Chamberlain 5100-2K User Manual
The Chamberlain Group, Inc.
A DUCHOSSOIS ENTERPRISE
845 Larch Avenue
Elmhurst, Illinois 60126-1196
Garage Door Opener
®
®
Owner’s Manual
For Residential Use Only
Complies with UL 324
Regulations effective
January 1, 1993.
Model 5100-2K – 1/2HP
■ Please read this manual and the enclosed safety materials carefully!
■ Fasten the manual near the garage door after installation.
■ The door WILL NOT CLOSE unless the Protector System
properly aligned.
■ Periodic checks of the opener are required to ensure safe operation.
■ The model number label is located on the front end panel of your opener.
®
is connected and
Contents Page
A review of safety alert symbols . . . . . . . . . . . . . .2
You'll need tools . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety information regarding garage door locks
and ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Testing your garage door for sticking, binding
and balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Illustration of sectional door installation . . . . . . . .4
Illustration of one-piece door installation . . . . . . .5
Carton inventory . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hardware inventory . . . . . . . . . . . . . . . . . . . . . . . .7
Assembly section - pages 8 – 11
Assemble T-rail . . . . . . . . . . . . . . . . . . . . . . . . . .8
Attach cable pulley bracket . . . . . . . . . . . . . . . . .8
Install trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fasten T-rail to opener . . . . . . . . . . . . . . . . . . . .9
Install chain/cable . . . . . . . . . . . . . . . . . . . . . . .10
Attach sprocket cover . . . . . . . . . . . . . . . . . . . .10
Tighten the chain and cable . . . . . . . . . . . . . . .11
Installation section - pages 11 – 27
Installation safety instructions . . . . . . . . . . . . . .11
Determine header bracket location
Sectional door . . . . . . . . . . . . . . . . . . . . . . . . .12
One-piece door . . . . . . . . . . . . . . . . . . . . . . . .13
Install the header bracket . . . . . . . . . . . . . . . . .14
Attach the T-rail to header bracket . . . . . . . . . .15
Position the opener . . . . . . . . . . . . . . . . . . . . . .16
Hang the opener . . . . . . . . . . . . . . . . . . . . . . . .17
Install the door control . . . . . . . . . . . . . . . . . . . .18
Contents Page
Install the lights and lenses . . . . . . . . . . . . . . . . . . .19
Attach manual release rope and handle . . . . . . . . .19
Electrical requirements . . . . . . . . . . . . . . . . . . . . . .20
The Protector System®safety reversing
sensor information . . . . . . . . . . . . . . . . . . . . . . . . . .21
Install the safety reversing sensor . . . . . . . . . . . . . .22
Fasten door bracket (sectional door) . . . . . . . . . . . .24
Fasten door bracket (one-piece door) . . . . . . . . . . .25
Connect door arm to trolley (sectional door) . . . . . .26
Connect door arm to trolley (one-piece door) . . . . .27
Adjustment section - pages 28 – 30
Travel limit adjustments . . . . . . . . . . . . . . . . . . . . . .28
Force adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .29
Test the safety reversing sensor . . . . . . . . . . . . . . .30
Test the Protector System® . . . . . . . . . . . . . . . . . . .30
Operation safety instructions . . . . . . . . . . . . . . . . . . .31
Care of your opener . . . . . . . . . . . . . . . . . . . . . . . . . .31
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . .31
Operation of your opener . . . . . . . . . . . . . . . . . . . . . .32
Receiver and remote control programming . . . . . . . .33
Having a problem? . . . . . . . . . . . . . . . . . . . . . . . . . .34
Repair parts, rail assembly . . . . . . . . . . . . . . . . . . . .36
Repair parts, installation . . . . . . . . . . . . . . . . . . . . . .36
Repair parts, opener assembly . . . . . . . . . . . . . . . . .37
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
How to order repair parts . . . . . . . . . . . . . . . . . . . . . .40
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Start by reviewing these important safety alert symbols:
When you see these safety symbols on the following pages, they will alert you to the possibility of
serious injury or death
come from something mechanical or from electric shock.
if you do not comply with the corresponding instructions. The hazard may
Read the instructions carefully.
WARNING
WARNING
Mechanical Electrical
When you see this Safety Symbol on the following pages, it will alert you to the possibility of damage
to your garage door and/or the garage door opener if you do not comply with the corresponding
instructions.
Read the instructions carefully.
CAUTION
This garage door opener is designed and tested to offer safe service provided it is installed, operated,
maintained and tested in strict accordance with the safety instructions contained in this manual.
2
You'll Need Tools
During assembly, installation and adjustment of the opener, instructions will call for hand tools shown below.
Pencil
Carpenter's
Level
2
1
Tape Measure
Hack Saw
Wire Cutters
Drill
Stepladder
1/2" and 7/16" Sockets
and Wrench
WARNING
An unbalanced garage door might not reverse
when required and someone under the door
could be seriously injured or killed.
If your garage door binds, sticks or is out of
balance, call for professional garage door
service.
pulleys, brackets and their hardware, are
under extreme tension and can cause serious
injury or death.
adjust them yourself!
Ropes left on a garage door could cause
someone to become entangled and killed.
Remove all ropes connected to the door before
installing and operating the opener.
Identify the type and height of your door and any
special conditions that exist and any additional
materials that may be required by referring to the
lists on page 4 or page 5.
Garage doors, door springs, cables,
Do not try to loosen, move or
3/16", 5/16" and
5/32" Drill Bits
To avoid damage to the garage door and
opener, disable locks before installing and
operating the opener. Use a wood screw or nail
to hold locks in the "open" (unlocked) position.
Operation at other than 120V 60 Hz will cause
opener malfunction and damage.
Before you begin, complete the following test to
make sure your door is balanced, and is not
sticking or binding:
• Lift the door about halfway as shown. Release the
door. It should stay in place, supported entirely by
its springs.
• Raise and lower the door to see if there is any
binding or sticking.
Screwdriver
Claw Hammer
Pliers
Adjustable End Wrench
CAUTION
SECTIONAL DOOR
ONE-PIECE DOOR
3
SECTIONAL Door Installation
Before you begin, survey your garage area to see
whether any of the conditions below apply to your
installation.
Horizontal and vertical reinforcement
is needed for lightweight garage doors
(fiberglass, steel, aluminum, door with glass panels, etc.).
See page 24 for details.
Header Wall
— — — — — — — —
Door Center
Slack in Chain Tension
Garage Door is Closed
is Normal When
Extension Spring
Torsion Spring
FINISHED CEILING
Support bracket &
fastening hardware
is required.
See page 17.
OR
Access Door
Floor must be level
Safety Reversing Sensor
across width of door
Based on your particular requirements, there are
several installation steps which might call for materials
and/or hardware not included in the carton.
• Step 1, page 12 - Look at the wall or ceiling above
the garage door. The header bracket
must
be
securely fastened to structural supports.
• Step 5, page 17 - Do you have a finished ceiling in
your garage? If so, a support bracket and
additional fastening hardware may be required.
• Safety reversing sensor, page 21 - Depending
upon garage construction, wood blocks may need
to be fastened to mounting locations before
sensors are installed.
• Step 10, page 22 - Alternate floor mounting of the
safety reversing sensor will require hardware not
provided.
• Step 11, page 24 - Do you have a steel, aluminum,
fiberglass or glass panel door? If so, horizontal
and vertical reinforcement is required.
• Look at the garage door where it meets the floor. It
must close on the floor all the way across. Otherwise, the safety reverse system may not work
properly. See page 30. Floor or door should be
repaired.
• If your door is more than 7 feet high, see longer
rails available on page 38.
Safety
Reversing
Sensor
Closed Position
Header
Bracket
Header
Wall
Garage
Door
Cable Pulley
Bracket
Cable
Garage
Door
Spring
Door Bracket
Trolley
Straight
Door
Arm
Curved
Door
Arm
Chain
Manual
Release
Rope & Handle
• The opener can be installed within 2 feet of the left
or right of the door center if there is a torsion spring
or center bearing plate in the way of the header
bracket or door bracket area. If your door has
extension springs, the opener
must
be installed
in the center of the door . See pages 12 and 24.
• Do you have an access door in addition to the
garage door? If not, Model 7702CB Outside Quick
Release is required. See page 38.
Y ou may find it helpful to refer back to this page as
you proceed with the installation of your opener .
4
ONE-PIECE Door Installation
One-Piece Door Without Track
Before you begin, survey your garage area to
see whether any of the conditions below apply
to your installation.
Slack in chain tension
is normal when
garage door is closed.
Header
Wall
Access Door
Safety Reversing Sensor
Gap between floor and bottom
Safety Reversing Sensor
of door must not exceed 1/4"
Based on your particular requirements, there are
several installation steps which might call for materials
and/or hardware not included in the carton.
• Step 1, page 13 - Look at the wall or ceiling above
the garage door. The header bracket
must
be
securely fastened to structural supports.
• Step 5, page 17 - Do you have a finished ceiling in
your garage? If so, a support bracket and
additional fastening hardware (not supplied) may
be required.
• Safety reversing sensor, page 21 - Depending on
garage construction, wood blocks may need to be
securely fastened to mounting locations before
sensors are installed.
• Step 10, page 22 - Alternate floor mounting of the
safety reversing sensor will require hardware that
is not provided.
• Step 11, page 25 - Generally, a one-piece door
does not require reinforcement. If your door is
lightweight, you can refer to the information
relating to sectional doors on page 24.
• Step 11, page 25 - Depending on your door's
construction, you might need additional mounting
hardware for the door bracket.
• Do you have an access door in addition to the
garage door? If not, Model 7702CB Outside Quick
Release is required. See page 38.
• The gap between the bottom of the garage door
and the floor cannot exceed 1/4". Otherwise, the
safety reverse system may not work properly. See
page 30. The floor or the door should be repaired.
FINISHED CEILING
Support bracket
& fastening
hardware is required.
See page 17.
Closed Position
Cable
Header
Wall
Garage
Door
Pulley Bracket
Header
Bracket
Door Bracket
Cable
T-rail
Straight
Door
Arm
Curved
Door
Arm
Trolley
Manual
Release
Rope & Handle
One-Piece Door With Track
Slack in Chain Tension
is Normal When
Garage Door is Closed.
Access
Door
Safety
Trolley
Reversing
Sensor
Chain
T-Rail
Manual Release
Rope & Handle
Safety
Reversing Sensor
Floor must be level
across width of door
Closed Position
Header
Wall
Garage
Cable
Pulley Bracket
Header
Bracket
Door
Bracket
Door
Cable
Curved
Door Arm
Straight
Door
Arm
Y ou may find it helpful to refer back to this page as
you proceed with the installation of your opener.
5
Carton Inventory
Your garage door opener is packaged in one carton which contains all parts illustrated below. If anything is
missing, carefully check the packing material. Parts may be "stuck" in the foam. Hardware for assembly and
installation is shown on page 7.
LOCK
LIGHT
Multi-Function
Remote Control Transmitter (2)
Wireless Keyless Entry (1)
Light Lens (2)
Cable Pulley
Bracket
Trolley
T-Rail
End Section (2)
2-Conductor Bell Wire
White & White/Red
Rail Brace (3)
T-Rail
Center Section (2)
CEILING MOUNT ONLY
UP
Header Bracket
Multi-Function
Control Panel
Door Bracket
Door Bracket
Plate
Safety Reversing Sensor
Mounting Bracket
With Square Holes (2)
Safety Reversing Sensor
Mounting Bracket With Slot (2)
Hanging Brackets
Safety Reversing Sensor (2)
(1) Sending Eye
(1) Receiving Eye
Chain and Cable in
Dispensing Carton
"C" Wrap (2)
2-Conductor Bell Wire with Connector
White & White/Black (2 rolls)
6
Curved Door
Arm Section
Sprocket Cover
Straight Door
Arm Section
Safety Labels
and
Literature
Hardware
Separate all hardware from the packages in the rail carton and the opener carton as shown below, for the
assembly and installation procedures.
Assembly Hardware
Washered Screw
5/16" - 18 x 1/2" (2)
(mounted in chassis)
Hex Screw
5/16"- 18 x 7/8" (4)
Lag Screw
5/16"-18 x 1-7/8" (4)
Hex Screw
5/16" - 18 x 7/8" (3)
Threaded
Trolley Shaft (1)
5/16" - 18 (5)
Installation Hardware
NOTICE
Handle
Nut 5/16" - 18 (6)
Nut
Carriage Bolts
1/4" - 20 x 1/2" (12)
Lockwasher
5/16" (4)
RAIL GREASE
NO. 83A4
Rail Grease
Lockwasher 5/16" (6)
Master Link (2)
Lock Nut
1/4" - 20 x 7/16" (12)
Rope
Carriage Bolt
5/16"-18 x 2-1/2" (2)
Clevis Pin
5/16" x 2-3/4" (1)
Lag Screw
1/4 x 1-1/2" (4)
Hex Screw
1/4-20 x 1-1/2" (2)
Screw
6AB x 1" (2)
Insulated
Staples (10)
Safety Reversing Sensor
Installation Hardware
1/4" - 20 x 1/2" (4)
#10 - 32 x 3/8" (4)
Carriage Bolts
Screw
7
Clevis Pin
5/16" x 1" (2)
Lock Nut
1/4" - 20 (4)
Lock Nut
#10 x 32 (4)
Dry Wall Anchors (2)
Ring
Fastener (3)
Wing Nut (2)
Insulated
Staples (20)
Hex Screws
5/16"-18x7/8"
Cable Pulley
Bracket
Bracket & Rail Must Be Aligned
Lock Washer
5/16"
Nut
5/16"
4/16/89 6/27/89 3/9/92
T-RAIL BACK
(TO OPENER)
T-RAIL FRONT
(TO DOOR)
Cable pulley bracket
attaches to FRONT
END of T-rail
T-rail
(End Section)
T-rail
(Center Section)
Carriage Bolt
1/4"-20x1/2"
T-rail
(End Section)
Square Carriage
Bolt Hole
1/4" Lock Nut
Right Wrong
Assembly Section: Pages 8 – 1 1
T o avoid installation difficulties, do not run the garage door opener until instructed to do so.
Assembly Step 1
Assemble the T-rail
& Attach the Cable Pulley Bracket
• Align the 4 T-rail sections on a flat surface exactly
as shown. Center sections are interchangeable.
Front and back sections are also interchangeable
for ease of assembly.
• Insert the carriage bolts so the square bolt necks
seat in the square holes in the T-rail sections and
pass through the round holes in the rail braces.
Assemble lock nuts, ensure alignment and tighten.
If T-rail is not assembled
exactly as shown, trolley
will not travel smoothly
along length of rail or it
will hit against the nuts.
Make sure bolt
necks are
seated in the
square holes
and rails are
aligned before
you tighten lock
Right
nuts. (See right
and wrong
views).
Improper
assembly can
cause jerky
trolley
operation, noise
Wrong
and/or nuisance
door reversals.
Hardware Shown Actual Size
• Position the cable pulley bracket on the front end
of the T-rail as shown. Fasten securely with the
hardware shown.
Cable Pulley
Bracket
Lock Washer
5/16"
Hex Screws
5/16"-18x7/8"
Bracket & Rail Must Be Aligned
Nut
5/16"
Lock Nut
1/4"-20
Hex Screw
5/16"-18x7/8"
Carriage Bolts
1/4"-20x1/2"
Nut
5/16"-18
Lock Washer
5/16"
When tightening
the screws, be
sure to keep
bracket parallel
to the rail.
Otherwise, the
rail may bow
Right
8
Wrong
when the opener
is operated.
Assembly Step 2
Temporary Stop
Screwdriver
Trolley
Trolley
Threaded
Shaft
Lock Washer
5/16"
Outer Nut
5/16"
Inner Nut
5/16"
Trolley
Washered Screw
5/16"-18x1/2"
USE ONLY THIS
TYPE AND SIZE
SCREW
Trolley
Stop Hole
Hex Screw
5/16"-18x7/8"
Install the Trolley on the T-rail
Hardware Shown
Actual Size
• Attach the threaded shaft to the trolley with the
lock washer and nuts as shown.
Lock Washer
5/16"
Nut
5/16" - 18
• As a temporary stop, insert a screwdriver into the
hole in the front end of the T-rail.
• Slide the trolley assembly along the rail to the
screwdriver stop.
If trolley hits against the nut on the T-rail, the
bolts and nuts were attached from the wrong
side and must be repositioned. Review Step 1.
Assembly Step 3
Fasten the T -rail to the Opener
• Place the opener on packing material to protect
the cover. For convenience, put a support under
the cable pulley bracket.
• Remove the (2) 5/16"-18x1/2" washered screws
mounted in the top of the opener.
• Align the holes in the back section of the T-rail with
the holes in the opener.
• Fasten the rail with the (2) washered screws
previously removed. Tighten securely.
Remember to use only these screws!
screws will cause serious damage to the opener.
• Insert a 5/16"-18x7/8" hex screw into the trolley
stop hole in the T-rail as shown. Tighten securely
with a 5/16" lock washer and nut. This screw limits
trolley travel in the UP direction.
Hardware Shown Actual Size
Hex Screw
5/16" - 18 x 7/8"
Nut
5/16"-18
Lock washer
Any other
5/16"
(Back Section)
9
CAUTION
Use only those screws mounted in the top of the
opener. Any other screws will cause serious
damage to the opener.
Washered Screw
5/16"-18x1/2"
USE ONLY THIS
Hex Screw
5/16"-18x7/8"
Trolley
Stop Hole
T-Rail
Lock Washer
5/16"
Nut
5/16"-18
TYPE AND SIZE
SCREW
Assembly Step 4
Leave Chain and Cable
Inside Dispensing
Carton to Prevent Kinking.
Dispensing Carton
Keep Chain and Cable
Taut When Dispensing
Master Link
Clip-On Spri
Master
Link Cap
Cable
Pulley
Cable
Loop
Master
Link Bar
Master Link
Clip-On Spring
Trolley
T-rail
Pin
Pin Notch
Chain
Flat End of Trolley
Threaded Shaft
Master
Link Cap
Master
Link Cap
Master Link
Clip-On Spring
Install Chain and Cable
In This Direction
Install the Chain/Cable & Attach the Sprocket Cover
• Detach the cable loop from the carton and fasten it
to the trolley with a master link from the hardware
bag. See master link procedure, Figure 1.
• With the trolley against the screwdriver, dispense
the cable around the pulley.
• Proceed back around the opener sprocket,
Figure 2. Be sure sprocket teeth engage the chain.
Continue forward to the trolley threaded shaft,
Figure 3.
• Use the second master link to connect the
chain to the flat end of the shaft. Check to
make sure the chain is not twisted.
• Remove the screwdriver.
WARNING
Serious injury can result if fingers become
entangled in moving opener sprocket. Attach
sprocket cover securely. Never operate opener
while your hand is near the opener sprocket.
Figure 2
Opener
Sprocket
Figure 3
Front Tab Slot
Sprocket
Cover
Mounting
Back Tab Slot
Plate
Top of Opener
Push pins of master link bar through
cable loop and hole in front end of
trolley. Push cap over pins and into
notches. Slide clip-on spring over cap
and into notches until both pins are
securely locked.
To attach the sprocket cover:
• Insert the back tab in the opener slot. Squeeze the
cover slightly and insert the front tab in the slot on
Figure 1
Master Link Procedure:
the mounting plate.
10
Assembly Step 5
Tighten the Chain & Cable
• Spin the inner nut and lock washer down the
threaded shaft, away from the trolley.
• To tighten the chain, turn outer nut in the direction
shown. As you turn the nut, keep the chain
from twisting.
• When the chain is approximately 1/2" above the
base of the T-rail at its midpoint, re-tighten the
inner nut to secure the adjustment.
Sprocket noise can result if chain is either too
loose or too tight.
When installation is complete, you may notice some
chain droop with the door closed. This is normal. If
the chain returns to the position shown when the
door is open,
NOTE: During future maintenance,
pull the manual release handle to disconnect
trolley before adjusting chain.
do not re-adjust the chain.
ALWAYS
Outer Nut
To Tighten Outer Nut
Trolley
Base of T-rail
Chain
Lock
Washer
Inner Nut
To Tighten
Inner Nut
1/2 Inch
You have now finished assembling your garage door opener. Please read the following
warnings before proceeding to the installation section:
IMPORTANT INSTALLATION INSTRUCTIONS
WARNING
WARNING
To reduce the risk of severe injury or death to persons:
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS
2. Install only on a properly balanced and lubricated garage door.
could result in severe injury or death.
must be made by a professional service person before installing opener.
3. Disable all locks and remove all ropes connected to the garage door before installing the opener.
Repairs to cables, spring assemblies and other hardware
Ropes connected to a garage door can cause entanglement and death.
4. If possible, install door opener 7 feet or more above floor with the manual release handle
mounted 6 feet above the floor.
5. Do not connect the opener to power source until instructed to do so.
6. Locate the Door Control within sight of the door at a minimum height of 5 feet where small
children cannot reach and away from all moving parts of the door.
7. Install the User Safety Instruction Label on the wall adjacent to the control button and the
Maintenance Instruction Label in a prominent location on the inside of the garage door.
8. Upon completion of the installation, the door must reverse when it comes in contact with a oneinch high object (or a 2x4 laid flat) on the floor.
9. Do not wear watches, rings or loose clothing while installing or servicing an opener. Jewelry or
loose clothing can be caught in the mechanism of the garage door or the opener.
An improperly balanced door
11
Vertical
Guideline
Finished
Ceiling
Vertical
Guideline
Header
Wall
2 x 4
Structural
Supports
Installation Section: Pages 12 – 27
Installation Step 1
Determine Header Bracket Location
Installation procedures vary according to
garage door types. Follow the instructions
which apply to your door.
SECTIONAL Door and
ONE-PIECE Door With Track
WARNING
If the header bracket is not rigidly fastened to
a structural support on the header wall or
ceiling, the safety reverse system may not
work properly (see page 30).
not reverse when required, and could cause
serious injury or death.
The garage door springs, cables, pulleys,
brackets and their hardware are under extreme
tension.
Do not attempt to loosen, move or
adjust them yourself. Serious personal injury
or death could result.
service.
• Close the door and mark the inside
vertical centerline of the garage door.
• Extend the line onto the header wall
above the door.
Remember, you can fasten the
header bracket within 2 feet to the
left or right of the door center
a torsion spring or center bearing
plate is in the way; or you can attach
it to the ceiling (refer to page 14)
when clearance is minimal. (It may
be mounted on the wall upside down
if necessary, to gain approximately
1/2”.)
If you need to install the header bracket
on a 2x4 (on wall or ceiling), use lag
screws (not supplied) to securely fasten
the 2x4 to structural supports as shown
The door might
Call for garage door
only
if
• Open your door to the highest
point of travel as shown. Draw
an intersecting horizontal line
on the header wall 2" above
the high point. This height will
provide travel clearance for the
top edge of the door.
Proceed to Step 2, page 14.
Door
Sectional door
with curved track
Ceiling
Header
Wall
2"
Highest Point
of Travel
12
Track
Header
Wall
2"
Highest Point
of Travel
Door
One-piece door
with horizontal track
Track
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