Chamberlain HD800D User Manual

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

www.chamberlain.com

GARAGE DOOR OPENER

Model HD800D 1/2 HP

For Residential Use Only

Owner’s Manual

■ 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

is connected and properly

aligned.

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

■ The model number label is located on the front panel of your opener.

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 garage door and/or the garage door opener if you do not comply with the cautionary statements that accompany it. Read them carefully.

INTRODUCTION

Safety Symbol and Signal Word Review

This garage door opener 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.

Mechanical

Electrical

Introduction 2-7

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

Preparing your garage door................................................3

Tools needed.......................................................................3

Planning ..........................................................................4-5

Carton inventory..................................................................6

Hardware inventory.............................................................7

Assembly 8-11

Assemble the rail and install the trolley ..............................8

Fasten the rail to the motor unit..........................................9

Install the idler pulley ..........................................................9

Install the belt and attach the belt cap retainer.................10

Set the tension ..................................................................11

Installation 11-26

Installation safety instructions ...........................................11

Determine the header bracket location.............................12

Install the header bracket .................................................13

Attach the rail to the header bracket.................................14

Position the opener...........................................................15

Hang the opener ...............................................................16

Install the door control ......................................................17

Install the lights .................................................................18

Attach the emergency release rope and handle...............18

Electrical requirements .....................................................19

Install The Protector System®......................................20-22

Fasten the door bracket...............................................23-24

Connect the door arm to the trolley .............................25-26

Adjustment 27-29

Program the travel limits ...................................................27

Setting the force................................................................28

Test the safety reversal system ........................................29

Test The Protector System®..............................................29

Operation 30-36

Operation safety instructions ............................................30

Using your garage door opener ........................................30

Using the wall-mounted door control ................................31

To open the door manually ...............................................31

Battery backup unit ......................................................32-33

Care of your garage door opener .....................................34

Having a problem?............................................................35

Diagnostic chart ................................................................36

Programming 37-38

To add or reprogram a hand-held remote control.............37

To erase all codes from motor unit memory .....................37

3-Button remotes ..............................................................37

To add, reprogram or change

a Keyless Entry PIN..........................................................38

Repair Parts 39-40

Rail assembly parts...........................................................39

Installation parts................................................................39

Motor unit assembly parts.................................................40

Accessories 41

Operator Notes 42-43

Repair Parts and Service 44

Warranty 44

To prevent damage to garage door and opener:

• ALWAYS disable locks BEFORE installing and operating the opener.

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

To prevent possible SERIOUS INJURY or DEATH:

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

• NEVER try to loosen, move or adjust garage 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 garage door BEFORE installing and operating garage door opener to avoid entanglement.

Preparing your garage door

Before you begin:

• Disable locks.

• Remove any ropes connected to garage door.

• Complete the following test to make sure your garage 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.

Tools needed

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

Sectional Door

One-Piece Door

Carpenter's Level (optional)

Drill

Tape Measure

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

Pencil

Hack Saw

Claw Hammer

Wire Cutters

Screwdriver

Stepladder

Sockets and Wrench 1/2", 5/8", 7/16", 9/16" and 1/4"

Pliers

Adjustable End Wrench

Safety Reversing Sensor

Header Wall

Access Door

— — — — — — — —

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

Extension Spring

Horizontal and vertical reinforcement is needed for lightweight garage doors (fiberglass, steel, aluminum, door with glass panels, etc.). See page 23 for details.

Support bracket & fastening hardware is required. See page 16.

FINISHED CEILING

Motor Unit

Rail

Wallmounted Door Control

Torsion Spring

Vertical Centerline of Garage Door

Safety Reversing Sensor

SECTIONAL DOOR INSTALLATION

Planning

Identify the type and height of your garage door. Survey your garage 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 and the accompanying illustrations as you proceed with the installation of your opener.

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

• Installation Step 1 – Look at the wall or ceiling above the garage door. The header bracket must be securely fastened to structural supports.

• Installation Step 5 – Do you have a finished ceiling in your garage? If so, a support bracket and additional fastening hardware may be required.

• Installation Step 10 – Depending upon garage construction, extension brackets or wood blocks may be needed to install sensors.

• Installation Step 10 – Alternate floor mounting of the safety reversing sensor will require hardware not provided.

• Do you have an access door in addition to the garage door? If not, Model 7702CB Emergency Key Release is required. See Accessories page.

CLOSED POSITION

Header Wall

Garage Door

Header Bracket

Trolley

Straight Door Arm

Emergency Release Rope & Handle

Door Bracket

Curved Door Arm

Garage Door Spring

Belt

Trolley Stop Bolt

• Look at the garage door where it meets the floor. 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. See Adjustment Step 3. Floor or door should be repaired.

SECTIONAL DOOR INSTALLATIONS

• Do you have a steel, aluminum, fiberglass or glass panel door? If so, horizontal and vertical reinforcement is required (Installation Step 11).

• The opener should be installed above the center of the door. If there is a torsion spring or center bearing plate in the way of the header bracket, it may be installed within 4 feet (1.22 m) to the left or right of the door center. See Installation Steps 1 and 11.

• If your door is more than 7 feet (2.13 m) high, see rail extension kits listed on Accessories page.

Planning (Continued)

ONE-PIECE DOOR INSTALLATIONS

• Generally, a one-piece door does not require reinforcement. If your door is lightweight, refer to the information relating to sectional doors in Installation Step 11.

• Depending on your door’s construction, you may need additional mounting hardware for the door bracket (Step 11).

ONE-PIECE DOOR WITHOUT TRACK

Without a properly working safety reversal system, persons (particularly small children) could be SERIOUSLY INJURED or KILLED by a closing garage door.

• The gap between the bottom of the garage door and the floor MUST NOT exceed 1/4" (6 mm). Otherwise, the safety reversal system may not work properly.

• The floor or the garage door MUST be repaired to eliminate the gap.

ONE-PIECE DOOR WITH TRACK

Header Wall

FINISHED CEILI

Support bracket & fastening hardware is required. See page 16.

Access Door

Rail

Wall-mounted Door Control

Motor Unit

CLOSED POSITION

Trolley Stop Bolt

Belt

Trolley

Gap between floor

Safety Reversing Sensor

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

Gap between floor

Safety Reversing Sensor

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

Safety Reversing Sensor

Access Door

Safety Reversing Sensor

Header Wall

Trolley Stop Bolt

Header Bracket

Door Bracket

CLOSED POSITION

Header Bracket

Curved Door Arm

Door Bracket

Garage Door

Belt

Straight Door Arm

Rail

Straight Door Arm

Trolley

Curved Door Arm

Emergency Release Rope & Handle

Rail

Emergency Release Rope & Handle

Straight Door Arm Section

Curved Door Arm Section

Safety Labels

and

Literature

2-Conductor Bell Wire White & White/Red

Idler Pulley

Hanging Bracket

Door Bracket

Trolley

Safety Sensor Bracket (2)

Rail Center/Back Sections

"U" Bracket

Rail Front (header) Section

Header Bracket

Belt

Motor Unit with Light Lens

Belt Cap Retainer

Battery Backup Unit

Remote Control Transmitter Visor Clip

SECURITY✚

3-Button Remote Control (2)

LOCK

LIGHT

Motion Detecting Door Control Panel

SECURITY✚

Keyless Entry

The Protector System

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

Your garage door opener is packaged in one carton which contains the motor unit and all parts illustrated below. Accessories will depend on the model purchased. If anything is missing, carefully check the packing material.

Parts may be stuck in the foam. Hardware for assembly and installation is shown on the next page. Save the carton and packing material until installation and adjustment is complete.

Carton Inventory

Hardware Inventory

Separate all hardware and group as shown below for the assembly and installation procedures.

ASSEMBLY HARDWARE

INSTALLATION HARDWARE

Spring/Trolley Nut (1)

Bolt 1/4"-20x1-3/4" (2)

Carriage Bolt 1/4"-20x1/2" (2)

Lock Nut 1/4"-20 (2)

Trolley Threaded Shaft (1)

Wing Nut 1/4"-20 (2)

Lock Washer 3/8" (1)

Ring Fastener (3)

Nut 5/16"-18 (8)

Master Link (2)

Nut 3/8" (1)

Idler Bolt (1)

Handle

Lag Screw 5/16"-9x1-5/8" (2)

Lag Screw 5/16"-18x1-7/8" (2)

Self-Threading Screw 1/4"-14x5/8" (2)

Clevis Pin 5/16"x1-1/2" (1)

Hex Bolt 5/16"-18x7/8" (4)

Screw 6ABx1-1/4" (2)

Drywall Anchors (2)

Clevis Pin 5/16"x1" (1)

Lock Washer 5/16" (7)

Insulated Staples (30)

Screw 6-32x1" (2)

Rope

Spacer (2)

Clevis Pin 5/16"x1-1/4" (1)

FRONT RAIL (TOP)

KEEP LARGER HOLE ON TOP

ASSEMBLY STEP 1

Assemble the Rail & Install the Trolley

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

Front Rail (TO DOOR)

Window Cut-Out

Screwdriver

Idler Pulley Hole

Ta bs

Back Rails (TO MOTOR UNIT)

Trolley

Tapered End

Inner Trolley

Wear Pads

Outer Trolley

Tapered End

To prevent INJURY from pinching, keep hands and fingers away from the joints while assembling the rail.

The front rail has a cut out “window” at the door end (see illustration). The hole above this window is larger on the top of the rail than on the bottom. A smaller hole 3-1/2" (8.9 cm) away is close to the rail edge. Rotate the back rail so it has a similar hole close to the opposite edge, about 4-3/4" (12 cm) from the far end.

1. Remove the straight door arm and hanging bracket packaged inside the front rail and set aside for Installation Step 5 and 12. NOTE: To prevent INJURY

while unpacking the rail carefully remove the straight door arm stored within the rail section.

2. Align the rail sections on a flat surface as shown and slide the tapered ends into the larger ones. Tabs along the side will lock into place.

3. Place the motor unit on packing material to protect the cover, and rest the back end of the rail on top. For convenience, put a support under the front end of the rail.

4. As a temporary trolley stop, insert a screwdriver into the hole 10" from the front end of the rail, as shown.

5. Check to be sure there are 4 plastic wear pads inside the inner trolley. If they became loose during shipping, check all packing material. Snap them back into position as shown.

6. Slide the trolley assembly along the rail from the back end to the screwdriver.

To avoid SERIOUS damage to garage door opener, use ONLY those bolts/fasteners mounted in the top of the opener.

ASSEMBLY STEP 2

Fasten the Rail to the Motor Unit

• Insert a 1/4"-20x1-3/4" bolt into the cover protection bolt hole on the back end of the rail as shown. Tighten securely with a 1/4"-20 lock nut. Do NOT overtighten.

• Remove the two bolts from the top of the motor unit.

• Place the “U” bracket, flat side down, on the motor unit and align the bracket holes with the bolt holes. Fasten with the previously removed bolts.

• Align the rail assembly with the top of the motor unit. Slide the rail end onto the “U” bracket, all the way to the

stops that protrude on the top and sides of the bracket.

ASSEMBLY STEP 3

Install the Idler Pulley

• Lay the belt beside the rail, as shown. Grasp the end with the hooked trolley connector and pass approximately 12" (30 cm) of belt through the window. Keep the ribbed side toward the rail, and allow it to hang until Assembly Step 5.

• Remove the tape from the idler pulley. The inside center should be pre-greased. If dry, regrease to ensure proper operation.

• Place the idler pulley into the window as shown.

• Insert the idler bolt from the top through the rail and pulley. Tighten with a 3/8" lock washer and nut underneath the rail until the lock washer is compressed.

• Rotate the pulley to be sure it spins freely.

• Insert a 1/4"-20x1-3/4" bolt into the trolley stop hole in the front of the rail as shown. Tighten securely with a 1/4"-20 lock nut.

Idler Pulley

Trolley Stop Hole

Bolt

Trolley Connector

Pulley

Rail

Bolt

Nut

Washer

Lock Washer 3/8"

Nut 3/8"

Idler Bolt

Screwdriver

Idler Pulley

Grease Inside Pulley

Lock Nut

HARDWARE SHOWN ACTUAL SIZE

Motor Unit Sprocket

Bolts

"U" Bracket

Bolt

Cover Protection Bolt Hole

Lock Nut

Bolt 1/4"-20x1-3/4"

1/4"-20

Lock Nut

Foam Packaging

SLIDE RAIL TO STOPS ON TOP AND SIDES OF BRACKET

Idler Bolt

Bolt 1/4"-20x1-3/4"

Lock Nut 1/4"-20

Nut 3/8"

Lock Washer 3/8"

ASSEMBLY STEP 4

Install the Belt and Attach the Belt Cap Retainer

1. Pull the belt around the idler pulley and toward the

trolley. The ribbed side must contact the pulley.

2. Hook the trolley connector into the retaining slot on the

trolley as shown.

3. With the trolley against the screwdriver, dispense the

remainder of the belt along the rail length toward the motor unit and around the sprocket. The sprocket teeth must engage the belt.

4. Check to make sure the belt is not twisted and the

FLAT side of the trolley threaded shaft is facing the rail. Connect the trolley threaded shaft with the master link, as illustrated:

• Push pins of master link bar through holes in end of belt and trolley threaded shaft.

• Push master link cap over pins and past pin notches.

• Slide clip-on spring over cap and onto pin notches until both pins are securely locked in place.

5. Insert the trolley threaded shaft through the hole in the trolley. Be sure the belt is not twisted and the FLAT

side faces the rail.

6. Hold the belt at the trolley shaft as you thread the spring nut by hand onto the shaft until finger tight against the trolley. Do not use any tools.

7. Remove the screwdriver.

8. Position the belt cap retainer over the motor unit sprocket as shown and fasten to the mounting plate with 8x3/8" hex screws provided.

To avoid possible SERIOUS INJURY to fingers from moving garage door opener:

• ALWAYS keep hand clear of sprocket while operating opener.

• Securely attach sprocket cover BEFORE operating.

HARDWARE SHOWN ACTUAL SIZE

Hex Screw 8x3/8"

Spring/Trolley Nut

Master Link Clip-On Spring

Master Link Cap

Idler Pulley

Spring Nut

Trolley Connector

Retaining Slot

Hole

Trolley Threaded Shaft

Hex Screws 8x3/8"

Pin Notch

Master Link Bar

Belt Cap Retainer

Motor Unit Sprocket

Mounting Plate

INSTALLATION

ASSEMBLY STEP 5

Set the Tension

• Insert a screwdriver tip into one of the nut ring slots and

brace it firmly against the trolley.

• Place a 7/16" open end wrench on the square end.

Rotate the nut about 1/4 turn until the spring releases and snaps the nut ring against the trolley.

This sets the spring to optimum belt tension.

You have now finished assembling your garage door opener. Please read the following warnings before proceeding to the installation section.

Nut Ring

Trolley

1" 1-1/4"

BEFORE AFTER RELEASE

Nut Ring Slot

Square End

(2.5 cm)

(3.18 cm)

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

WARNING

WARNINGWARNING

1. READ AND FOLLOW ALL INSTALLATION WARNINGS AND INSTRUCTIONS.

2. Install garage door opener ONLY on properly balanced and lubricated garage 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 opener.

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

5. Install garage door opener 7 feet (2.13 m) or more above floor.

6. Mount emergency release handle 6 feet (1.83 m) above floor.

7. NEVER connect garage door opener to power source until instructed to do so.

8. NEVER wear watches, rings or loose clothing while installing or servicing opener. They could be caught in garage door or opener mechanisms.

9. Install wall-mounted garage door control:

• within sight of the garage door.

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

(1.5 m).

• away from ALL moving parts of the door.

10. Place entrapment warning label on wall next to garage door control.

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

12. 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

Determine the Header Bracket Location

Installation procedures vary according to garage door types. Follow the instructions which apply to your door.

1. Close the door and mark the inside vertical centerline of the garage door.

2. Extend the line onto the header wall above the door.

You can fasten the header bracket within 4 feet (1.22 m) of the left or right of the door center only if a torsion spring or center bearing plate is in the way; or you can attach it to the ceiling (see page 13) when clearance is minimal. (It may be mounted on the wall upside down if necessary, to gain approximately 1/2" (1 cm).)

If you need to install the header bracket on a 2x4 (on wall or ceiling), use lag screws (not provided) to securely fasten the 2x4 to structural supports as shown here and on page 13.

3. Open your door to the highest point of travel as shown. Draw an intersecting horizontal line on the header wall above the high point:

• 2" (5 cm) above the high point for sectional door and one-piece door with track.

• 8" (20 cm) above the high point for one-piece door without track.

This height will provide travel clearance for the top edge of the door.

NOTE: If the total number of inches exceeds the height available in your garage, use the maximum height possible, or refer to page 13 for ceiling installation.

To prevent possible SERIOUS INJURY or DEATH:

• Header bracket MUST be RIGIDLY fastened to structural support on header wall or ceiling, otherwise garage door might not reverse when required. DO NOT install header bracket over drywall.

• Concrete anchors MUST be used if mounting header bracket or 2x4 into masonry.

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

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

Header Wall

Sectional door with curved track

Highest Point of Travel

Door

2" (5 cm)

One-piece door with horizontal track

Door

Track

Header Wall

Highest Point of Travel

2" (5 cm)

Track

Header Wall

Vertical Centerline of Garage Door

Level (optional)

2x4

Structural Supports

OPTIONAL CEILING MOUNT FOR HEADER BRACKET

Unfinished Ceiling

Door

Jamb Hardware

One-piece door without track: jamb hardware

8" (20 cm)

Highest Point of Travel

Door

Pivot

8" (20 cm)

One-piece door without track: pivot hardware

Highest Point of Travel

Header Wall

Lag Screws 5/16"x9x1-5/8"

– Finished Ceiling –

Door Spring

Header Wall

Ceiling Mounting Holes

6" (15 cm) Maximum

Header Bracket

Vertical Centerline of Garage Door

Garage Door

Vertical Centerline of Garage Door

INSTALLATION STEP 2

Install the Header Bracket

You can attach the header bracket either to the wall above the garage door, or to the ceiling. Follow the instructions which will work best for your particular requirements. Do

not install the header bracket over drywall. If installing into masonry, use concrete anchors (not provided).

WALL HEADER BRACKET INSTALLATION

• Center the bracket on the vertical centerline with the bottom edge of the bracket on the horizontal line as shown (with the arrow pointing toward the ceiling).

• Mark the vertical set of bracket holes. Drill 3/16" pilot holes and fasten the bracket securely to a structural support with the hardware provided.

HARDWARE SHOWN ACTUAL SIZE

CEILING HEADER BRACKET INSTALLATION

• Extend the vertical centerline onto the ceiling as shown.

• Center the bracket on the vertical mark, no more than 6" (15 cm) from the wall. Make sure the arrow is pointing away from the wall. The bracket can be mounted flush against the ceiling when clearance is minimal.

• Mark the side holes. Drill 3/16" pilot holes and fasten bracket securely to a structural support with the hardware provided.

Wall Mount

Optional Mounting Holes

Lag Screws 5/16"x9x1-5/8"

Highest Point of Garage Door Travel

Vertical Centerline of Garage Door

Header Wall

Garage Door

Door Spring

2x4 Structural Support

Vertical Centerline of Garage Door

Header Bracket

Horizontal Line

Lag Screw 5/16"-9x1-5/8"

Header Bracket

Idler Pulley

Header Wall

OPTION WITH SOME EXISTING INSTALLATIONS

Header Bracket

Mounting Hole

Existing Header Bracket

Spacer

Mounting Hole

Existing Clevis Pin

Clevis Pin 5/16"x1-1/2"

Ring Fastener

Garage Door

Opener Carton or Temporary Support

INSTALLATION STEP 3

Attach the Rail to the Header Bracket

NOTE: (Optional) With some existing installations, you may re-use the old header bracket with the two plastic spacers included in the hardware bag. Place the spacers inside the bracket on each side of the rail, as illustrated.

• Position the opener on the garage floor below the header bracket. Use packing material as a protective base. NOTE: If the door spring is in the way you’ll need

help. Have someone hold the opener securely on a temporary support to allow the rail to clear the spring.

• Position the rail bracket against the header bracket.

• Align the bracket holes and join with a clevis pin 5/16"x1-1/2" as shown.

• Insert a ring fastener to secure.

HARDWARE SHOWN ACTUAL SIZE

+ 30 hidden pages

Chamberlain HD800D User Manual

TABLE OF CONTENTS

INTRODUCTION

Safety Symbol and Signal Word Review

Preparing your garage door

Tools needed

Planning

Carton Inventory

Hardware Inventory

INSTALLATION