Chamberlain door opener User Manual

This Operator Features
the Enhanced
Radio Receiver
Built on Board
OO WW NN EE RR SS MM AA NN UU AA LL
GG HH
IINNDDUUSSTTRRIIAALL DDUUTTYY CCOOMMMMEERRCCIIAALL DDOOOORR OOPPEERRAATTOORR
L
3
NOT FOR RESIDENTIAL USE
A
L
E
R
T
S
Y
S
T
E
M
M
A
I
N
T
E
N
A
N
C
E
PATENT PENDING
The Maintenance Alert System™ allows the installer to set an internal Maintenance Cycle Counter. The Logic 3 operator incorporates a self-diagnostic feature built into the (MAS) Maintenance Alert System LED. An LED on the 3-button station will signal when the set number of cycles/months is reached or when the operator requires immediate service.
Serial # Box
Installation Date
2 YEAR WARRANTY
315MHz
When you see these Safety Symbols and Signal Words on the following pages, they will alert you to the possibility of serious injury or death if you do not comply with the 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 door and/or the door operator if you do not comply with the cautionary statements that accompany it. Read them carefully.
Mechanical
Electrical

TABLE OF CONTENTS

WARNING
WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING
2
SPECIFICATIONS
Carton Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PREPARATION
Hand Chain Right/Left Conversion . . . . . . . . . . . . . . . . . . . . . . .5
Disconnect Lever Right/Left Conversion . . . . . . . . . . . . . . . . . . .5
Horizontal Mounting Conversion . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION
Mount the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Entrapment Protection Accessories . . . . . . . . . . . . . . . . . . . . . .8
ADJUSTMENT
Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Adjust Torque Limiter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
POWER & GROUND WIRING
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Power Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Ground Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CONTROL STATION WIRING & INSTALLATION
Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
External Radio Wiring Connections . . . . . . . . . . . . . . . . . . . . . .11
DIAGRAMS
Standard Power & Control Connection Diagrams . . . . . . . . . . .12
1 Phase Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3 Phase Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
PROGRAMMING
Logic Control Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Determine and Set Wiring Type . . . . . . . . . . . . . . . . . . . . . . . . .16
Failsafe Wiring Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Self-Monitoring Safety Device Options . . . . . . . . . . . . . . . . . . . .17
Programming Remotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
Maintenance Alert System (MAS) . . . . . . . . . . . . . . . . . . . . . . .20
Mid Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Timer to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-22
AUTOMATICALLY LEARNED PROGRAMMING
Auxiliary Reversal System/RPM Sensor . . . . . . . . . . . . . . . . . . .22
Maximum Run Timer (MRT) . . . . . . . . . . . . . . . . . . . . . . . . . . .23
OPTIONAL PROGRAMMING
Red/Green Warning Light Card . . . . . . . . . . . . . . . . . . . . . . . . .23
Resetting Factory Defaults - Clearing Memory . . . . . . . . . . . . . .24
MAINTENANCE SCHEDULE
. . . . . . . . . . . . . . . . . . . . . . . .24
TROUBLESHOOTING
Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Troubleshooting Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Troubleshooting Radio Functionality . . . . . . . . . . . . . . . . . . . . .28
REPAIR PARTS
Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
Repair Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-33
Operator Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
Control Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .36
IMPORTANT NOTES:
• BEFORE attempting to install, operate or maintain the operator, you must read and fully understand this manual and follow all safety instructions.
• DO NOT attempt repair or service of your commercial door and gate operator unless you are an Authorized Service Technician.
Before beginning your installation check that all components were provided.

CARTON INVENTORY

OPERATOR DIMENSIONS

3
14.00"
Hand Chain Wheel
See Note #1
See Note #2
A
X
B
Y
C
D
Y
See
Note #3
A
11-1/2
12-1/2
12-3/4
12-3/4
11
11
12
12-1/2
12-3/4
13-1/4
28-5/8B
25-3/4
26-3/4
27
27
25-1/4
25-1/4
26-1/4
26-3/4
27
28-5/8
C
14.13
14.13
14.13
15.13
14.13
14.13
14.13
15.13
15.13
17.13
33D
3
3
3
3-1/2
3
3
3
3-1/2
3-1/2
3
1/2
3/4
1
1-1/2
1/2
3/4
1
1-1/2
2
3
1
1
1
1
3
3
3
3
3
3
HP
DIMENSIONS
NOTES:
1) Output Shaft with 1" x 1/4" Key for 1/2 thru 2HP operators, 1-1/4" x 1/4" Key for 3HP operators.
2) Mounting Centers: X = 4-3/4"; Y = 5-1/2" for 1/2 thru 2HP operators X = 7-17/32"; Y = 9-1/16" for 3HP operators
3) Hand Chain Wheel extends 1-5/8" beyond operator in vertical mounting position as shown.
PHASE
WEIGHTS AND DIMENSIONS
HANGING WEIGHT: 80-110 LBS.
DESCRIPTION
POWERHEAD ASSEMBLY OWNER’S MANUAL AND CAUTION LABELS HARDWARE BOX (INCLUDES FASTENERS, DISCONNECT AND CHAIN HOIST WALL BRACKET) 3-BUTTON CONTROL STATION WITH LED HOIST HAND CHAIN DOOR SPROCKET DOOR/OPERATOR DRIVE CHAIN
14.13"
13.25"
4

OPERATOR SPECIFICATIONS

SAFETY
DISCONNECT: . . . . . . . . . .Floor level chain hoist with electrical
interlock for manual door operation.
CLUTCH (Optional): . . . . . . . . . . .Adjustable torque limiter type
SAFETY PHOTO EYES (Optional CPS-L):Through beam or retro
reflective devices used to provide non-contact safety protection.
SAFETY EDGE (Optional): Electric or pneumatic sensing device
attached to the bottom edge of door.
MOTOR
TYPE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Continuous Duty
HORSEPOWER: . . . . . . . . . . . . . .1/2, 3/4. 1, 1-1/2, 2 and 3 HP
SPEED: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1725 RPM
VOLTAGE: . . . . . . . . . . . . . . . . . . . . . . .115/220/230V 1 Phase,
208/230/380/460/575V 3 Phase
CURRENT: . . . . . . . . . . . . . . . . . . . . . . . .See Motor Nameplate
ELECTRICAL
TRANSFORMER: . . . . . . . . . . . . . . . . . . . . . .24Vac Secondary
CONTROL STATION: . . . . . . . . . . . . . . .NEMA 3-Button Station
Open/Close/Stop w/LED
WIRING TYPE: . . . . . . . . . . . . . . . . . . . . . . . . . . .C2 (Standard)
Momentary contact to OPEN & STOP, constant pressure to CLOSE, plus wiring for sensing device to reverse and auxiliary devices to open and close with open override. See pages 16 and 17 for optional wiring types and operating modes.
LIMIT ADJUST: . . . . . . . . .Linear driven, fully adjustable screw
type cams.
MECHANICAL
DRIVE REDUCTION: . . . . . . . . . . . .45:1 for 1/2, 3/4, and 1 HP
44:1 for 1-1/2, 2 42:1 for 3 HP
OUTPUT SHAFT SPEED: . . . . . . . . .38.3 for 1/2, 3/4, and 1 HP
39.2 for 1-1/2 and 2 HP
41.1 for 3 HP
DOOR SPEED: . . . . . . . .4 - 10" per second depending on door
BRAKE: . . . . . . . . . . . . . . . . . . . . .Solenoid actuated disc brake
HOIST WHEEL: . . . . . . .Standard mounting on left or right side
5

PREPARATION

It is imperative that the wall or mounting surface provide adequate support for the operator.
This surface must:
a. Be rigid to prevent play between operator and door shaft. b. Provide a level base. c. Permit the operator to be fastened securely and with the
drive shaft parallel to the door shaft.
The safety and wear of the operator will be adversely affected if any of the above requirements are not met. For metal buildings, fasten 2" x 2" x 3/16" (or larger) angle iron frames to the building purlins. Retain 5-1/2" (13.97 cm) between frames.
The GH operator may be mounted on either the right (standard) or left side of door, and in either a vertical (standard) or horizontal mounting position. Refer to the steps below if you require the hand chain and/or disconnect chain to be on the opposite side of the operator; or if the operator is being mounted in a horizontal position.
HAND CHAIN RIGHT/LEFT CONVERSION
Remove the two snap rings (1 piece outer, 1 piece inner) on hand chain shaft assembly. Position roll-pin to fit through cutout in frame and slide complete shaft assembly through housing and bevel gear. Insert shaft assembly on opposite side of housing, and replace bevel gear, bearing, hardware, and snap rings on the opposite side of shaft in the same manner.
DISCONNECT LEVER RIGHT/LEFT CONVERSION
Remove cotterpins on the ends of the disconnect shaft (square shaft), move the disconnect lever arm to the opposite side, and replace the cotterpins. Be sure to keep (2) 12 gauge washers on the side without the lever arm.
HORIZONTAL MOUNTING CONVERSION
Remove cotterpins on the ends of the disconnect shaft (square shaft), and remove lever. Replace lever using square hole on opposite end of lever. Reposition sash chain to opposite end of lever also. Replace cotterpins.
To prevent possible SERIOUS INJURY or DEATH:
• DO NOT connect electric power until instructed to do so.
• If the door lock needs to remain functional, install an interlock switch.
• ALWAYS call a trained professional door serviceman if door binds, sticks or is out of balance. An unbalanced door may not reverse when required.
• NEVER try to loosen, move or adjust doors, door springs, cables, pulleys, brackets or their hardware, ALL of which are under EXTREME tension and can cause SERIOUS personal INJURY.
• Disable ALL locks and remove ALL ropes connected to door BEFORE installing and operating door operator to avoid entanglement.
WARNING
WARNING
5-1/2" (13.97 cm)
Shaft Support Bracket with Bearing (Not Provided)
Door Sprocket
Chain Guide
Hand Chain Wheel
Cutout for Rollpin (typical both sides)
Disconnect Lever
Cotterpin
6

INSTALLATION

IMPORTANT NOTE: Before your operator is installed, be sure the door has been properly aligned and is working smoothly. The operator may be wall mounted or mounted on a bracket or shelf. If necessary, refer to the preparation on page 5. Refer to the illustrations and instructions below that suit your application.
Optimum Distance
12 - 15" (30.5 - 38.1 cm)
Mounting Bracket
P/N 08-9098
OPTIONAL
Optimum Distance
12 - 15" (30.5 - 38.1 cm)
Figure 1
Figure 2
MOUNT THE OPERATOR
1. Wall Mount: The operator should generally be installed below
the door shaft, and as close to the door as possible (Figure 1). Bracket Shelf Mounting: The operator may be mounted either above or below the door shaft (Figure 2).
IMPORTANT: The shelf or bracket must provide adequate support, prevent play between operator and door shaft, and permit operator to be fastened securely and with the drive shaft parallel to the door shaft.
NOTE: The optimum distance between the door shaft and operator drive shaft is between 12" - 15" (30.5 - 38.1 cm).
2. Place door sprocket on the door shaft. Do not insert the key at this time.
3. Place drive sprocket on the appropriate side of the operator. Do not insert the key at this time.
4. Wrap drive chain around door sprocket and join roller chain ends together with master link.
5. Raise operator to approximate mounting position and position chain over operator sprocket.
6. Raise or lower operator until the chain is taut (not tight). Make sure the operator output shaft is parallel to door shaft and sprockets are aligned. When in position, secure the operator to wall or mounting bracket.
7. Align sprockets and secure (Figure 3).
8. Install Hand Chain Place hand chain around hand chain wheel. Be sure to pass it through both openings in the chain guide. Remove enough links so chain hangs approximately 2' (.61 m) above the floor.
9. Mount Chain Keeper / Keyhole Bracket Using suitable hardware mount the chain keeper approximately 4' (1.22 m)above the floor, near the free hanging chain. Remove disconnect sash chain from bag and place the end through the keyhole in the the chain keeper. Remove excess links if necessary.
Chain Keeper 4' (1.22 m) above floor
Be sure door sprocket is properly aligned wiht drive before securing to shaft.
Figure 3
Typical Right Hand
Wall Mounted Operator
7

MANUAL OPERATION

This operator has provisions for manually operating the door in case of emergency or power failure. These operators are equipped with a manual hoist. An electrical interlock will disable the electrical controls when the hoist is used.
To operate the hoist:
1. Pull the disconnect chain (small chain) to engage the interlock to disable the controls. The disconnect chain may be locked in position by slipping the end through the keyhole of the chain keeper mounted on the wall.
2. Operate the door in the desired direction by pulling on one side or the other of the continuous loop hoist chain (large chain).
3. The disconnect chain must be released from the chain keeper before the door will operate again electrically.
Chain Keeper (with pad locking provisions)
INSTALLATION
To prevent possible SERIOUS INJURY from a moving chain, ENGAGE interlock BEFORE manually operating your door.
WARNING
WARNING
8

ENTRAPMENT PROTECTION ACCESSORIES (OPTIONAL)

PHOTO EYES & SENSING EDGES
Sensing devices provided for door industry type operators with an isolated normally open (N.O.) dry contact output are compatible with your operator. This includes pneumatic and electric edges, and through beam and retro reflective photo eyes. If you would like to order or receive more information on safety devices, please contact your local Authorized Dealer.
If not pre-installed by the door manufacturer, mount the sensing edge on the door according to the instructions provided with the edge. The sensing edge may be electrically connected by either coiled cord or take-up reel.
Important Notes:
a. Proceed with limit switch adjustments described below before
making any sensing edge wiring connections to operator.
b. Electrician must hardwire the junction box to the operator
electrical box in accordance with local codes.
WIRING
For wiring of your sensing device to the operator, refer to the wiring diagrams provided on pages 13 and 14. See field connection terminals identified as Reversing Device.
TAKE-UP REEL
Take-up reel should be installed 12" (30.48 cm) above the top of the door.
COIL CORD
Connect operator end of coil cord to junction box (not provided) fastened to the wall approximately halfway up the door opening.

ADJUSTMENT

To avoid SERIOUS personal INJURY or DEATH from electrocution, disconnect electric power BEFORE manually moving limit nuts.
WARNING
WARNING
LIMIT SWITCH ADJUSTMENT
NOTE: Make sure the limit nuts are positioned between the limit switches before proceeding with adjustments.
1. Depress retaining plate to allow nut to spin freely. After adjustment, release plate and move nut back and forth to ensure it is fully seated in slot.
2. To increase door travel, spin nut away from limit switch. To decrease door travel, spin limit nut toward limit switch.
3. Adjust open limit nut so that door will stop in open position with the bottom of the door even with top of door opening.
4. Repeat steps 1 and 2 for close cycle. Adjust close limit nut so that the limit switch is engaged as door fully seats at the floor.
INSTALLATION
To reduce the risk of SEVERE INJURY or DEATH, ALWAYS install reversing sensors when the 3-button control station is out of sight of door or ANY other control (automatic or manual) is used. Reversing devices are recommended for ALL installations.
WARNING
WARNING
CLOSE OPEN
SAFETY
(Aux. Close) Limit Switch
CLOSE Limit Switch
OPEN Limit Switch
9

ADJUST TORQUE LIMITER CLUTCH (OPTIONAL MODIFICATION)

1. Loosen set screws on clutch nut.
2. Back off clutch nut until there is very little tension on the clutch spring.
3. Tighten clutch nut gradually until there is just enough tension to permit the operator to move the door smoothly but to allow the clutch to slip if the door is obstructed. When the clutch is properly adjusted, it should generally be possible to stop the door by hand during travel.
(3) Set Screws

BRAKE ADJUSTMENT

The brake is adjusted at the factory and should not need additional adjustment for the the life of the brake assembly.
Replace brake assembly when necessary. Refer to the illustration for identification of components for the solenoid type brake system.
ADJUSTMENT
Brake Plate Assembly
Release Lever
Solenoid
Brake Assembly
Actuator Plate
10
To reduce the risk of SEVERE INJURY or DEATH:
• ANY maintenance to the operator or in the area near the operator MUST NOT be performed until disconnecting the electrical power and locking-out the power via the operator power switch. Upon completion of maintenance the area MUST be cleared and secured, at that time the unit may be returned to service.
• Disconnect power at the fuse box BEFORE proceeding. Operator MUST be properly grounded and connected in accordance with local electrical codes. The operator should be on a separate fused line of adequate capacity.
• ALL electrical connections MUST be made by a qualified individual.
• DO NOT install ANY wiring or attempt to run the operator without consulting the wiring diagram. We recommend that you install an optional reversing edge BEFORE proceeding with the control station installation.
• ALL power wiring should be on a dedicated circuit and well protected. The location of the power disconnect should be visible and clearly labeled.
• ALL power and control wiring MUST be run in separate conduit.

POWER WIRING & GROUND WIRING

WARNING
WARNING
POWER WIRING CONNECTIONS
1. Connect power wires coming from the main to the captive terminal block in the electrical box enclosure marked with the label. All power and control wiring must be run in separate conduit in accordance with local electrical codes.
2. Be sure to run all power wires through the conduit hole in the electrical box enclosure marked with the label shown below.
NOTE: Must use #14 AWG or thicker wire for power wiring.
ON THREE PHASE MACHINES ONLY: Incorrect phasing of the power supply will cause the motor to rotate in the wrong direction. To change motor rotation, exchange incoming power leads L1 and L2.

GROUND WIRING CONNECTIONS

1. Connect earth ground to the chassis ground screw in the electrical box enclosure.
2. Use same conduit entry into the electrical box as the power wiring.
IMPORTANT NOTE: This unit must be properly grounded. Failure to properly ground this unit could result in electric shock and serious injury.
Neutral
Hot
Gnd
Single Phase Power Wiring
Line Power
115/230 Vac
Single Phase
Three Phase Power Wiring
Phase 1
Phase 2
Phase 3
Gnd
Line Power
208/230/380/460/575 Vac
Three Phase
11

CONTROL STATION WIRING AND INSTALLATION

CONTROL WIRING CONNECTIONS
1. Connect control wires to the P1 terminal block located on the logic board as shown.
2. Connect conduit with all control wires through the conduit hole in the electrical box enclosure marked with the label shown below.
3. Apply power to the operator. Press OPEN push button and observe direction of door travel and then Press the STOP
button.
If door did not move in the correct direction, check for improper wiring at the control station or between operator and control station. NOTE: In “Diag” mode the 3-button control station can be
tested to verify correct wiring of Open, Close and Stop buttons without moving the door.
If the door moves in the wrong direction and or the limits move in the wrong direction, simply move the motor direction jumper located on the logic board from the factory default setting (STD) to the (REV) pins. This will change the motor rotation as well as the functional position of the OPEN and CLOSE limit switch’s. Then relocate the safety limit switch (SLS) only to the opposite side with the new functional close limit location. Orient the arm (lever) of the limit switch away from the center. NOTE: The motor
direction change is not available on the DJ and DH models.

EXTERNAL RADIO WIRING CONNECTIONS

On all models a radio terminal bracket marked R1 R2 R3 is located on the outside of the electrical enclosure. In B2 mode the operator will then open a fully closed door, close a fully open door, stop an opening door, and reverse a closing door from the radio remote. In TS control wiring the operator will only open the door or reset the timer to close. However, for additional door control from a 3-button remote, a commercial three-channel radio receiver (with connections for OPEN/CLOSE/STOP) is recommended.
NOTE: If an external radio receiver is being used in place of the built-in receiver, remove or disconnect the coaxial cable from the logic board.
MOUNTING INSTRUCTIONS
1. Mount WARNING NOTICE beside or below the control station.
2. Mount MAINTENANCE ALERT label to either side of control station.
3. Mount control station(s) within line of sight of door(s).
CONTROL WIRING
USE COPPER WIRE ONLY
40-10032B
To prevent possible SERIOUS INJURY or DEATH, install reversing sensors when the 3-button control station is out of sight of the door or ANY other control (automatic or manual) is used. Reversing devices are recommended for ALL installations.
WARNING
WARNING
OR IN THE AREA NEAR THE OPERATOR MUST NOT BE PERFORMED UNTIL DISCONNECTING THE ELECTRICAL POWER AND LOCKING-OUT
THE POWER VIA, THE MAIN DISCONNECT
SWITCH. UPON COMPLETION OF MAINTENANCE THE AREA MUST BE CLEARED AND SECURED, AT THAT TIME THE UNIT MAY
BE RETURNED TO SERVICE.
Maintenance Alert System
TM
If light is Flashing Rapidly, it is time
for routine door maintenance.
If light is Flashing Slowly, followed by a pause, call for immediate service.
Service every
cycles/months
4'
Approximate
Control Station
Optional Controls
POWER
TIMER
DEFEAT
MAS
4
TS
DIAG
24V AC
24V AC
TIMER
DEFEAT
CMN
MAS
EYES
EDGE
OPEN
CLOSE
STOP
CMN
SBC
11
10
9
14
13
12
8
7
6
5
4
3
2
1
STOP
OPEN
EDGE
EYES
P1
D34
F1
D1 E2
)
D23
D15
R8
C18
D8
U7
R31
D31
C3
Ø
D7
D6
D5
D4C25
C17
P1
Ø
D2
Ø
D21
D13
D14
D28
D17
D19
SBC
24V
AC
24V
AC
TIMER
DEFEAT
CMN
MAS
EYES
EDGE
OPEN
CLOSE
STOP
CMN
SBC
11
10
9
14
13
12
8
7
6
5
4
3
2
1
24 VOLT AC
24 VOLT AC
TIMER DEFEAT
COMMON
MAINTENANCE ALERT SYSTEM
PHOTO EYES (LiftMaster Only)
REVERSE
OPEN
CLOSE
STOP
COMMON
INTERLOCK
INTERLOCK
SINGLE BUTTON CONTROL
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