tousek Rollco LWA 115/1A User manual

Installation and operating instructions
Aluminium cantilever system
Rollco®LWA 115/1A

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Important warning and safety notes for installation and operation
• These installation- and operating instructions form an integral part of the product “cantilever system”. They have been specically written for
professional installers trained and skilled in the trade and should be carefully read in their full length before carrying out the installation. After the
installation this manual has to be handed over to the user.
• Installation, connection, adjustments, putting into operation, and servicing may only be carried out by trained professionals in full accordance with
these installation- and operating instructions. Faulty assembling can cause severe injury and material damage.
• The EU Machine Directive, laws and rules concerning the prevention of accidents, and laws and standards which are in force in the EU and in the
individual countries have to be strictly followed.
• The TOUSEK Ges.m.b.H. cannot be held liable for any claims resulting from disregards of the laws and standards in force during the installation
and operation.
• The product may only be used in accordance with its original purpose, for which it has been exclusively designed, and which is described in these
installation and operating instructions. The TOUSEK Ges.m.b.H. rejects any liability if the product is used in any way not fully conforming to its
original purpose as stated herein.
• The packaging materials (cardboard, plastic, EPS foam parts and lling material etc.) have to be properly disposed of in accordance with the
applying recycling- and environmental procection laws. They may be hazardous to children and therefore have to be stored out of children´s reach.
• Before beginning with the installation the installer has to make sure that all mechanical components of the gate facility, like carrier prole/rail, gate
frame and panels, guiding elements etc. are sufciently supportive and resistant for the purpose of gate automation. Check also whether the
product has transport damages.
• After installation the proper function of the gate facility has to be checked!
• Place warning signs and notes of the valid regulations to indicate danger areas
• Children have to be instructed, that the gate facility as well as the belonging parts may not be used improperly, e.g.
playing.
• Only original spare- and replacement parts may be used for repair of the product.
• The TOUSEK Ges.m.b.H. rejects any liability for claims resulting from usage of the product in combination with components or devices which do
not fully conform to the applying safety laws and rules.
• The installer has to supply to the user all instructions relating to the safe operation of the gate facility.
The installation and operating instructions also have to be handed over to the user.
• For perfect function and avoiding damages at the cantilever system, the following planning- and processing
rules have to be strictly followed!
Maintenance
According to the frequency of actuation, but at least once a year, we recommend to carry out the following
maintenance works:
• Check if the rolling gears are standing in-line.
• Check if the gate is smooth running without jamming.
• Check the upper gate guiding.
• Check the assembly screws.
• Check if the door runs correctly into the guide-in bracket resp. guide-in fork bracket.
• Clean the inside of the prole.
This manual is the sole property of the TOUSEK Ges.m.b.H. and may not be made available to competitors. All rights reserved. No part of it may be reproduced without our prior
written permission. We will not accept liability for any claims resulting from misprints or errors. This edition of the manual replaces all earlier publications of the same.
ATTENTION: blocking of the gate (see page 9) !
• Firmly bolted mechanical stops prevent the running of the sliding gate on the rolling gears, when in OPEN or
CLOSED position!
• Examples of xed limit stops as safety devices:
(1) Guide-in bracket, (2) counter pillar

tousek / E_LWA-115/1A_40800708 / 29. 10. 2018 - 3 -
1b
2b
3
4b
4a
2a
1a
9
3
5b
5a 6
7b
7a
73 mm
336 mm
150 mm
8
10
11
12
1. General Aluminium cantilever system Rollco®LWA 115/1A
General features
The aluminum-track Rollco® LWS 115 with hollow chamber design is the perfect system for
cantilever gates. The integrated for plastic gear rack, limit stop and hammer head bolts (for gate
frame installation) guarantee an easy mouting. Modern, cantilever gate constructions have the
big advantage that they can glide over any ground uneveness. The rolling gear with ball bearing
polyamide rollers ensures an optimal drive guidance. The adjusting bolts on the rolling gears are
for avoiding a tilt effect when there are changes of alternation of load during gate movement.
Characteristics
• aluminium prole in hollow-chamber design with
integrated guiding for plastic gear rack and limit switch
• cantilever prole in two different stock lengths
• olling gears of galvanized steel with ball-bearing
polyamide-rollers
• smooth running and easy assembly
• optimal for use with gate operators of PULL series
• corrosion-resistant - natural aluminium
• gate frame without drilling on track
• load weight up to 40kg/m, gate cycles: max. 50/day,
weight: approx.. 5kg/m
•
(1a) front end plate with lateral
plastic guidings
(1b) back end plate
(2a) front seal (V)
(2b) back seal (H)
(3) clamping (for gear rack)
(4a) front limit stop with rubber
bumper and support roller
(4b) back limit stop with
rubber bumper
(5a) T-head bolts single
(5b) T-head bolts double
(6) prole
(7a/b) front/back rolling gear
and mounting plate in
stainless steel
(8) rolling gear cover
(9) guide-in bracket
134
70
108
189,5
105
0–12 3140
87,5–99,5
10
11
12
6
7
(10) opening for T-head bolts for
connection with the gate frame
(11) guiding for limit switches
(12) guiding for plastic gear rack
CLOSING direction
Technical data
Aluminium cantilever system Rollco®LWA 115/1A Art.Nr.
Aluminium proles load capacity: 40kg/m, weight: ca. 5kg/m, frequency of actuation: 50 cycles/day
for max. DL 3.000mm ± 10mm 4.300mm prole length ± 10mm natural aluminium 14630200
for max. DL 4.300mm ± 10mm 6.000mm prole length ± 10mm natural aluminium 14630020
for max. DL 5.800mm ± 10mm 8.000mm prole length ± 10mm natural aluminium 14630030
Rolling gear LWA 115/1A 2 units necessary!, made of galvanised steel (adjustable in height and inclination)
with polyamide rollers, incl. covers for rolling gear 14630080
optional accessories
INOX mounting plate, heavy-lift anchor, motor mounting plate for tousek sliding gate operators, end plates (aluminium), limit
stops with and without support rollers, guide-in bracket (aluminium), guide bracket (stainless steel), turnbuckle (stainless
steel), guide-in fork bracket (stainless steel), T-head bolts (stainless steel), gear rack (plastic)
ATTENTION: The assembly of cantilever system and gate may only be carried out by trained and qualied
professionals. For perfect function and avoiding damages at the cantilever system, the following planning- and
processing rules have to be strictly followed!

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Important
• The max. loading may not be higher as shown in the table (page 5)
• The cantilever prole is made of aluminium AlmgSi 0,5 according
to DIN 1725.
• The surface of the prole is alu-nature. If it is powder coated or painted, please take care that the prole is
covered (see Aabove drawing) in the area of the running surfaces LF as well as the guidance for the plastic
gear rack 12 .
• The gate frame may not be welded onto the cantilever prole. Screw joints have to be used.
• When using different materials (e.g. steel gate frame), an anti-corrosion contact tape has to be inserted between
gateframe and cantilever system.
• The gate frame may not show any distortion.
• Recommended dimensions for aluminium gate frame: steel prole 80/60/2,5 mm, on edge. Starting from a clearance
width of 3 m, an additional vertical tie SS has to be set in the gate frame. Furthermore we recommend to insert
diagonal ties DS .
These values are only standard values, the gate frame has to be designed according to the static requirements.
• In the area of the support length, a diagonal tie ZS has to be set in. From 5000mm DL on, this tie has to be adjustable.
Therefore a turnbuckle designed for gate ties 60/60/3 is available.
• Load through wind: The calculation of the cantilever system is based on a gate with bars or lattice.
No wind-impermeable materials may be used as gate-lling.
• For relieving the gate, a support roller and a guide-in bracket have to be mounted in position gate CLOSED.
• For the upper gate guiding, a guide bracket with rollers and a guide-in fork bracket have to be foreseen in gate
position CLOSED.
• The rolling gears have to be mounted in-line and perpendicular.
• The measurements of the foundation are only standard values. The foundation always has to be adjusted to
the structure of the ground. It should consist of concrete quality C20/25 at ground class 3. The foundation has
to be horizontal and free of cracks. A reinforcement (armour iron) may only be carried out from 200 mm upper
concrete edge (heavy-lift dowels).
• These technical notes are only valid for horizontally running gates.
ATTENTION: blocking of the gate (see page 9) !
• Firmly bolted mechanical stops prevent the running of the sliding gate on the rolling gears, when in OPEN or
CLOSED position (see page 9) !
Taking into operation
After installation and before taking into operation, the following points have to be carried out:
• Clean the inside of the cantilever prole (remove possibly existing dirt)
• Check if the gate is smooth running without jamming.
Maintenance
According to the frequency of actuation, but at least once a year, we recommend to carry out the following
maintenance works:
• Check if the rolling gears are standing in-line.
• Check if the gate is smooth running without jamming.
• Check the upper gate guiding.
• Check the assembly screws.
• Check if the door runs correctly into the guide-in bracket resp. guide-in fork bracket.
• Clean the inside of the prole.
80 2,5
60
(ZS) hinged tie bar
(DS) diagonal tie
(SS) vertical tie
ZS DS SS DS
LF
A
12

tousek / E_LWA-115/1A_40800708 / 29. 10. 2018 - 5 -
120140
126
145
189,5
0–12
3
6
(6) prole
(7) rolling gears
(9) guide-in bracket
(13) turnbuckle
(14) guide bracket
(15) guide-in fork bracket
(ZS) diagonal tie bar
(DS) diagonal tie
(SS) vertical tie
Rollco® LWA115/1A and
sliding gate operator PULL T
clearance width DL
overall length L
INTERIOR
110 mind. = 1) min. distance between foundation edge and rail axis
center of cantilever system
dimensions in mm
275
800 min.
275
ca. 90
13
15
14
ZS DS DS
7
9
450
= =
116,5
32
265
SS
6
Mounting plate sliding gate operator:
center of cantilever system
min. 1101)
mounting plate
guidance of gear rack
foundation
Ø12,5
350
380
116,5
120
85 55
273
M10
32
2. Mounting Aluminium cantilever system Rollco®LWA 115/1A
Dimensions Rollco®LWA 115 dimensions in mm
DL prole length Em max. load
3000 4300 750 40kg/m
3500 4900 850 40kg/m
4000 5600 1050 40kg/m
4300 6000 1150 40kg/m
4500 6250 1200 35kg/m
5000 6900 1350 35kg/m
5500 7550 1500 30kg/m
5800 8000 1650 30kg/m
NOTE: overall length L = prole length + 6mm
The cantilever prole Rollco®LWA 115 is available in
stock length 4.300, 6.000 and 8.000mm. Lengths in
between these measurements have to be shortened.
Foundation- and assembly plan
Em
support length

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50mm
97mm
Important
• the cantilever track and gate frame have to be connected together in a stable way!
Version: T-head bolts
Version: Through bolts
2a. Mounting gate frame on Rollco®LWA 115/1A Mounting
Examples for mounting the gate frame on Rollco®LWA 115/1A
(6) prole
(TR) gate frame
• Recommended dimensions for aluminium gate frame: steel prole 80/60/2,5mm, on edge.
• In the area of the support length the gate frame should be furthermore equipped with a diagonal
tie, and for an overall length of 5 m and more, a turnbuckle has to be foreseen.
• Starting from a clearance width DL of 3 m, the gate frame should at least be parted in 2 sections
and equipped with diagonal ties. Further important notes (see page 4).
• These values are only standard values, the gate frame has to be designed according to the static
requirements.
• The gate frame is xed with T-head bolts, at the ends of the gate frame the double T-head bolts
are inserted.
• The xation of the ends should be carried out as far on the ends of the gate frame as possible.
• The gate frame should generally be xed in distances of max. 500 mm.
80 2,5
60
distance Ø15/2
welded-in
M10
The gate frame is screwed every 500 mm, at the ends of the frame the double
T-head bolts are used, everywhere else the single ones.
T-head bolts (M10, single
and double) are inserted
in the foreseen guiding at
the prole.
TR
500mm 500mm500mm
6
TR
6
distance Ø15/2
welded-in
M10
14,5
max. 12
Allen srews
TR
6
screwed all 500mm

tousek / E_LWA-115/1A_40800708 / 29. 10. 2018 - 7 -
2b. Mounting the rolling gears Mounting
• Put the rolling gears on the ground plates in line with the
thought gate axis. The support length “Em” may not be
lower than given in the table (see page 5).
• The adjusting bolts of both rollers (JS) have to show into
direction of clearance width.
Important
• The support length “Em” may not be lower than
given in the table (see page 5).
• Note the true sided arrangement of the rolling gears
(see illustrations)
45
Install rollers wiht adjusting bolts JS showing
into direction of clearance width.
• Now it has to made sure, that both rolling gears are standing
in line (e.g. by applying an aluminium lath).
• Now bore the holes, blow them out
and drive in the heavy-duty anchors.
Do exclusively use the supplied heavy-
duty anchors!
Anchor M12-50/145 (M12 X 145)
bore hole depth Ø hole nut torque
100mm 12mm 50Nm
• Before fastening the rolling gears please check with the help
of a water level, if they are standing horizontally.
Eventually re-adjust them with the adjusting screws (S).
• Now the cantilever prole with the mounted gate frame is
put on the rolling gears
Arrangement at LEFT installation Arrangement at RIGHT installation
JSJS
clearance
width DL
JS JS
clearance
width DL
(7) rolling gear
(7G) mounting plate
7G
7
aluminium lath
guide-in bracket
gate axis
Em
Em
275 275
JS JS
DL
S S

- 8 - tousek / E_LWA-115/1A_40800708 / 29. 10. 2018
A B
LEFT installa-
tion
JS JS
• When the cantilever system has been adjusted with the
bolts of the rolling gears, the front and back limit stops are
inserted in the prole and xed with xing disks/-bolts (F).
• Therefore it has to be taken care, that the front limit stop
(4a)– opposed to the back limit stop (4b) – has a support
roller.
• Both limit stops have to be inserted in the prole in the way,
that the rubber bumpers show in direction of the rolling
gears.
Vertical adjustment of the rolling gears
ADrive gate in positon CLOSED and with adjusting bolt (JS) put up the indicated roller of the rear rolling gear as much as
possible so that it can be moved by hand - then tighten counter nut of adjusting bolt again.
BDrive gate in position OPEN and with adjusting bolt (JS) put up the indicated roller of the front rolling gear as much as
possible so that it can be moved by hand - then tighten counter nut of adjusting bolt again.
2c. Assembly of limit stops Mounting
BA
RIGHT installa-
tion
JS JS
F
4a
4b
F
guide-in bracket
CLOSING direction

tousek / E_LWA-115/1A_40800708 / 29. 10. 2018 - 9 -
2d. Assembly of the end plates Mounting
Important
• The front end plate (1a) must be mounted with the
enclosed seal (V) and the back end plate (1b) with
the seal (H) !
• After xing the front and back limit stop at the prole, the two
endplates are set with seals on the ends of the prole and
xed with 4 screws each. At the assembly of the end plates
it has to be taken care, that they are executed in different
ways. The front end plate (1a) has two plastic guidings at
the sides and has to be mounted at the side of the prole,
which is running into the guide-in bracket.
1a
1b
H V
H
ATTENTION: blocking of the gate
• Firmly bolted mechanical stops prevent the running of the sliding gate on the rolling gears,
when in OPEN or CLOSED position! see page 8, point 2c
• Examples of xed limit stops as safety devices: (1) Guide-in bracket, (2) counter pillar
rolling gear
rolling gear
2
1
1 1
1
2
1

- 10 - tousek / E_LWA-115/1A_40800708 / 29. 10. 2018
2f. Mounting the rolling gear covers Mounting
• When installation of the cantilever system is nished put
both parts of the covers on each rolling gear, one from the
left and the other from the right, and push them together.
Z
3
3
• The plastic gear racks (Z) (parts of 49 cm length) have to
be sequentially lead in the foreseen guiding at the prole.
• It has to be taken care that they touch each other without
gaps.
• The two clampings (3) serve as xation of the gear rack,
they are also lead in the guiding for the gear rack at both
ends of the prole and xed with screws.
Attention
• If a guide-in bracket (9) is used, the front clamping
has to be mounted with at least 125 mm distance
to the prole end, to make sure that the prole runs
properly in the guide-in bracket !
2e. Mounting the gear rack Mounting
125mm
Z
9

tousek / E_LWA-115/1A_40800708 / 29. 10. 2018 - 11 -
77 53,5 max.
132 max.
rolling gear Rollco®LWA 115/1A
limit stop
Rollco®LWA 115/1A
limit stop with
support roller
Rollco®LWA 115/1A
C-prole
Rollco®LWA 115/1A
guide-in bracket
Rollco®LWA 115/1A
20
25
Ø35
77
30
Ø77
82,5
103,5
145
96,5
85
5
120
Prole length:
6.000mm ± 10mm
8.000mm ± 10mm
105
70
134
108
14,5
3. Dimensioned drawing Aluminium cantilever system Rollco®LWA 115/1A
We reserve the right to change dimensions and
technical specifications without prior notice.
(dimensions in mm)
244
175
12
0–12
3
270
140
220
240
100
25
M10
Ø79
Ø77
25
50
14
25

your service partner:
Tousek Ges.m.b.H. Austria
A-1230 Vienna
Zetschegasse 1
Tel. [phone]
Fax [phone]
[email protected]
Tousek GmbH Germany
D-83395 Freilassing
Traunsteiner Straße 12
Tel. [phone]
Fax [phone]
[email protected]
Tousek Benelux NV
BE-3930 Hamont - Achel
Buitenheide 2A/ 1
Tel. [phone]
Fax [phone]
[email protected]
Tousek Sp. z o.o. Poland
PL 43-190 Mikołów (k/Katowic)
Gliwicka 67
Tel. [phone]
Fax [phone]
[email protected]
Tousek s.r.o. Czech Republic
CZ-130 00 Praha 3
Jagellonská 9
Tel. [phone]
Fax [phone]
[email protected]
We reserve the right to change dimensions and/or technical specications with-
out prior notice. Claims resulting from misprints or errors cannot be accepted.
tousek PRODUCTS
• sliding gate operators
• cantilever systems
• swing gate operators
• garage door operators
• folding door operators
• trac barriers
• electronic controls
• radio remote controls
• key operated switches
• access control
• safety devices
• accessories
tousek
E_LWA-115/1A_40800708
29. 10. 2018