Chamberlain 3900PLD User Manual

DOOR OPERATOR Model 3900PLD

For Light Duty Commercial Use Install On Sectional Doors With Torsion Assemblies Only

The Chamberlain Group, Inc. 845 Larch Avenue Elmhurst, Illinois 60126-1196

www.liftmaster.com

Owner’s Manual

■ Please read this manual and the enclosed safety materials carefully!

■ Fasten the manual near the door after installation.

■ The door WILL NOT CLOSE unless The Protector System

connected and properly aligned.

■ Periodic checks of the operator are required to ensure safe operation.

■ The model number label is located behind the hinged door of your operator.

■ Do NOT exceed 10 complete cycles of door operation per hour.

2 YEAR WARRANTY

Serial #

Installation Date

and cable tension monitor are

Introduction 2-5

Safety symbol review and signal word review . . . . . . . . . . 2

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparing your door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Carton inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hardware inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly 6

Attach the collar to the operator . . . . . . . . . . . . . . . . . . . . . 6

Attach mounting bracket to the operator . . . . . . . . . . . . . . 6

Installation 7-16

Installation safety instructions . . . . . . . . . . . . . . . . . . . . . . 7

Position the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Attach the emergency release rope and handle . . . . . . . . 8

Install power door lock (Not Provided) . . . . . . . . . . . . . . . . 8

Attach the cable tension monitor (Required) . . . . . . . . . . . 9

Install the single button control station . . . . . . . . . . . . . . . 10

Install the light (Not Provided) . . . . . . . . . . . . . . . . . . . . . 11

Electrical requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mount the Standby Power Unit (SPU) (Not Provided) . . . 13

Install The Protector System®. . . . . . . . . . . . . . . . . . . 14-16

Adjustment 17-20

Program the travel limits . . . . . . . . . . . . . . . . . . . . . . . . . 17

Set the force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Test the safety reversal system . . . . . . . . . . . . . . . . . . . . 19

Test The Protector System®. . . . . . . . . . . . . . . . . . . . . . . 19

Test cable tension monitor . . . . . . . . . . . . . . . . . . . . . . . . 20

To open door manually . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operation 21-25

Operation safety instructions . . . . . . . . . . . . . . . . . . . . . . 21

Using your door operator . . . . . . . . . . . . . . . . . . . . . . . . . 21

Care of your operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Having a problem? (Troubleshooting) . . . . . . . . . . . . 23-24

Diagnostic Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Programming 26-28

To add or reprogram a hand-held

remote control (Not Provided) . . . . . . . . . . . . . . . . . . . . . 26

To erase all codes from motor unit memory . . . . . . . . . . 26

3-Button remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

The remote control battery . . . . . . . . . . . . . . . . . . . . . . . . 26

To add, program or change a keyless entry

PIN (Not Provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Programming remote light (Not Provided) . . . . . . . . . . . . 28

Repair Parts 29

Installation parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Motor unit assembly parts . . . . . . . . . . . . . . . . . . . . . . . . 29

Accessories 30 Notes 31 Repair Parts and Service 32

INTRODUCTION

Safety Symbol Review and Signal Word Review

This door operator has been designed and tested to offer safe service provided it is installed, operated, maintained and tested in strict accordance with the instructions and warnings contained in this manual.

When you see these Safety Symbols and Signal Words on the following pages, they will alert you to the possibility of

Mechanical

Electrical

serious injury or death

warnings that accompany them. The hazard may come from something mechanical or from electric shock. Read the warnings carefully.

When you see this Signal Word on the following pages, it will alert you to the possibility of damage to your garage door and/or the garage door operator if you do not comply with the cautionary statements that accompany it. Read them carefully.

if you do not comply with the

Safety Reversing Sensor

Torsion Spring

Motor unit

Wall-mounted Single Button Control Station

Access Door

Gap between floor and bottom of door must not exceed 1/4" (6 mm).

Cable Tension Monitor

Drum

Planning

Survey your area to see if any of the conditions below apply to your installation. Additional materials may be required. You may find it helpful to refer back to this page as you proceed with the installation of your operator.

Depending on your requirements, there are several installation steps which may call for materials or hardware not included in the carton.

This operator is compatible with:

• Doors that use a torsion bar, springs and a door no

more than 14' (4.2 m) high.

• 4"-6" (10 cm - 15 cm) drums, not to be used on tapered

drums over 6" (15 cm).

• High lift and standard lift sectional doors up to 14'

(4.2 m) high.

• Doors up to 18' (5.4 m) wide.

• Doors up to 180 sq. ft. (16.7 sq. m).

• 1" (2.5 cm) torsion bar only.

• Review or inspect proposed installation area. Operator

can be installed on left or right side of door. Select the side that meets the requirements listed below.

- Must have minimum of 2-1/2" (6.4 cm) between the wall and the center of the torsion bar.

- Must have minimum of 3" (7.6 cm) between the ceiling and the center of torsion bar.

- Must have minimum of 8" (20.3 cm) between the side wall (or obstruction) and the end of torsion bar.

• The torsion bar must extend at least 1" to 5"

(2.5 cm to 12 cm) past the bearing plate.

• An electric outlet is required within 6' (1.8 m) of the

installation area. If outlet does not exist, contact a qualified electrician.

• Depending upon building construction, extension

brackets or wood blocks may be needed to install safety reversing sensors.

• Alternate floor mounting of the safety reversing sensors

will require hardware not provided.

• A model 475LM EverCharge

Standby Power Unit is strongly recommended if there is no access door to the garage, as this operator cannot be used in conjunction with an external emergency release mechanism.

• Any gap between the floor and the bottom of the door

must not exceed 1/4" (6 mm). Otherwise the safety reversal system may not work properly.

NOTE: Inspect the torsion bar while the door is raised and lowered. It is important that there is no noticeable movement up and down or left and right. If this type of movement is not corrected, life of this operator will be greatly reduced.

Preparing your Door

Pliers

Wire Cutters

Claw Hammer

Screwdriver

Adjustable End Wrench

1/4", 5/16" & 3/8" Sockets and Wrench with 6" Extension

Drill

Tape Measure

Stepladder

Pencil

3/16" and 1/8" Hex Key Wrench

Needle Nose Pliers

5/32", 3/16", 5/16" and 3/4" Drill Bits

Before you begin:

• Disable locks.

• Remove any ropes connected to door.

• Complete the following test to make sure your door is

balanced and is not sticking or binding:

1. Lift the door about halfway as shown. Release the door. If balanced, it should stay in place, supported entirely by its springs.

2. Raise and lower the door to see if there is any binding or sticking.

If your door binds, sticks or is out of balance, call a

trained door systems technician.

3. Verify equal cable tension on each side of door. Cable tension should remain equal during the entire travel of the door.

To prevent possible SERIOUS INJURY or DEATH:

• ALWAYS call a trained door systems technician if door binds, sticks or is out of balance. An unbalanced door may not reverse when required.

• NEVER try to loosen, move or adjust door, door springs, cables, pulleys, brackets or their hardware, ALL of which are under EXTREME tension.

• Disable ALL locks and remove ALL ropes connected to door BEFORE installing and operating door operator to avoid entanglement.

To prevent damage to door and operator:

• ALWAYS disable locks BEFORE installing and operating the operator.

• ONLY operate door operator at 120V, 60 Hz to avoid malfunction and damage.

• DO NOT exceed 10 complete cycles of door operation per hour.

Sectional Door

Tools needed

During assembly, installation and adjustment of the operator, instructions will call for hand tools as illustrated below.

Specifications

Volts . . . . . . . . . . . . . . . . . . . 120Vac - 60 Hz, ONLY

Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 AMP

Rated Load. . . . . . . . . . . . . . . . . 325 in.lb/sec

10 Cycles per Hour

Torque Meter (not shown)

2-Conductor Bell Wire White & White/Red

Safety Labels

and

Literature

Mounting Bracket

The Protector System

(2) Safety Reversing Sensors (1 Sending Eye and 1 Receiving Eye) with 2-Conductor White & White/Black Bell Wire attached

Safety Sensor Bracket (2)

Operator

Collar with Screws

Cable Tension Monitor with 2-Conductor Green/White Bell Wires

Single Button Control Station

Carton Inventory

Your door operator is packaged in one carton which contains the motor unit and the parts illustrated below.

Note that accessories will depend on the model purchased. If anything is missing, carefully check the packing material.

Hardware Inventory

INSTALLATION HARDWARE

Hex Screw #14-10x1-7/8" (4) Screw #6x-1-1/4" (2) Machine Screw #6x1" (2) Carriage Bolt 1/4"-20x1/2" (2) Wing Nut 1/4"-20 (2) Pan Head Screw 1/4"-20x1/2" (2) Hex Head Screw #8x1" (2)

Self Tapping Screw #10-32 (2) Drywall Anchor (2) Drywall Anchor (Screw-In) (2) Handle Rope Insulated Staples (30)

ASSEMBLY STEP 1

Collar Screw

Set Screw

Socket Wrench

Attach the Collar to the Operator

To avoid installation difficulties, do not run the door operator until instructed to do so.

• Loosen the collar screws.

• Attach collar to either the left or the right side of the

operator. Ensure that the collar is seated all the way on motor shaft until stop is reached (Figure 1).

• Position the collar so that the screws are facing up

(accessible when attached to the torsion bar).

• Tighten both sides of collar screws equally to secure

collar to the motor unit (12-14 ft./lbs. of torque) (Figure 2).

NOTE: For most installations the screws should be facing up for easy access. Do not tighten set screws until indicated.

To prevent possible SERIOUS INJURY or DEATH, the collar MUST be properly tightened. The door may not reverse correctly or limits may be lost due to collar slip.

Figure 1

ASSEMBLY STEP 2

Attach Mounting Bracket to the Operator

• Loosely attach slotted side of mounting bracket to the

same side of the operator as the collar, using self-threading screws provided.

NOTE: Do not tighten until instructed. Illustrations shown are for left side installation.

HARDWARE SHOWN ACTUAL SIZE

Screw #10-32

Figure 2

RIGHT

WRONG

INSTALLATION

Operator

Staple

Torsion Bar

WARNING

WARNING WARNING

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

1. READ AND FOLLOW ALL INSTALLATION WARNINGS AND INSTRUCTIONS.

2. Install door operator ONLY on properly balanced and lubricated door. An improperly balanced door may not reverse when required and could result in SEVERE INJURY or DEATH.

3. ALL repairs to cables, spring assemblies and other hardware MUST be made by a trained door systems technician BEFORE installing operator.

4. Disable ALL locks and remove ALL ropes connected to door BEFORE installing operator to avoid entanglement.

5 Mount emergency release handle no higher than 6 feet

(1.83 m) above floor.

6. NEVER connect door operator to power source until instructed to do so.

7. NEVER wear watches, rings or loose clothing while installing or servicing operator. They could be caught in door or operator mechanisms.

8. Install wall-mounted door control:

• within sight of the door.

• out of reach of children at minimum height of 5 feet

(1.5 m).

• away from ALL moving parts of the door.

9. Install the entrapment warning placard next to the control station in a prominent location.

10. Place manual release/safety reverse test label in plain view on inside of door.

11. Upon completion of installation, test safety reversal system. Door MUST reverse on contact with a 1-1/2" (3.8 cm) high object (or a 2x4 laid flat) on the floor.

INSTALLATION STEP 1

Position the Operator

NOTE: For additional mounting options see

accessories page.

1. Close the door completely.

2. Slide the operator with collar over the end of the torsion bar. Ensure that the collar does not touch the bearing plate. Check to make sure the mounting bracket is located on a solid surface such as wood, concrete or door/flag bracket. Snug collar screws to help assure proper alignment of operator. Mark the bracket holes. It may be necessary to cut the torsion bar if it is too long or damaged.

3. Loosen collar screws from torsion bar and remove the operator. Drill 3/16" pilot holes at the marked locations. Drill through steel plate if needed.

4. Reinstall the operator by sliding the collar over the torsion bar until pilot holes align with bracket. Securely tighten collar screws that attach to the torsion bar to 12-14 ft./lbs. of torque. Securely tighten both set screws firmly, without damaging the motor unit.

5. Fasten bracket securely with 14-10x1-7/8" screws. Tighten all mounting bracket hardware.

NOTE: The motor unit does not have to be flush to wall.

6. Use a staple to secure the antenna wire to prevent antenna from being entangled in a door roller.

To prevent possible SERIOUS INJURY or DEATH:

• Concrete anchors MUST be used if mounting bracket into masonry.

• NEVER try to loosen, move or adjust door, springs, cables, pulleys, brackets or their hardware, ALL of which are under EXTREME tension.

• ALWAYS call a trained door systems technician if door binds, sticks or is out of balance. An unbalanced door might not reverse when required.

• Operator MUST be mounted at a right angle to the torsion bar to avoid premature wear on the collar.

HARDWARE SHOWN ACTUAL SIZE

14-10x1-7/8" Hex Screw

NOTICE

Overhand Knot

Emergency Release Handle

Overhand Knot

Rope

Motor Unit

Emergency Release Cable

INSTALLATION STEP 2

Lock Template

Roller

Garage Door Track

TOP

DRI

LL 5/16"

DRILL

3/4"

DRI

LL 5/

16"

132A2505

Approx. 3" (7.6 cm)

TOP

D R I L

L 5

/16"

D R I

L L 3

D R I L

L 5

132A2505

Attach the Emergency Release Rope and Handle

• Thread one end of the rope through the hole in the top

of the red handle so “NOTICE” reads right side up as shown. Secure with an overhand knot at least 1" (2.5 cm) from the end of the rope to prevent slipping.

• Thread the other end of the rope through the loop in the

emergency release cable.

• Adjust rope length so the handle is no higher than 6'

(1.83 m) above the floor. Secure with an overhand knot.

NOTE: If it is necessary to cut the rope, heat seal the cut

end with a match or lighter to prevent unraveling.

To prevent possible SERIOUS INJURY or DEATH from a falling door:

• If possible, use emergency release handle to disengage door

ONLY when door is CLOSED. Weak or broken springs or unbalanced door could result in an open door falling rapidly and/or unexpectedly.

• NEVER use emergency release handle unless doorway is

clear of persons and obstructions.

INSTALLATION STEP 3

Install Power Door Lock (Not Provided)

The lock is used to prevent the door from being manually opened once the door is fully closed.

1. Select a door roller to mount the lock above. Check for clearance. If possible select a roller on the same side of the door as the motor unit. The second roller up from the bottom is ideal in most installations.

2. Ensure rail surface is clean and adhere lock template to achieve a 3" (7.6 cm) distance between the center of the roller and the pin hole (Figure 1).

3. Drill holes as marked on the template.

4. Fasten power door lock to the outside of the garage door track with hardware provided.

5. Run bell wire up wall to motor unit. Use insulated staples to secure wire in several places.

6. Plug connector into the motor unit (Figure 2).

NOTE: Lock must be mounted within 10' of the power head.

Figure 1

Door Track

Figure 2

HARDWARE SHOWN ACTUAL SIZE

Lock Screw 1/4-20 x 1/2" (2)

Staples

WHT/GRN

To insert or release wire, push in tab with screwdriver tip

Cable Tension Monitor

7/16" (11mm)

Strip wire 7/16" (11mm)

WHT/GRN

Cable Tension Monitor

Cable Tension Monitor Roller

Cable

2"-6" (5 cm15 cm)

Drum

Torsion Bar

Operator

1/8"-1/4" (3 mm-6 mm)

With Door Closed Preferred Orientation

#8 Hex Head Screw (2)

Screw #6 (2) Wall Anchor (2)

Staples

3/4" Min. (18 mm Min.)

Wall

Drum

Cable

INSTALLATION STEP 4

Attach the Cable Tension Monitor (Required)

This operator comes standard with the cable tension monitor. It is supplied as a device to monitor the cables for ANY slack that may occur and will reverse the door when excessive slack is detected, eliminating service calls.

The cable tension monitor properly installed before the door operator will move in the down direction.

NOTE: The cable tension monitor is shipped for left side

installation. It is preferred that the cable tension monitor be installed on the same side of the door as the operator. If required, it can be mounted on the opposite side of door. Remove the snap-ring holding the roller in place and reassemble it on the opposite side of the cable tension monitor.

1. Position the cable tension monitor as shown (Figures 1 and 2). The cable tension monitor should be located as close to the drum as possible.

NOTE: There must be no obstructions in the installation area that prevent the cable tension monitor or the cable itself from closing completely when slack is detected.

2. Make sure cable tension monitor is located over a wood support member.

NOTE: If the cable tension monitor can not be mounted

into wood with the lag screws provided, it can be mounted into 1/2" or greater drywall using the wall anchors (2) and the #8 hex head screws (2) provided in the hardware bag.

3. Mark and drill 3/16" pilot holes for screws (pilot holes are not required for anchors).

4. Attach the cable tension monitor to the wall using the hardware provided. Make sure that the roller is on top of the cable.

5. Run bell wire to operator. Use insulated staples to secure wire in several places.

6. Connect bell wire to the green quick-connect terminals (polarity is not important) (Figure 3).

NOTE: Cable must have tension through entire travel.

Make sure there is no slack in cable on opposite side of door during normal operation. If this condition exists, adjust cables as required.

HARDWARE SHOWN ACTUAL SIZE

MUST

be connected and

Figure 1

Figure 2

Figure 3

INSTALLATION STEP 5

WHT/RED

WHT

Door Control Connections

Single Button Control Station

Install the Single Button Control Station

1. Remove the control station cover.

2. Fasten the control station to the wall at least 5’ (1.5 m) above the ground. The installation surface must be smooth and flat.

3. Select appropriate knockout and run the wires to the operator.

4. Connect wires to the control station and replace the control station cover.

5. Fasten the warning placards to the wall.

DO NOT EXCEED 10 DOOR OPERATIONS PER HOUR.

FASTEN LABEL ADJACENT TO DOOR.

NE PAS FAIRE FONCTIONNER LA PORTE PLUS DE 10 FOIS PAR HEURE.

FIXER L’ÉTIQUETTE PRÈS DE LA PORTE.

132A2112-2

To prevent possible SERIOUS INJURY or DEATH from electrocution:

• Be sure power is not connected BEFORE installing door control.

• Connect ONLY to 24 VOLT low voltage wires. To prevent possible SERIOUS INJURY or DEATH from a closing

door:

• Install door control within sight of door, out of reach of children at a minimum height of 5 feet (1.5 m) and away from ALL moving parts of door.

• NEVER permit children to operate or play with door control push buttons or remote controls.

• Activate door ONLY when it can be seen clearly, is properly adjusted and there are no obstructions to door travel.

• ALWAYS keep door in sight until completely closed. NEVER permit anyone to cross path of closing door.

Factory installed jumper must be in place for proper operation. Operator will not function without the jumper.

WARNING

Moving Door Can Cause

Serious Injury or Death

Keep Clear! Door May Move at any Time

Without Prior Warning

Do Not Let Children Operate the Door or Play

in the Door Area

Keep Door in Sight at all Times When Door is Moving

WHT/RED

WHT

Door Control Connections

Single Button Control Station

+ 22 hidden pages

Chamberlain 3900PLD User Manual

TABLE OF CONTENTS

INTRODUCTION

Safety Symbol Review and Signal Word Review

Planning

Preparing your Door

Tools needed

Specifications

Carton Inventory

Hardware Inventory

INSTALLATION