safety brake jumper is pre-fitted to terminals
5 and 6.
Hard wired safety edge connection
Se c
SafetyEdgeStop
KeySwitch
5678910 11 1
Brown
Brown
Brown
White
White
White
Green
Green
Green
Dipswitch 4 receiver position
The cable connects via a
plug-in connector block,
(this comes pre-wired).
IMPORTANT! Make sure you connect the
pre-wired green terminal block before
bringing power to the control board.
Pre-wired block Control panel
connector
Push to fit Pre-wired block in place

16
SOMFY ROLLIXO QUICK COMMISSIONING
bmeh]j
nUnfold the aerial so
that it points verti-
cally downwards.
Powering up the Rollixo RTS
oScrew the bulb
supplied into the
light fitting.
3 421
Prog
STOP
pRefit the panel
cover and secure
with the screw.
rPlug in the supply cable and con-
nect the the mains supply.
qRefit the
courtesy light
cover.
1
2
If the motor LED comes on, check the
safety brake or link connection.
If the safety edge LED comes on, the safety
edge transmitter has not been recognised.
3 421
Prog
STOP
All the LED’s
come on briefly
and then go out.
If the safety edge LED comes on, this may
be due to plugging the terminal block in
after power was switched on. To restore,
switch power off and on

17
SOMFY ROLLIXO QUICK COMMISSIONING
Motor direction
nPress the motor limit buttons AFto
allow the motor to rotate during the
direction and limit setting procedure.
oAt the same time press and hold the UP & DOWN buttons on the control panel until the door
moves mh AND \gof, then release the buttons – the controller is now in
‘motor adjustment mode’, the motor LED light will flash slowly.
pPress and hold the UP button to check the motor
direction
If the motor direction is correct, move on to page
*(.
If the motor direction is incorrect, press and hold
the STOP button until the door jogs up and down >
the direction has been reversed > check again and
move on to page *(.
3 421
Prog
STOP
Correct direc-
tion of rotation
Incorrect direc-
tion of rotation
3 421
Prog
STOP
3 421
Prog
STOP
3 421
Prog
STOP
Buttons Out Buttons In
Remove yellow top limit switch
cover. Press the motor limit
buttons IN to allow the motor to
rotate during the direction and
limit setting procedure.
Press and hold the UP & DOWN buttons on the control panel until the barrel
jogs up AND down, then release the buttons - the controller is now in ‘motor adjustment
mode’, the motor LED light will flash slowly.
22 if correct direction.
BgfhmhkZ]cnlmf^gmfh]^%ma^Ni=hpg\hgmkhe[nmmhglZk^ahe]mhkng
mode - you must press and hold the respective button in to operate the door up and
down.
If the motor direction is correct, connect the
curtain as shown on the facing page.
If the motor direction is incorrect press and
hold the STOP button until the door jogs up
and down> the direction has been revered >
check again and connect the curtain as shown
on the facing page.

18
ATTACH CURTAIN TO AXLE
Align the autolock
and the top slat re-
enforcements.
The correctly
attached
Autolock &
curtain.
Slide the two
components together so
they interlock to secure.
Autolocks are
pre-installed to
the barrel.
Top Slat re-
enforcements
are pre-fitted to
the top slat.
Attach the Autolocks to the top slat re-enforcement 12
3

19
SOMFY ROLLIXO QUICK COMMISSIONING
Motor limit setting
During the limit setting procedure, the Rollixo push button controls are in HOLD TO RUN mode.
nMotor limit directions as shutter box projects towards you.
Left hand motor
installation
Right hand motor
installation
Yellow button
Open / Up
White button
Open /Up
White button
Close /Down
Yellow button
Close /Down
3 421
Prog
STOP
Prog
123 4
Press the motor ‘bottom limit’ button IN to
release out to set the ‘bottom limit’ posi-
tion (see diagrams to the right). Tocheck,
run the door up 200-300mm and returnto
check ‘bottom limit’ has been accepted.
Motor limit directions as viewed from back of door
Setting the top limit
Press and holdthe UP
button to move the door to
the top limit position (use
the UP & Down
buttons to ne tune the door
to the desired position).
Top limit Top limitBottom limit Bottom limit
Brieypress the PROG button until the
door jogs to complete the motor set up
procedure
The motor & safety brake LED goes out.
3
4
6
3 421
Prog
STOP
Fine tuning the bottom limit
Press and holdthe DOWN
button to move the door to the
desired ‘bottom limit’ position
(use the UP & Down
buttons to ne tune the door to
the desired position).
Press the ‘top limit’ button in, ensur-
ing the limit button is fullyout, to set
the ‘top limit’ position (see diagrams to
right). Tocheck, run the door down 200-
300mm and returnto check ‘top limit’
has been accepted.
2
5
Right hand motor
Right hand motor
Left hand motor
Left hand motor
IMPORTANT: at the top limit position the bottom lath should
be completely within the guide.

20
SOMFY ROLLIXO QUICK COMMISSIONING
Pairing Keygo RTS keyfob’s (supplied paired)
nPress the ‘Prog’ button on the Rollixo RTS front panel until the LED above the Prog button
lights up RED.
oPress the button on the Keygo RTS keyfob that you want to control the Rollixo RTS controller
with until the ‘Prog’ LED on the Rollixo RTS controller flashes and then goes out.
3 421
Prog
STOP
3 421
Prog
STOP
3 421
Prog
STOP
3 421
Prog
STOP
FITTING THE 45º COVER
The optional 45° cover is installed once
motor limit setting is complete. The 45°
box hooks into the 90° box along the join.
To fit the knuckle override, mark and notch
out the endplate, then drill a hole through
the box to allow insertion of the knuckle
override shaft to locate into the motor.
Fit the 45º box and fix in place using
self drilling screws supplied, locate the
override shaft into the motor and secure
the knuckle to the box with the fixings
provided.
If a 45º box is not fitted, secure the
knuckle to the endplate flanges.
e
If a 45º box is not
fitted, secure the
knuckle to the
endplate flange.
Drill the box Secure the KnuckleNotch the endplate