Rollerdor RD77 User manual

Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
Rollerdor RD77 Econ Roller Garage Doors
Installation Guide
Edition 2021/1

1
Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
CONTENTS
02 CHECKLIST & COMPONENTS
04 1. PREPARING SITE FOR INSTALLATION
05 2. HEADER ASSEMBLY CONSTRUCTION
07 3. PREPARING GUIDE RUNNERS FOR INSTALLATION
09 4. INSTALLING HEADER ASSEMBLY
10 5. INSTALLING (TYPE 2) RECEIVER BOX (HOLD TO RUN)
11 8. PROGRAMMING REMOTE CONTROL HANDSETS
AND PUSH BUTTON (HOLD TO RUN)
12 7. INSTALLING (TYPE 3) RECEIVER BOX (HOLD TO RUN)
13 8. PROGRAMMING REMOTE CONTROL HANDSETS (HOLD TO RUN)
14 9. SOMFY OPTICAL SAFETY EDGE (ROLLIXO RTS)
16 10. INSTALLING CURTAIN TO BARREL
18 11. INSTALLING CURTAIN TO BARREL (SOMFY ROLLIXO RTS ONLY)
20 12. SETTING MOTOR LIMITS (ALL HOLD TO RUN)
21 13. SETTING MOTOR LIMITS (SOMFY ROLLIXO RTS ONLY)
25 14. INSTALLATION OF BACK CASE
26 15. OPTIONAL EXTRAS
32 TROUBLESHOOTING

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
CHECKLIST & COMPONENTS
DOOR OVERVIEW
Please check all components for any
visible damage, if there is any please
contact your supplier.
1 Head Plate
2 Guides
3 Full Box
4 Tube End
5 Barrel
6 Security Straps
7 Curtain
8 Motor
9 Motor Plate
10 Guide Rail
11 Plastics Caps
12 End Lock
13 Base Rail
14 Safety Break
15 Handsets
16 Receiver Box and switches
(if any purchased)
EQUIPMENT REQUIRED
• 2 x Step ladders or hop ups
• Spirit level
• Tape measure
• Power drill
• 10mm A/F Spanner
• Pozi- screwdriver or drive bits
• 4mm, 7mm and 10mm Metal drill bit
• 7mm Masonry drill bit
• Hacksaw
• Small electrical screwdriver
• 4mm A/F Allen key
• Permanent Marker Pen
• Silicon Gun
• Silicon Sealer
• Rivet Gun
• 4mm Rivets
ROLLERDOR COMPONENT CHECKLIST
• Door Curtain.
• Barrel Assembly (Barrel, Tube End, Security Springs,
Security Collars).
• Head Plate with Motor Attached.
• Head Plate with Safety Break Attached.
• One Pair of Guide Runners.
• Control System with Two Remote Fobs.
• Fixings Kit (Qty 10: 5 x 50 screws 7mm brown rawl plugs, plastic
caps and Qty 1 plastic adjustment wand). Please note: fixings
supplied work on the majority of materials but if you know that
you require specialised fixing please replace with these.
10 11 12 13 7 16 15
1 14 2 3 4 5 6 7 8 9 1
Diagram 1

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
IMPORTANT SAFETY
INSTRUCTIONS
The RD77 must be installed
and operated in accordance
with the instructions supplied;
failure to do so could result
in damage to your door and
compromise your safety.
These fitting instructions are for guidance only, you should always assess your garage
construction for installation as each garage & opening has its own specific needs.
Please read these instructions carefully and in full before commencing the installation
of the roller garage door.
WARNING AND GUIDANCE NOTES
1 At least TWO people are required to install this
product.
2 Prior to installing please remove all rings,
watches and sharp objects to avoid any
possibility of damage.
3 Prior to installing please remove any items of
loose clothing to avoid any risk of entanglement
or injury.
4 Your door comes complete with a 3 pin plug as
standard (this is supplied and must be fitted
with a 13amp fuse) which should be plugged
straight into a 13amp 3 pin switched socket in
the vicinity of your door, should you need any
extra electrical work. This must be carried out
by a suitably qualified person, if you have
any doubts please consult an electrician.
5 Your receiver box should be installed in
a location that is at a comfortable height to
operate the push buttons, but out of the easy
reach of children.
6 Please do not allow children to operate the
push buttons or remote control fobs, as
serious injury can occur from misuse.
7 Warning: you must have a clear line of sight
of the whole of your roller garage door when
the door is in operation. Failure to do so may
result in harm to persons or damage to your
roller garage door.

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
1. PREPARING SITE FOR INSTALLATION
Drive Through
Width
Estimate Drive
Through Height
Total Door
Height to
Top of Box
Guide
Height
Total Door Width
Including Guides
1 Check all measurements
of your opening (fig.1.1) as
well as the measurements
of your new delivered
roller garage door against
your confirmation
(fig.1.2) to make sure
everything is correct.
2 Carefully remove your
old garage door and
frame if applicable.
3 Sweep down the sides
and lintel with a sti brush
and clear all debris.
4 Make sure the opening
is free from any raised
metal or brick work.
Plan Of here To Take The Measurements
RL
Aerial View Of Garage
Notes
Which Side Is The
Power Supply On? Right
4L
Power viewed from inside look
at back of garage door
4R
Opening Width
Opening Height
Headroom Height
mm
4
Side Room
R
4
Side Room
L
mm
mm
mm
mm
Requirements For The Opening & Taking Measurements
>
All measurements should be taken from
multiple places and the smallest size used.
>Please make us aware of any heating pipes, water pipes, ducts, electrical
cables or anything else that may impede the installation of your new door.
View From Inside Garage
Name:Address:
Tel:
Standard Back FixingIn-between Fixing Limited Fixing Back & Between Fixing
Roll Under Lintel Half & Half Roll Above Lintel
PLAN OF WHERE TO TAKE MEASUREMENTS
Name
Tel
Address
REQUIREMENTS FOR THE OPENING & TAKING MEASUREMENTS
Company Registration Number. 10676267
fig.1.1
fig.1.2

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
2. HEADER ASSEMBLY CONSTRUCTION
fig.2.1
fig.2.4
fig.2.5
fig.2.2
fig.2.3
1 On unpacking your door you will see that the
barrel has the motor in 1 end (fig.2.1) and the
adjustable bung end the other (fig.2.2).
2 If your header plates are separate from the casing
please drill though the ‘L’ shaped front case and
the flange on the header plate at each end, then
secure ‘L’ shaped front case to the flange with at
least 4 rivets (2 per face) (fig.2.3).
3 Remove screws from header plate (fig.2.4)
and keep them safe for later.
4 Round shape safety brake (fig.2.5): Loosen screw
at the end of adjustable bung end to allow it to slide.
Check the position of the safety brake to make sure
that the big silver allen key bolt is running parallel to
the shortest edge near the inlet wheel as in (fig 2.5).
Square shape safety brake (fig.2.6): Make sure
the cable is coming out of the top of the safety break
in line with the long flat side and the red curve on
the safety break (fig.2.10) is going from fat to thin
towards the front case. Loosen screw at the end of
adjustable bung end to allow it to slide.
5 (For IMO system) remove winding stem from your
winding handle where it has been taped securely
(fig.2.8.IMO). (For EMO system) remove metal
sha via the plastic circlet (fig.2.9.EMO).
6 Insert barrel assembly into casing, whilst one
person holds the motor end the other will extend
the adjustable tube end so that it goes all the
way into the safety break as far as possible
Round safety break (fig.2.11) Square safety
break (fig.2.12).

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
fig.2.6
fig.2.10
fig.2.12
fig.2.7
7 Remove the screw from the end of the
winding stem and insert the stem into
head of motor turn until both the wire is
facing towards the casing (downwards
so when installed into place later the
wire comes out of the top of the motor)
(fig.2.7) and the square plate of the
motor lines up for easy fitment into the
holder, remove winding stem and keep
safe for later then pull plate into place
and refit screws to fix motor plate.
8 The cable coming from the brake is a 2
core wire, needs to be connected to the 2
core extension wire via connection blocks
as follows; Brown to Brown and Blue
to Blue.
9 Drill a hole through the flange of the
header plate for the winding stem where
it lines up with the hole in the motor, then
reinsert the winding stem through the
hole and back into the motor securing in
place with the screw. Please check the
barrel is all the way to the motor head as
(fig.2.7) and then slide the locking collar
all the way up to the bung and tighten
into place (we advise using a thread lock
adhesive to hold in place) as (fig.2.11) or
(fig.2.12).
fig.2.9.EMOfig.2.8.IMO
fig.2.11
Front Case

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
3. PREPARING GUIDE RUNNERS
FOR INSTALLATION
1 We use 2 types of guide runners
whichever is supplied with your door
will be marked with the letter ‘F’ to
indicate the front, as seen in (fig.3.1
type 1) and (fig.3.1 type 2). This
marked face will fit against the wall
for a standard back fixing or face out
of the garage for a between fixing
(Diagram 1).
2 Measure from floor to lintel and refer to
(Diagram 2), checking the lintel is level.
Your guide runner will be oversized,
make sure you cut the guide runners
to size as needed using a hack saw,
for best results cut the end which will
be the bottom (fig.3.2).
3 Offer both cut guide runners up
against the walls they will be fixed
to and mark the fixing points, either
on the flat face for a behind fixing
(fig.3.3) or for a between fixing in
the opening (fig.3.4). For best
results these should be as follows;
A Top fixing between 50mm to
100mm down from the top of
the guide rail.
B Bottom fixing 50mm to
100mm up from the floor.
C Marking as many fixings as
necessary but must be at
least two extra fixings, spread
these evenly between the two
already marked points on
the guide runners so that you
have a secure fix.
D Drill a 7mm hole all the way
through each of the marks
on the guide runners and
then drill a 10mm hole to
countersink through the first
layer only so you can get the
screw head through.
fig.3.2
fig.3.4
fig.3.3
(fig.3.1 type 1)
Front Face
(fig.3.1 type 2)
Front Face

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
Standard Back Fixing:
This means that the guide runners go on the back of the pillars, inside the
garage. It will leave you with your desired width of the door. You would
need a minimum of 65mm each side for the RD55 and 95mm for the RD77.
In Between Fixing:
With this the guide runners will be fitted between the walls and visible
from the outside.
Diagram 1
LINTEL
ROOF OR
JOISTS
GUIDE
RUNNER GUIDE
RUNNER GUIDE
RUNNER
TOP
ROLL
TOP
ROLL
TOP
ROLL
LINTEL LINTEL
ROOF OR
JOISTS
Behind lintel fixing’ 3Limited opening fixing 2Below lintel fixing 1
300
MM
< >
300
MM
< >
300
MM
< >
ROOF OR
JOISTS
123
FIXING OPTIONS
Below Lintel Fixing:
Cut guide runners to measured height less 310 mm.
Limited Opening Fixing:
Measure from floor to highest point, deduct 310 mm and cut guide runners to size.
Behind Lintel Fixing:
Cut guide runners to measured height.
Diagram 2

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Rollerdor RD77 Econ Roller Garage Door, Edition 2021/1
4. INSTALLING HEADER ASSEMBLY
1 Place your hop ups / step ladders
and one guide runner each side of
the opening.
2 With one person each end, lift the
header assembly by the header plate
up and then guide the locating stem
at each end into the hollow section
of guide runners (this can be made
easier by slightly angling the header
if there is not enough room to simply
drop the locating stem in) (fig.4.1)
making sure to insert the stem fully
into the guide runner (fig.4.6).
3 Lift the whole unit flush into place
and check that the top box and guide
runners are plumb level and square
(fig.4.2 & fig.4.3).
4 Drill a 7mm fixing through the top
hole in the guide runners and secure
into place (fig.4.4).
5 Check the case and guide runners are
still level and square, then proceed
to drill a 7mm fixing through the
remaining holes, remembering to
check the guide runners are square
and plumb aer each fixing.
6 Once the guide runners are fixed you
will need to secure the top box with
2 fixings each side. This is best done
by drilling through the end flanges of
the header plate for a behind fix, or
sideways through the header plate
itself if a between fixing (fig.4.5),
PLEASE NOTE: The large cut outs in
header plate are only for use with
larger fixings e.g. shield anchor or
coach screw.
7 Check to make sure all fixings have
not caused the front fascia to be
pulled in, as this will rub against the
slats causing damage and scratching
to the face.
fig.4.5
fig.4.1 fig.4.2
fig.4.3 fig.4.4
fig.4.6