Chamberlain K001D8395, K001A5729, K001A6837 User Manual

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SAFETY INFORMATION

Mechanical

Electrical

IMPORTANT NOTES:

• BEFORE attempting to install, operate or maintain the commercial door operator, you must read and fully understand this manual and follow all safety instructions.

• DO NOT attempt repair or service of a commercial door operator unless you are an Authorized Service Technician.

• A commercial door operator should only be installed on a properly balanced door only. Ensure door is properly balanced prior to installation.

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.

IMPORTANT INSTALLATION INSTRUCTIONS

TO REDUCE THE RISK OF SEVERE INJURY OR DEATH:

1. READ AND FOLLOW ALL INSTALLATION WARNINGS AND INSTRUCTIONS.

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

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

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

5. Install an operator, a minimum of 8 feet (2.44 m) from the floor.

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

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

ENTRAPMENT PROTECTION DEVICES: LiftMaster Monitored Entrapment Protection (LMEP)

Monitored photoelectric sensors and/or door edge sensors are required for any momentary contact to close modes of operation. Refer to operator manual for additional information. Refer to the ‘Commercial Door Entrapment Protection Systems’, and accessories page 64, for available options.

8. Install a control station:

• within sight of the door

• out of reach of small children and at a minimum height of 5 feet (1.5 m) above floors, landings, steps, or any other adjacent walking surface.

• away from ALL moving parts of the door

9. Install the control station far enough from the door to

prevent the user from coming in contact with the door while operating the controls.

10. Install the entrapment warning placard on the wall next to

the control station in a prominent location, visible from the door.

11. Place the manual release/safety reverse test label in plain

view on the inside of door.

12. Upon completion of installation, test the entrapment

protection device(s).

13. SAVE THESE INSTRUCTIONS.

General Information

This guide is intended to help with Commercial Door Operator maintenance and troubleshooting. The guide offers several different troubleshooting scenarios and provides answers to frequently asked questions. The comprehensive, yet user-friendly guide will hopefully be used as a tool to solve all of the Commercial Door Operator maintenance problems you may encounter.

SECTION A

Basic Troubleshooting 4-6

SECTION B

Logic Operators

Industrial Duty Logic Operators 8-26

Medium Duty Logic Operators 27-31

SECTION C

Mechanical Operators 34-36

SECTION D

Basic Electrical Information 38-45

SECTION E

General Information 46-52

SECTION F

Wiring Diagrams 54-62

Commercial Door Entrapment Protection Systems 64

Table of Contents

SECTION A

Page

Basic Troubleshooting 5

Basic Troubleshooting

Always Follow Local Electrical Codes

WARNING! If you are not trained in electrical safety, contact a professional electrical safety trainer. It is in your best interest to have electrical safety training. Do not attempt to work on a powered (turned on) operator if you have not received electrical safety training. Remember, it is dangerous to deal with high-voltage electricity. Many people incurred serious injuries, including fatalities, as a result of electrical accidents. You must be very careful when checking line voltages.

The high-voltage wiring to the operator, low-voltage wiring to the control station(s), and safety devices may require a licensed electrician for installation.

Make Sure The Door Is Working Properly

Close the door and disconnect the door from the operator. Manually operate the door. The lifting force needed by most doors should be manageable by one person and the door should move smoothly. Check all hardware for wear, binding and tightness. Replace any marginal parts. The door should be in good working order. An unbalanced or jerking door will put excess wear on the operator and cause premature failure. When checking a door with a hoist operator, be sure the door is disconnected from the operator and lifted by hand and not by the hoist/hand chain. It is very difﬁ cult to determine if the door is balanced when using the operator chain hoist. Repair any door problems before reattaching the operator.

Remove All Accessories And Control Devices

In many cases an operator may be malfunctioning due to accessories or control devices attached to the operator’s control circuit. The ﬁ rst step in troubleshooting is to use a process of elimination. Disconnect all wired accessories and control devices. Many times in complicated installations, there will be extra devices installed by an electrician or other subcontractor that may not be functioning properly with the operator. If the door functions properly after disconnecting additional devices, start reconnecting each device one at a time. Determine if any of the control device(s) are causing the problem. Advise the customer of your ﬁ ndings and their options for repairs/replacements.

NOTE: When monitored entrapment protection devices are removed from operators that require a monitored entrapment protection device such as photo eyes; they will no longer function unless they are under constant pressure.

Basic Troubleshooting

Check Incoming Voltage

Check the incoming power voltage to ensure readings are within 10% of the rated voltage. For example, a 115VACrated power line should read between 103.5 to 126.5VAC. Continue to monitor voltage as the operator is activated through one cycle. Voltage drops occur, but should not drop more than 5% under load from the non-functioning position, +/- 10% at startup and +/- 5% while the operator is running. Low voltages can cause damage to components and cause functionality issues.

NOTE: The installation of a dedicated circuit is required for achieving optimal voltage.

Check The Overload

Look at the overload button (when present) on the outside or inside of the electrical box. To conﬁ rm if the overload has been tripped, press the overload button. If the overload has been tripped, look for a short or bad wire in the operator. Resetting the overload will only ﬁ x the problem temporarily. LiftMaster recommends the cause of the overload be identiﬁ ed and resolved. Logic operators are equipped with a thermal overload and will automatically reset themselves. After the operator cools it must be run a full cycle.

Check Any Interlock Switches

Check any interlock and/or disconnect switches for full activation. Manually activate any interlock switches to verify proper motion of the switch and use a multimeter across the switch leads to verify proper electrical output. The output should show a closed circuit (low resistance) when the door is ready to be activated.

All of the above testing is generic for Logic 3.0, Logic 4.0, Logic 5.0, Medium Duty Logic and Mechanical operators. Mechanical operators are also known as Contactor or Electro-Mechanical operators. Efﬁ ciency in troubleshooting operators differs from this point. Logic operators have many LEDs and special controls to speed up diagnosis. For a Mechanical operator, refer to Section C. For Logic 3.0, 4.0, 5.0 operators, continue on to Section B.

Table of Contents

SECTION B

Logic Operators

Industrial Duty Logic Operators

Page

Logic Board Overview 9

Troubleshooting 13

Selected Features 21

Diagnostic Chart 22

Symptoms And Solutions 23

Error Codes 25

Remote Controls 27

Medium Duty Logic Operators

Page

Troubleshooting 28

Symptoms And Solutions 29

Error Codes 30

Programming 31

Logic Board Overview

LOGIC 5.0 - SERVICE KIT# K001D8395

Optional Auxiliary Card Receptacles

Motor Direction Jumper

Current Sense

Industrial Duty Logic Operators

Single Phase & Three Phase Jumper

Receiver LED

Maximum Run Timer Button

Radio Learn Button

Mid Stop Learn Button

Timer-To-Close Learn Button

Selector Dial (used for programming and selecting wiring type)

Maintenance Alert System Button for Programming

Open Button

Close Button

Stop Button

Control Wiring Terminal Block

Main Motor Control Harness Connection

Logic Board Overview

Logic 5.0 Power Board - Dual Voltage Connections

• Reduces stocking a wide variety of operators due to range of potentially required voltages.

• Minimizes lost time if operator does not meet predetermined job site voltage requirements.

Industrial Duty Logic Operators

1 Phase Power Board 115/230V

Service Kit# ...................................... K001D8396-1

3 Phase 208/230/460V

Service Kit# ..........................................K001D8397

N4 & N4X Electrical Box Board Requirements

The N4 & N4X Electrical Boxes require speciﬁ c power boards. When installing power boards for the N4 or N4X Electrical boxes, choose one of the compatible power boards outlined below that ﬁ t your speciﬁ c voltage requirements.

3 Phase Power Board 575V

Service Kit# ...................................... K001D8397-1

1 Phase Power board - 115/230V, N4/N4X

Service Kit#

3 Phase Power board - 230/460/575V, N4/N4X

Service Kit#

.............................................................................................................................................................................K001D8398

.........................................................................................................................................................................K001D8116-1

Logic Board Overview

LOGIC 4.0 K001A6837

Optional Auxiliary

Card Receptacles

Motor

Direction

Jumper

Receiver LED

Maximum Run

Timer Button

Radio

Learn Button

Industrial Duty Logic Operators

Single Phase

& Three Phase

Jumper

Maintenance

Alert System

Button for

Programming

Mid Stop

Learn Button

Timer-To-Close

Learn Button

Selector Dial

(used for

programming

and selecting

wiring type)

Main Motor Control Harness Connection

Open Button

Close Button

Stop Button

Control Wiring Terminal Block

Open Button

Close Button

Stop Button

Control Wiring Terminal Block

Logic Board Overview

LOGIC 3.0 K001A5729

Optional Auxiliary Card Receptacles

Industrial Duty Logic Operators

Single Phase and Three Phase Jumper

Motor Direction Jumper

Open Limit Switch LED

Mid-Stop LED

Safety Limit Switch LED

Close Limit Switch LED

Receiver LED

Radio Learn Button

Maximum Run Timer Learn Button

Mid-Stop Learn Button

Timer to Close Learn Button

Power LED

Timer Defeat LED

MAS Learn Button and LED

Entrapment Protection LED

Edge LED

Open Button LED

Close Button LED

Stop Button LED

Relay LEDs

Selector Dial

Failsafe/Non-Failsafe Selector Switch

Control Wiring Terminal Block

Timer Enable LED

On-Board 3-Button Control Station

Single Button Control LED

Troubleshooting

Look For Green “POWER” LED

The Industrial Duty Logic Operator has many features reducing time required to identify and make repairs, as well as time spent training service technicians. Please note when working on an operator, always follow proper electrical safety guidelines and local codes.

The transformer should produce 24VAC (±10 %) on the secondary side. If the green power LED, which is located near terminal 13, is illuminated then 24VAC is present on the logic board. Verifying with a multimeter is still recommended. To check the secondary side of the transformer, set the meter to volts AC and check across the yellow and blue wires on the transformer or terminals 13 and 14 on the logic board. If working properly, they should each show 24VAC +/10%.

The logic board and all the controls are run on 5VDC. The 5VDC control signal allows 1000 ft. control runs with 18AWG wire. Be sure any incoming signal to the board is from a dry contact and not a voltage source. A dry contact, such as a standard switch, is a device connecting two wire leads to make a closed circuit. Some examples are the open or close buttons on LiftMaster’s standard 3-button control station, limit switches and standard relay outputs.

If the green “POWER” LED does not turn on, the transformer may not be working correctly. Verify primary voltage feeding the transformer by checking: Logic 3.0 and Logic 4.0 - White and Brown wires. Logic 5.0 - Common and appropriate wire. See the chart for high voltage wires.

Industrial Duty Logic Operators

Transformer - High Voltage Color Code

LOGIC 3.0 AND LOGIC 4.0 LOGIC 5.0

115V Brown and White White and Gray 208/230V Single Phase Brown and White White and Purple 208/230V Three Phase Brown and White White and Gray 460V Brown and White White and Purple 575V Brown and White White and Gray

Check Control Station

Verify the control stations are wired to the terminal strip correctly. This is easily checked by using the “OPEN,” “CLOSE”, and “STOP” LED diagnostic LEDs. The operator should have the “OPEN” and “CLOSE” LEDs off and the green “STOP” LED on.

Turn the selector dial to DIAG to put the operator in diagnostic mode. Conﬁ rm the wiring is correct on the board by pressing the “OPEN” and “CLOSE” button on the board separately. When each button is pressed, the corresponding LED should turn on. When working properly, the STOP LED should be illuminated. Pressing the STOP button should make this LED turn off. If the LED’s respond accordingly to the on-board OPEN/CLOSE/STOP buttons, test the 3-button control station or the wiring to the 3-button control station.

To test the 3-button control station, open the control station and use a multimeter to verify continuity. When working properly, an idle 3-button control station with no depressed buttons should read inﬁ nite resistance (open circuit) across the “OPEN” and “CLOSE” buttons and 0 Ohms (closed circuit) across the “STOP” button. The meter should read 0 Ohms (closed circuit) when the “OPEN” and “CLOSE” buttons are pressed, and inﬁ nite resistance (open circuit) when the “STOP” button is pressed. If the continuity test on the 3-button control station yields different results than listed, the control station will have to be replaced.

NOTE: Don’t run control wiring and power wiring in the same conduit, these wirings should be separated by 18”.

Troubleshooting

Check Control Station (Continued)

Terminals 2 and 3 are also a normally closed circuit used when an external interlock is present. If the external interlock is activated the “STOP” LED will not be lit.

If the LEDs do not respond, disconnect the wall control station(s), put a jumper between the “STOP” and “COMMON” terminals, and try activating the LEDs by pressing the on-board 3-button control station next to the terminal strip. If the LEDs do not respond, there is a problem with the logic board and will require replacement.

If the lights do respond, but the operator still does not run, reset the operator to factory defaults.

Industrial Duty Logic Operators

Resetting Factory Defaults - Clearing Memory

To reset most of the user installed settings back to factory defaults:

1) Turn the selector dial to DIAGNOSTIC.

2) Press and hold the STOP button for 5 seconds. The MAS LED will ﬂ ash

momentarily when the factory defaults have been restored.

3) Return the selector dial to the desired wiring type.

Factory Defaults:

a) Timer-To-Close is set to 0 seconds. b) The Mid Stop is deactivated. c) The Maintenance Alert System is deactivated. d) The Maximum Run Timer is set to 90 seconds. e) Car Dealer Mode is deactivated. f ) The remote controls and myQ® devices will still be learned. g) Remote control programming via the 3-button control station. h) The LiftMaster Monitored Entrapment Protection (LMEP) device(s) will

be unprogrammed.

NOTE: Life of Operator feature (Odometer/Cycle Counter) and programmed remote controls and myQ devices are not cleared.

SELECTOR DIAL

Operation will vary depending on wiring type

Troubleshooting

Advanced Troubleshooting: Testing Single Phase Logic 3.0 And 4.0 Relays

The following tests should be performed by a qualiﬁ ed technician. A multimeter is required.

Industrial Duty Logic Operators

(YE)

(WH)

(WH) (WH)

(WH)

(YE)

(YE) (OR)

(GY)

(PU)

(OR)

(PU)

(BL) (GY)

See Motor

Connections

SLOT 1

hot

neutral

ground

(YE)

SLOT 2

MOV

L3 L2 L1

(WH)

COM

+24 VAC -24 VAC

(BK)

120 VAC

OLS

REV

STD

120 / 240

VAC

MID

SLS

MOTOR

DIRECTION

(BR)

(WH)

CLS

See Motor

Connections

COM

COIL

RADIO

(WH)

(GY)

(WH)

Testing C Relay

Check Coil Wires. 0VDC at idle, 24VDC when given a command either direction. Check NO Contact. Metering L1 to either white wire on C relay should read line voltage when given a command.

Testing B Relay

Check Coil Wires. 0VDC at idle, 24VDC when given an OPEN command. *Special applications might show voltage in the opposite direction. Check NO Contact. Metering L2 to 6 on B relay should read line voltage when given an OPEN command. *Special applications might show voltage in the opposite direction.

Testing A Relay

Check Coil Wires. 0VDC at idle, 24VDC when given a CLOSE command. *Special applications might show voltage in the opposite direction. Check NO Contact. Metering L2 to 2 on A relay should read line voltage when given a CLOSE command. *Special applications might show voltage in the opposite direction.

Testing K3 Relay (Start Winding Relay On Board With White And Yellow Wires)

K3 is a NO relay that closes for 1.25 seconds during start up. To test, remove White and Yellow wires and test for continuity across the contacts on the relay. Reading should be OPEN when operator is idle and should close for 1.25 seconds when operator is given a command.

NOTE: 1) This test will put the operator into a restricted close mode. Simply cycle power to reset.

2) If the K3 relay is stuck CLOSED, the motor will 'GROWL' loudly and trip the circuit breaker.

3) If the K3 relay is stuck OPEN, motor will only hum.

Troubleshooting

Advanced Troubleshooting: Testing Three Phase Logic 3.0 And 4.0 Relays

The following tests should be performed by a qualiﬁ ed technician. A multimeter will be required.

Industrial Duty Logic Operators

SLOT 1

208/230/460

VOLT 3PH.

POWER IN

(YE)

SLOT 2

L3 L2 L1

(WH)

COM 120

+24 VAC

MOV

(WH)

(BK)

VAC

240 / 460 / 575 VAC

-24 VAC

OLS

REV

STD

MID

SLS

MOTOR

DIRECTION

CLS

MRT

COM

COIL

(WH)

RADIO

(WH)

(PU) (BR) (BR)

See Motor

Connections

(WH)

COM

COIL

(WH)

(GY)

(GY) (YE)

(RD) (WH) (PU) (YE) (OR)

(GY)

(PU)

(OR)

(WH) (WH) (WH)

(WH)

(YE)

(GY)

See Motor

Connections

Testing C And D Relays

Check Coil Wires. Both are 0VDC at idle. Metering across either coil should read 12VDC when given a command. Check NO Contact. Metering L1 to either white wire on C or D relay should read line voltage when given a command.

Testing B Relay

Testing A Relay

Troubleshooting

Advanced Troubleshooting: Checking Logic 5.0 Single Phase Motor

The following tests should be performed by a qualiﬁ ed technician. A multimeter will be required.

Industrial Duty Logic Operators

123

456

789

10 11 12

1) Turn power off to the operator.

2) Locate the motor plug on the POWER BOARD and unplug.

3) Set the multimeter to continuity/ohms. Ω *Certain meters have a setting that beeps when a closed circuit is

detected. This setting is preferred for the test.

4) Using the guide below, check for continuity across the following pins on the motor harness:

a. Place probe between Thermal Protector, Pins 4 and 10. Continuity should be present. b. Place probe between Run Winding 1, Pins 12 and 8. Continuity should be present. c. Place probe between Run Winding 2, Pins 11 and 9. Continuity should be present. d. Place probe between Start Winding, Pins 1 and 7. Continuity should NOT be present.

5) If the readings are different than the results expected above, the motor will have to be replaced.

Troubleshooting

Advanced Troubleshooting: Checking Logic 5.0 Three Phase Motor

The following tests should be performed by a qualiﬁ ed technician. A multimeter will be required.

Industrial Duty Logic Operators

123

456

789

10 11 12

13 14 15

1) Turn power off to the operator.

2) Locate the motor plug on the POWER BOARD and unplug.

3) Set the multimeter to continuity/ohms. Ω *Certain meters have a setting that beeps when a closed circuit is

detected. This setting is preferred for the test.

4) Using the guide below, check for continuity across the following pins on the motor harness:

a. Place probe between Thermal Protector, Pins 1 and 4. Continuity should be present. b. Place probe between Motor Winding 1, Pins 14 and 8. Continuity should be present. c. Place probe between Motor Winding 2, Pins 15 and 7. Continuity should be present. d. Place probe between Motor Winding 3, Pins 9 and 5. Continuity should be present. e. Place probe between Motor Winding 4, Pins 6, 11 and 12. Continuity should be present. *Any combination

between Pins 6, 11 and 12, continuity should be present.

5) If the readings are different than the results expected above, the motor will have to be replaced.

Troubleshooting

Advanced Troubleshooting: Checking Logic 5.0 Single Phase Brake And Power Board

The following tests should be performed by a qualiﬁ ed technician. A multimeter is required.

To Check Brake (when present)

Industrial Duty Logic Operators

To Check Power Board

To Check Brake (When Present)

1) Turn power off to the operator.

2) Locate the brake plug on the POWER BOARD and unplug.

3) Set the multimeter to continuity/ohms. Ω *Certain meters have a setting that beeps when a closed circuit is

detected. This setting is preferred for the test.

4) Using the guide below, check for continuity across the following pins on the brake harness:

a. On 115v operators, place probe between the White and Yellow wires on the brake

harness. Continuity should be present.

b. On 208/230v operators, place probe between the Blue and Black on the brake

harness. Continuity should be present.

5) If the readings are different than the results expected above, the brake solenoid will have to be replaced.

To Check Power Board

This measurement is done with power removed from the operator and the low voltage harness plugged in to the Power Board. Set meter to ohms(Ω) and check : Orange to Gray should read 335 ohms Orange to Purple should read 648 ohms Orange to Black should read 335 ohms Orange to Yellow should read 648 ohms * Readings are to allow +/- 10% deviation If the readings are different than the results expected above, the Power

Board will have to be replaced.

Troubleshooting

Advanced Troubleshooting: Checking Logic 5.0 Three Phase Brake And Power Board

The following tests should be performed by a qualiﬁ ed technician. A multimeter will be required.

To Check Brake (when present)

Industrial Duty Logic Operators

To Check Power Board

To Check Brake (When Present)

1) Turn power off to the operator.

2) Locate the brake plug on the POWER BOARD and unplug.

3) Set the multimeter to continuity/ohms. Ω *Certain meters have a setting that beeps when a closed circuit is

detected. This setting is preferred for the test.

4) Using the guide below, check for continuity across the following pins on the brake harness:

a. Place probe between Pins 1 and 4 on the brake harness. Continuity should be present.

5) If the readings are different than the results expected above, the brake solenoid will have to be replaced.

To Check Power Board

This measurement is done with power removed from the operator and the low voltage harness plugged in to the Power Board. Set meter to ohms(Ω) and check : Orange to Gray should read 350 ohms Orange to Purple should read 640 ohms Orange to Black should read 350 ohms Orange to Yellow should read 350 ohms *Readings are to allow +/- 10% deviation If the readings are different than the results expected above, the Power Board will have to be replaced.

NOTE: Fusing on the 3-Phase Power Board is not ﬁ eld-replaceable. An Open Fuse indicates that the 3-Phase Power Board is damaged and must be replaced. Failure to replace the complete 3-Phase Power Board may result in additional damage to the Operator.

+ 45 hidden pages

Chamberlain K001D8395, K001A5729, K001A6837 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual