Allstar Products Group AC9500, AC9300, ACJ9500 User Manual
110060
BY
CHALLENGER AC9000 SERIES
Residential Vehicular Garage Door Operator
MODEL NUMBERS AC9300, AC9500, and ACJ9500
INSTALLATION AND OWNER’S MANUAL
INSTALLER: Place this manual in the plastic envelope provided and permanently
attach to the wall near the pushbutton.
110044
As of date of manufacture,
meets all ANSI/UL 325
Safety Requirements for
Vehicular Garage Door
Operators
Serial #:
Date Installed:
Your Dealer:
READ THIS MANUAL
READ THIS MANUAL
READ THIS MANUAL READ THIS MANUAL
CAREFULLY BEFORE
CAREFULLY BEFORE
CAREFULLY BEFORE CAREFULLY BEFORE
INSTALLATION OR USE
INSTALLATION OR USE
INSTALLATION OR USEINSTALLATION OR USE
SAVE THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONSSAVE THESE INSTRUCTIONS
1
TABLE OF CONTENTS
Product Features ................................................... 3
Component Identification/Tools Required ........... 4
Section A: Assembly Instructions ....................... 5
Section B: Important Installation Instructions .... 6
Section C: Installing the Operator ....................... 7
Identify Your Door Type .................................... 7
Mounting the Front Bracket .............................. 8
Mounting the Power Head ................................. 9
Door Bracket Installation .................................. 9
Door Arm Installation ...................................... 10
Connecting Electrical Power .......................... 11
The Convenience Lamp .................................. 11
Section D: Control & Auxiliary Equipment ......... 12
Standard Wall Button Installation ................... 12
Safe Finish™ Photosystem Installation ......... 13
Radio Control Installation ............................... 13
Section E: Operation & Adjustments .................. 15
Important Safety Instructions ........................ 15
Turning on the Power ...................................... 15
Basic Operating Parameters ...........................15
How To Activate The Opener ...........................15
How the Door Moves When Activated ............16
How the Light Works ......................................16
How To Operate The Door Manually ...............16
Adjustments .....................................................17
Opening Travel Adjustments ...........................17
Open & Closing Force Adjustment .................17
Setting The Close Limit ...................................18
Obstruction Sensing Adjustment ....................18
Testing The Obstruction Sensing ...................18
Photoelectric Obstruction Test .......................19
Positive Mechanical Lock Adjustment ...........19
Resetting The Travel Timer Adjustment .........19
Safe Finish Wiring Diagram .................................20
Maintenance Schedule .........................................20
Installation Checklist ............................................21
Troubleshooting Guide ........................................22
Parts Breakdown and Listing ..............................23
Warranty Information ..........................................24
READ THESE STATEMENTS CAREFULLY AND FOLLOW THE
The Warning and Caution boxes throughout this manual are there to protect you and
your equipment. Pay close attention to these boxes as you follow the manual.
WARNING
WARNING
WARNINGWARNING
Indicates a MECHANICAL
hazard of INJURY OR
DEATH. Gives instructions
to avoid the hazard.
INSTRUCTIONS CLOSELY.
CAUTION
CAUTION
CAUTIONCAUTION
Indicates a MECHANICAL hazard
of DAMAGE to your door, door
operator, or equipment. Gives
instructions to avoid the hazard.
WARNING
WARNING
WARNINGWARNING
Indicates an ELECTRICAL
hazard of INJURY OR
DEATH. Gives instructions
to avoid the hazard.
2
CAUTION
CAUTION
CAUTIONCAUTION
Indicates an ELECTRICAL hazard
of DAMAGE to your door, door
operator, or equipment. Gives
instructions to avoid the hazard.
PRODUCT FEATURES
The purpose of this booklet is to provide assembly,
installation and operation information concerning the
Challenger AC9000 Series (Models AC9300, AC9500, and
ACJ9500) Residential Garage Door Openers and related
Accessory Products.
NOTICE
IT IS IMPORTANT THAT THIS INSTRUCTION
MANUAL BE READ AND UNDERSTOOD
COMPLETELY BEFORE INSTALLATION OR
OPERATION IS ATTEMPTED.
NOTICE
THE IMPORTANT SAFEGUARDS AND
INSTRUCTIONS IN THIS MANUAL CANNOT
COVER ALL POSSIBLE CONDITIONS AND
SITUATIONS WHICH MAY OCCUR DURING ITS
USE. IT MUST BE UNDERSTOOD THAT
COMMON SENSE AND CAUTION MUST BE
EXERCISED BY THE PERSON(S) INSTALLING,
MAINTAINING AND OPERATING THE
EQUIPMENT DESCRIBED HEREIN. DO NOT
USE THIS EQUIPMENT FOR ANY OTHER THAN
ITS INTENDED PURPOSE - OPERATING
OVERHEAD GARAGE DOORS.
STANDARD FEATURES:
Safe Finish™ Photosystem: An invisible infrared beam of
light guards the door opening and reverses a downward moving
door if the beam is broken by a stationary or moving object.
The AC9000 Series motor control circuitry constantly monitors
the Safe Finish Photosystem for proper operation.
Manual Release: A pull cord allows separation of the drive
mechanism and manual operation of the door when desired, as
in the event of a power failure. (Page 16)
Automatic Reconnection: Once power is restored, or
automatic operation of the door is again desired, initiating
operation in the normal manner (Push Button, Radio Control,
etc.) will effect automatic reconnection of the Manual Release
Mechanism. (Page 16)
Alternating Action Operation: The mechanical wall
pushbutton functions in an Open/Stop/Close/Stop mode in
normal operation. (Page 16)
Sensing System: A built-in sensing system detects
obstructions during door operation. If in the downward
(close) travel mode, the Opener will sense an obstruction
and reverse the direction of the door. In the open mode,
the Opener will stop. Since all doors are different, the
Sensing System has independent adjustments for
customizing the level of force required for the normal
opening and closing of specified doors. ( Page 18)
Close Limit Switch: In winter months it's common
for small pieces of ice or packed snow to be trapped
under the door. Ground swelling can also effect the
close limit setting of the Opener. The AC9000 Series
Close Limit Switch overrides the Sensing System during
the last one inch of closing travel and prevents the door
from reversing if it encounters an obstruction at this
point.
Constant Contact To Close: For utmost safety and
security, the standard operation mode requires constant
contact on the mechanical Push Button to close the door
if the Safe Finish™ Photosystem becomes misaligned
or if there is an irregularity in the wiring to the device.
In this mode of operation, a Radio Transmitter cannot be
used to close the door. (Page 19)
OPTIONAL FEATURES:
Digital Radio Controls: The AC9000 Series
Openers covered in this Manual can be fitted with
Allstar’s optional Radio Controls. Up to 19,683 private
codes can be easily selected without use of tools.
(PageZ14)
Super Station Deluxe Wall Push Button: A
feature-packed accessory unit, the Deluxe Wall Station
allows access to all of the Opener's functions. Open/
Close button permits full control of the door’s operation.
The Opener's built-in light can be turned on or off
independent of door operation. A Security Switch
allows the Opener to be deactivated for extended periods
of time. (Page 12)
Keyless Entry System: A tamper resistant outdoor
keypad, the optional Keyless Entry System permits entry
to the garage without use of key or radio transmitter.
Easily programmable, it accommodates four separate
access codes of 4 digits. Lighted Buttons enhance
nighttime use.
110044
BY
3
COMPONENT IDENTIFICATION
!
!
A
j
j
TRANSMITTER
OPTIONAL
POWER HEAD/DRIVE
RAIL ASSEMBLY
WALL
BRACKET
DOOR ARM ROD
DOOR ARM
TUBE SECTION
SENSOR ‘L’
BRACKET
MANUAL RELEASE
TAG
BELL WIRE
SPOOL
(when supplied)
110045
OPENER
HARDWARE
BAG
TOOLS REQUIRED
DOOR
BRACKET
PUSHBUTTON
“WARNING” LABEL
WALL PUSHBUTTON
WARNING
!
!
Child can be pinned under automatic ga rage
door. Death or serio us injury can re sult.
•
Never let child walk or run under movi ng door.
•
Never let child use door opener controls.
•
lways keep moving door in s ight.
•
If person is pinned, push c ontrol button or use
emergency release.
•
Test door opener monthly:
Refer to your owner’s manual
ect (or 2x4 laid flat) on floor.
Place one-inch ob
If door fails to reverse on contact, ad
If opener still fails to reverse door, repair or replace opener .
ust opener.
SENSOR ‘U’
BRACKET
RED
RELEASE
KNOB
SAFE FINISH
PHOTOSYSTEM
SENSORS
110046
SAFE FINISH HARDWARE
HAMMER
DRILL
1/2” OPEN END
HACKSAW
WRENCH
DRILL & BITS
STEPLADDER
SOCKET W RENCH
3/8” SOCKET
7/16” SOCKET
SMALL SCREW DRIVER
(1/8” HEAD)
LEVEL
WOOD
BLOCK
TAPE MEASURE
SCREW DRIVER
4
A: ASSEMBLY INSTRUCTIONS
If Your Opener Is Supplied Fully Assembled, Please Disregard This Page.
NOTE: The Rail/Chain Assembly is
packaged separately from the Power
Head Unit. The trolley, front idler/
Spring
tension adjustment assembly, chain,
drive gear and limit cams are assembled
to the Rail/Chain Assembly at the
factory. Follow the steps outlined
below to complete assembly prior to
installation. Refer to the component
identification illustrations on the
previous page.
Assembled and
In Position
STEP 1: Prior to attaching the motor
drive unit to the rail assembly, the Open
and Close adjustment bolts must be
installed. Place the threaded end of the
adjustment bolt through the hole in the
rail and then slip the head of the bolt
through the center of the double key
hole. Slide the spring over the bolt and attach load adjusting nut. Tighten until the tip of the bolt extends 3/16” outside the nut.
Repeat above for the other side.
Spring
L-Shaped Adjustment Bolt
Force Adjusting
Plastic-Insert
Locking Nut
Double Key Hole
110047-1
STEP 2: Protect the Power Unit cover from scratching during assembly by placing it on cardboard. Loosen the two 5/16" lock
washer nuts on top of the power head drive unit.
STEP 3: VERY IMPORTANT ! Position a paper shim around the power head unit drive gear (standard weight paper, see
illustration). Shim must remain in place while assembling the power head unit to the Rail/Chain assembly to ensure a proper gear
mesh and avoid excessive long term wear.
STEP 4: Align the four key holes in the Rail/Chain assembly with
the two front guide tabs and the two rear bolt studs on the power
head unit and place the rail/chain assembly in place over the power
head unit. The power head drive unit limit lever protrudes up
through the rail/chain assembly sensing plate. Take care not to bend
the lever when
assembling. Slide the
power head drive unit
110047-2
Limit Lever
forward until the gear
meshes with the rail/
chain assembly drive
gear. Check to make
sure the front guide tabs
on the power head unit
are securely locked on
the rail/chain assembly.
Take care not to
bend limit lever
5/16” Lock
Washer Nuts
Limit
Lever
Front Guide
Tabs (2)
Paper Shim
110047-3
STEP 5: The power head drive unit should be move forward until
all play between the gears has been eliminated, but no additional force should be used that could cause pressure on the motor (power
head unit) drive gear. Tighten the two 5/16" lock washer nuts on top of the power head drive unit that were loosened in Step 2 above.
When the opener is first activated the paper shim will be ejected. The paper shim should have the profile of the gears to indicate the
proper mesh between them.
STEP 6: Recheck the nuts used to secure the Rail/Chain assembly to the Power Head Unit, making sure they are tight.
Assembly is now complete and you are ready to begin installation of the opener.
5
B: IMPORTANT INSTALLATION INSTRUCTIONS
IMPORTANT INSTALLATION INSTRUCTIONS
TO REDUCE THE RISK OF SEVERE
INJURY OR DEATH: READ AND FOLLOW
WARNING
WARNING: AN UNBALANCED DOOR OR
ONE THAT STICKS OR BINDS MAY
PREVENT THE SENSING SYSTEM FROM
WORKING PROPERLY, CAUSING INJURY OR
DEATH. ENSURE DOOR IS PROPERLY
BALANCED AND ELIMINATE ANY STICKING OR
BINDING PRIOR TO INSTALLATION OF
OPERATOR. A properly balanced door will open
slowly from a 3/4 open position, close slowly from a
3/4 closed position, and remain still at a 1/2 open
position. If the door is not properly balanced, HAVE
A QUALIFIED SERVICE PERSON MAKE
REPAIRS TO CABLES, SPRING ASSEMBLIES
AND OTHER DOOR HARDWARE BEFORE
INSTALLING THE OPENER
WARNING:
LARGEST MOVING OBJECT IN YOUR
HOUSE, THE SPRINGS, PULLEYS, CABLES
AND MOUNTING HARDWARE UTILIZED TO
BALANCE ITS OPERATION ARE UNDER
EXTREME TENSION AT ALL TIMES AND CAN
CAUSE SERIOUS PERSONAL INJURY, EVEN
DEATH, IF DISTURBED. DO NOT ATTEMPT
ADJUSTMENT. CALL A QUALIFIED SERVICE
PERSON TO MOVE, LOOSEN OR ADJUST
DOOR SPRINGS OR HARDWARE.
• REMOVE ALL ROPES AND REMOVE OR MAKE
INOPERATIVE ALL LOCKS CONNECTED TO
THE GARAGE DOOR BEFORE INSTALLING
THE OPENER.
• DO NOT WEAR RINGS, WATCHES OR LOOSE
CLOTHING WHILE INSTALLING OR
SERVICING GARAGE DOOR OPENERS.
WEAR SAFETY GOGGLES OR OTHER
PROTECTIVE EYEWEAR.
• IF POSSIBLE, INSTALL THE DOOR OPENER
7zFT OR MORE ABOVE THE FLOOR. MOUNT
THE EMERGENCY RELEASE 6 FT ABOVE THE
FLOOR.
• REINFORCE LIGHTWEIGHT FIBERGLASS,
YOUR GARAGE DOOR IS THE
ALL INSTALLATION INSTRUCTIONS!
ALUMINUM AND STEEL DOOR TOP SECTIONS
TO AVOID DAMAGE AND TO INSURE PROPER
OPERATION OF THE SAFETY REVERSE
SYSTEM. CONTACT YOUR DOOR
MANUFACTURER FOR A REINFORCEMENT
KIT.
• DO NOT CONNECT THE OPENER TO A
POWER SOURCE UNTIL INSTRUCTED TO DO
SO.
• CHECK LOCAL BUILDING AND ELECTRICAL
CODES FOR MANDATORY INSTALLATION
AND WIRING REQUIREMENTS.
• CONNECT POWER CORD ONLY TO A
PROPERLY GROUNDED OUTLET. IF
PERMANENT WIRING IS REQUIRED BY
CODES, DISCONNECT POWER AT FUSE BOX
OR CIRCUIT BREAKER BEFORE ATTEMPTING
ANY WIRING CONNECTIONS.
• LOCATE THE CONTROL PUSH BUTTON:
A. WITHIN SIGHT OF THE DOOR, AND,
B. AT A MINIMUM HEIGHT OF 5 FT SO SMALL
CHILDREN CAN'T REACH IT, AND,
C. AWAY FROM MOVING PARTS OF THE
DOOR.
• INSTALL THE ENTRAPMENT WARNING LABEL
NEXT TO THE CONTROL PUSH BUTTON IN A
PROMINENT LOCATION. INSTALL THE
EMERGENCY RELEASE INSTRUCTION CARD,
ATTACHING IT ON OR NEXT TO THE
EMERGENCY RELEASE.
• ADJUST THE SENSITIVITY ADJUSTMENTS
ENOUGH TO ALLOW THE DOOR TO
OPERATE, BUT NOT SO FIRMLY AS TO
EXERT EXCESSIVE PRESSURE ON AN
OBSTRUCTION BEFORE REVERSING.
• AFTER INSTALLING THE OPENER, THE DOOR
SHOULD REVERSE WHEN IT CONTACTS A
1-1/2" HIGH OBJECT (A PIECE OF STANDARD
2 X 4 BOARD LAID FLAT) ON THE FLOOR.
6
C: INSTALLING THE OPERATOR
IMPORTANT!
IDENTIFY YOUR DOOR TYPE FROM THOSE ILLUSTRATED BELOW AND FOLLOW
INSTRUCTIONS FOR THAT TYPE OF DOOR
104367
SECTIONAL DOOR
CURVED TRACK
ONE PIECE DOOR
HORIZONTAL TRACK
JAMB HARDWARE
HIGH ARC OF
DOOR TRAVEL
TRACK
DOOR DOOR
HIGH ARC OF
DOOR TRAVEL
TRACK
FOR THESE TYPES OF DOORS USE 1/3 HP
MODEL AC9300 OR 1/2 HP MODEL AC9500.
USE 7 FT, 8 FT OR 10 FT RAIL ASSEMBLY
(MATCH DOOR HEIGHT)
REINFORCE THE HEADER WALL
Reinforce the header wall (wall above the door opening as required,
to ensure rigid mounting of the front wall bracket.
Locate the vertical centerline of your garage door and mark it on the
header above the door and on the top rail of the door.
ONE PIECE DOOR
NO TRACK
JAMB HARDWARE
HIGH ARC OF
DOOR TRAVEL
DOOR
JAMB
HARD-
WARE
FOR THESE TYPES OF DOORS USE
1/2 HP MODEL ACJ9500.
(FOR DOOR HEIGHT UP TO 8 FT)
110048
104368
ONE PIECE DOOR
NO TRACK
PIVOT HARDWARE
HIGH ARC OF
DOOR TRAVEL
DOOR
PIVOT
USE 7J RAIL
Reinforce with 2” x 6”
as required to insure
rigid mounting.
Vertical Center
Line
WARNING
WARNING
WARNINGWARNING
HORIZONTAL
LINE
104369
SPRINGS, PULLEYS, CABLES AND MOUNTING HARDWARE USED TO BALANCE YOUR
GARAGE DOOR ARE UNDER EXTREME TENSION AT ALL TIMES AND CAN CAUSE SEVERE
INJURY OR DEATH IF DISTURBED. DO NOT ATTEMPT ADJUSTMENT.
VERTICAL
CENTERLINE
STEP 1: Mounting the Front Bracket — Sectional Doors and One-
Piece Doors with Track (For One-Piece Doors without track see Step 1A,
next): Mark a vertical centerline on the header above the door. By
manually raising the door, determine the high arc of the door’s travel (see
illustration, top of previous page) and using a level, transfer this
measurement to the header (see illustration at left). Draw a horizontal line,
crossing the previously drawn centerline, at this point. Install the Front
Mounting Bracket securely wit lag screws as shown below. If necessary,
reinforce the header with steel angle iron or wood to ensure a secure
mount.
7
C: INSTALLING THE OPERATOR
WARNING
WARNING
WARNINGWARNING
10437
Door
FRONT MOUNTING BRACKET MUST BE INSTALLED TO A STRUCTURAL SUPPORT
(STUD) ON THE HEADER WALL. FAILURE TO DO SO COULD CAUSE SENSING
SYSTEM TO MALFUNCTION, RESULTING IN ENTRAPMENT, INJURY OR DEATH.
REINFORCE HEADER USING 2 x 6 WOOD STUDS AND LAG SCREW OR ANGLE
IRON AND LAG SCREWS AS NECESSARY (NOT PROVIDED).
STEP 1A: Mounting the Front Bracket — One
Header Bracket
Bracket Distance Above Floor
(See Chart)
Highest Point
of Travel
Measure
Distance
to Floor
Garage
Floor
Piece Doors Without Track: Mark a vertical
centerline on the header above the door. Manually raise
the door to its high arc position and temporarily clamp
in that position. With the door in this high arc position,
measure the distance from the top of the door to the
floor (see figure at left). Subtract the actual door height
from the high arc distance to the floor. This is the high
arc rise of the door. Unclamp and close the door.
Using the table below, draw a horizontal line at the
appropriate height above the door to intersect with the
vertical centerline.
110049
1/2” Above
High Arc Mark
Front Wall
Bracket
Center of
HIGH ARC RISE HIGH ARC RISE
High Arc Mark
Door
HORIZONTAL LINE
4 INCHES 8 INCHES
Mount the Front Mounting Bracket securely with lag
screws as shown in figure above. If necessary,
4 TO 8 INCHES 13 INCHES
8 TO 12 INCHES 18 INCHES
reinforce the header with steel angle iron or wood to
ensure a secure mount.
STEP 2: Raise the front of the Rail/Chain assembly so that the Front Rail Bracket and Wall Mounting Bracket align. Insert the
1/4” x 4” bolt and tighten nut loosely for now. Later in the installation, this nut must be tightened securely.
STEP 3 — Sectional Doors and One Piece Doors with Track: Raise the Opener and rest the Power Unit on a ladder or other
sturdy support. Open the door the full open position.
Allow 2" of space between the Tee Rail and the top
section of the door (as shown in the illustration on page
9).
STEP 3A — One Piece Doors without Track: Raise
the opener and rest the power unit on a ladder or other
sturdy support. Open the door to the high arc position.
Allow 2” of space between the tee rail and the door (at the
high arc position) as shown in the illustration on page 9.
The opener will be angled as shown. This is necessary for
proper operation.
NOTE: Since the Opener will be secured permanently
in this position, open and close the door a few times to be
sure the door does not rub on the Tee Rail and that you
have allowed the proper clearances before proceeding.
Wall
Mounting
Bracket
Wall Mounting Bracket
Nut
1/4” x 4”
Hex Head Bolt
Cardboard or Cloth to
protect the Housing
110050-1
8
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