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.

TABLE OF CONTENTS
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

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

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.

Electrical

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.

2

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.

Sectional Door

One-Piece Door

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.

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.

Tools needed

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

Carpenter's

Level (optional)	1	2

Tape Measure

Drill Bits

Drill 3/16", 5/16"

and 5/32"

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

Pencil

Hack Saw

Claw Hammer

Wire Cutters

Screwdriver

Pliers

Adjustable End Wrench

3

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.

•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.

	SECTIONAL DOOR INSTALLATION	FINISHED CEILING
		Support bracket &
	Horizontal and vertical reinforcement	fastening hardware
		is required.
	is needed for lightweight garage doors
		See page 16.
	(fiberglass, steel, aluminum, door with
	glass panels, etc.). See page 23 for details.
		Rail
	Header Wall
		Motor Unit
		Extension Spring
		OR
		Torsion Spring

	Vertical	—
	Centerline	—
	of Garage
		—
	Door
		— — —
		— —

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

Wall-

mounted

Door Access Door Control

Safety Reversing

Sensor

	Header		CLOSED POSITION
	Bracket	Trolley	Trolley
		Stop Bolt
	Garage
	Door		Belt
	Spring
		Straight
		Door	Emergency Release
			Rope & Handle
		Arm
Header		Curved
		Door
Wall		Arm
Garage	Door
	Bracket
Door

4

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).

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 WITHOUT TRACK
		FINISHED CEILING
		Support bracket
		& fastening
		hardware is required.
		See page 16.
	Header Wall
		Rail	Motor Unit
		Wall-mounted
		Door Control
		Access
		Door		CLOSED POSITION
			Trolley Stop Bolt
				Belt Trolley
			Header	Rail
			Bracket
		Safety Reversing	Door Bracket		Emergency
					Release
		Sensor
	Gap between floor				Rope & Handle
	and bottom of door must not exceed 1/4" (6 mm).			Straight	Curved
Safety Reversing					Door
				Door
Sensor					Arm
				Arm
		Header
			Garage
		Wall
			Door

ONE-PIECE DOOR WITH TRACK

CLOSED POSITION

		Trolley Stop Bolt		Belt	Trolley
	Access
	Door	Header	Curved
	Header
		Bracket	Door Arm		Rail
	Wall
		Door			Emergency
		Bracket		Straight	Release
		Garage		Door	Rope &
					Handle
				Arm
		Door

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

5

Carton Inventory

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.

LOCK

LIGHT

Motion Detecting

Door Control Panel

Battery Backup Unit

Belt Cap Retainer

Motor Unit with Light Lens

Idler Pulley

Rail

Front (header)

Section

Header Bracket

Remote Control

Transmitter Visor Clip

SECURITY ®

3-Button Remote Control (2)

Trolley

Rail

Center/Back

Sections

"U" Bracket

Belt

Curved Door

Arm Section

Door Bracket

2-Conductor Bell Wire

White & White/Red

			The Protector System®	Safety Labels
	Safety Sensor
			(2) Safety Reversing Sensors
	Bracket (2)			and
			(1 Sending Eye and 1 Receiving Eye)
				Literature
			with 2-Conductor White & White/Black
			Bell Wire attached

SECURITY ®

Keyless Entry

Hanging Bracket

Straight Door

Arm Section

6

Hardware Inventory

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

ASSEMBLY HARDWARE

Spring/Trolley Nut (1)	Lock Nut	Lock Washer	Nut
	1/4"-20 (2)	3/8" (1)	3/8" (1)

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

Master
Link (2)	Idler Bolt (1)

Trolley Threaded Shaft (1)

		INSTALLATION HARDWARE
Carriage Bolt	Wing Nut	Ring	Nut 5/16"-18 (8)		Handle
1/4"-20x1/2" (2)	1/4"-20 (2)	Fastener (3)
Lag Screw		Hex Bolt			Insulated
5/16"-9x1-5/8" (2)		5/16"-18x7/8" (4)	Lock Washer	5/16" (7)	Staples (30)
Lag Screw		Screw		Screw 6-32x1" (2)
5/16"-18x1-7/8" (2)		6ABx1-1/4" (2)
					Rope
Self-Threading Screw					Spacer (2)
1/4"-14x5/8" (2)		Drywall Anchors (2)
Clevis Pin		Clevis Pin		Clevis Pin
5/16"x1-1/2" (1)		5/16"x1" (1)		5/16"x1-1/4" (1)
		7

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.

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.

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

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.

Trolley

Tapered

End

	KEEP LARGER	Tapered
		End
	HOLE ON TOP
	FRONT RAIL
	(TOP)	Back Rails
		(TO MOTOR UNIT)
		Tapered
		End
		Outer Trolley
	Tapered
	End
	Screwdriver
	Tabs	Inner Trolley
Window
Cut-Out	Front Rail
Idler	(TO DOOR)
Pulley
Hole		Wear Pads

8

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.

HARDWARE SHOWN ACTUAL SIZE

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

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.

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

Motor Unit

Sprocket

Bolts

"U" Bracket

Bolt

Cover

Protection

Bolt Hole

Foam Packaging

SLIDE RAIL TO STOPS

Lock Nut ON TOP AND SIDES

OF BRACKET

Bolt

		Rail
	Pulley
	Nut Washer
	Screwdriver
		Bolt
		Trolley
		Stop Hole
		Grease
		Inside Pulley
Lock Washer		Idler Pulley
3/8"
	Nut 3/8"
	Trolley
	Connector	Idler	Lock
		Pulley	Nut

HARDWARE SHOWN ACTUAL SIZE

Idler Bolt

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

Lock Nut 1/4"-20

Nut 3/8"

Lock Washer 3/8"

9

	ASSEMBLY STEP 4
	Install the Belt
			To avoid possible SERIOUS INJURY to fingers from moving
	and Attach the Belt Cap Retainer		garage door opener:
	1. Pull the belt around the idler pulley and toward the		• ALWAYS keep hand clear of sprocket while operating opener.
			• Securely attach sprocket cover BEFORE operating.
	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.	HARDWARE SHOWN ACTUAL SIZE
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	Hex Screw 8x3/8"
	spring nut by hand onto the shaft until finger tight	Spring/Trolley Nut
	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.	Master Link
	Clip-On Spring
	Master Link Cap
				Pin
				Notch
			Trolley	Master
			Threaded	Link Bar
			Shaft
			Hole
		Retaining
	Trolley	Slot	Hex Screws
			8x3/8"
	Connector
				Belt Cap
Idler Pulley				Retainer
				Motor Unit
				Sprocket
				Mounting
				Plate
Spring Nut

10

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 Slot

Square End

		Trolley
Square
End	Nut Ring	Nut Ring

BEFORE

AFTER RELEASE

1"

1-1/4"

(2.5 cm)

(3.18 cm)

INSTALLATION

IMPORTANT INSTALLATION INSTRUCTIONS

WARNING

To reduce the risk of SEVERE INJURY or DEATH:

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.

11

INSTALLATION STEP 1

Determine the Header Bracket

Location

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.

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.

Unfinished

Ceiling

OPTIONAL

CEILING

MOUNT

FOR

HEADER

BRACKET

Header Wall

2x4

Vertical Centerline

of Garage Door

2x4 Structural

Supports

Level (optional)

Header Wall
2" (5 cm)	Track	Header Wall	Track
		2" (5 cm)
Highest Point
of Travel		Highest Point
		of Travel
		Door
Door

Sectional door with curved track

One-piece door with horizontal track

		Header Wall
	Header Wall	8" (20 cm)
	8" (20 cm)
	Highest	Highest
Door		Point
	Point	of Travel
	of Travel	Door
Jamb
Hardware
		Pivot
One-piece door without track:		One-piece door without track:
jamb hardware		pivot hardware

12

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

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

Wall Mount

UP

Optional

Mounting Holes

		Vertical
		Centerline
		of Garage Door
	Wall	Lag Screws
	2x4	5/16"x9x1-5/8"
		Header
	Structural
		Bracket
	Support
		Door Spring

Horizontal

Line

Garage

Door

Highest Point of

Garage Door Travel Vertical

Centerline

of Garage Door

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.

Ceiling Mounting Holes

UP

Header

Bracket

6" (15 cm) Maximum

Door

Spring

Garage Door

– Finished Ceiling –

Vertical Centerline

of Garage Door

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

Header Wall

Vertical

Centerline

of Garage Door

13

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.

Header Wall

Header Bracket

Idler Pulley

Header

Bracket

Mounting

Hole

Existing

Header Bracket

Existing

Clevis Pin

Spacer

Mounting

Hole

N WITH

EXISTING

INSTALLATIONS

Garage

Door

Opener Carton or

Temporary

Support

HARDWARE SHOWN ACTUAL SIZE

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

Ring Fastener

14