Chamberlain PD460-2K, PD420, PD420-2, PD460-2 User Manual

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

www.chamberlain.com

GARAGE DOOR OPENER

Models PD420 • PD420-2 • PD460-2 • PD460-2K 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.

Introduction 2-5

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 .....................................................8-9

Fasten the rail to the motor unit and

install the trolley ........................................................10

Attach the rail brackets..............................................11

Installation 11-27

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

Determine the header bracket location................12-13

Install the header bracket..........................................14

Attach the rail to the header bracket.........................15

Install the Protector System

................................16-18

Position the opener ...................................................19

Hang the opener .......................................................20

Install the door control...............................................21

Install the lights ........................................................22

Attach the emergency release rope and handle .......22

Electrical requirements..............................................23

Complete safety reversing sensor installation ..........23

Fasten the door bracket .......................................24-25

Connect the door arm to the trolley .....................26-27

Adjustment 28-30

Adjust the up and down travel limits .........................28

Adjust the force .........................................................29

Test the safety reversal system.................................30

Test the Protector System®........................................30

Operation 31-34

Operation safety instructions.....................................31

Using your garage door opener ................................31

Using the wall-mounted door control ........................32

To open the door manually........................................32

Care of your garage door opener..............................33

Having a problem? ....................................................34

Programming 35-36

To add a hand-held remote control ...........................35

To erase all codes .....................................................35

Multi-function remotes ...............................................35

To add or change a Keyless Entry PIN.....................36

Repair Parts 37-38

Rail assembly parts...................................................37

Installation parts ........................................................37

Motor unit assembly parts .........................................38

Accessories 39

Repair Parts and Service 40

Warranty 40

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

WARNING

CAUTION

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.

WARNING

Sectional Door

One-Piece Door

WARNING

CAUTION

Carpenter's Level (Optional)

Drill

Tape Measure

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

Pencil

Hack Saw

Wire Cutters

Claw Hammer

Pliers

Stepladder

1/2" and 7/16" Sockets and Wrench

Screwdriver

Adjustable End Wrench

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 4 – Depending upon garage construction, extension brackets or wood blocks may be needed to install sensors.

• Installation Step 4 – Alternate floor mounting of the safety reversing sensor will require hardware not provided.

• Installation Step 6 – Do you have a finished ceiling in your garage? If so, a support bracket and additional fastening hardware may be required.

• 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 12).

• 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 12.

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

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

Header Wall

Vertical Centerline of Garage Door

Safety Reversing Sensor

— — — — — — — —

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

Rail

Torsion Spring

Wallmounted Door Control

Safety Reversing Sensor

Extension Spring

Access Door

FINISHED CEILING

Support bracket & fastening hardware is required. See page 19.

Header Wall

Garage Door

Header Bracket

Garage Door Spring

Straight Door Arm

Door Bracket

Motor unit

CLOSED POSITION

Rail Bracket

Curved Door Arm

Rail Assembly

Trolley

Emergency Release Rope & Handle

Access Door

Safety Reversing Sensor

Header Bracket

Door Bracket

Straight Door Arm

Curved Door Arm

Trolley

Emergency Release Rope & Handle

Rail Assembly

Garage Door

Header Wall

Rail Bracket

CLOSED POSITION

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

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 12.

• Depending on your door’s construction, you may need additional mounting hardware for the door bracket (Step 12).

ONE-PIECE DOOR WITHOUT TRACK

ONE-PIECE DOOR WITH 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.

WARNING

Header Wall

Safety Reversing Sensor

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

FINISHED CEILING

Support bracket & fastening hardware is required. See page 19.

Rail

Wall-mounted Door Control

Access Door

Motor unit

Header

Header Bracket

Garage Door Spring

Straight Door Arm

CLOSED POSITION

Rail Bracket

Curved

Rail Assembly

Trolley

Emergency Release Rope & Handle

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

Model 420 (1), Model 420-2 (2)

LIGHT

Multi-Function Door Control Panel

Motor Unit with a Light Lens

SECURITY✚

Single Button Remote Control

Rail Support Braces (4)

Model 460 (2) Model 460-2K (2)

SECURITY✚

3-Button Remote Control

Model 460-2K

SECURITY✚

Keyless Entry

Rail Assembly

Remote Control Transmitter Visor Clip

Sprocket Coupling

2-Conductor Bell Wire White & White/Red

Hanging Brackets

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

Header/Rail Brackets

Y L

N O T

G N I

L I E

Header Bracket

Trolley

Door Bracket

Safety Reversing Sensor Mounting Bracket (2)

Straight Door Arm Section

Curved Door Arm Section

Safety Labels

and

Literature

ASSEMBLY HARDWARE

INSTALLATION HARDWARE

Hardware Inventory

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

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

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

Bolt 1/4-20x1-3/4" (8)

Wing Nut 1/4"-20 (2)

Hex Bolt 1/4"-20x5/8" (4)

Ring Fastener (3)

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

Nut 5/16"-18 (6)

Lock Washer 5/16" (6)

Lock Nut 1/4"-20x7/16 (12)

Sprocket Coupling Sleeve

Handle

Insulated Staples (30)

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

Carriage Bolt 5/16"-18x2-1/2" (2)

Clevis Pin 5/16"x2-3/4" (1)

Screw 6ABx1-1/4" (2)

Dry Wall Anchors (2)

Clevis Pin 5/16"x1" (1)

Screw 6-32x1" (2)

Rope

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

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

WARNING

ASSEMBLY STEP 1

Assemble the Rail

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

1. Turn the opened rail carton upside down and empty its contents onto a level work surface.

2. Unfold the rails, taking care to avoid kinking the screw rod joint.

3. Rotate the rail sections so that the flat side is down and the screw side is up for all three lengths. Keep it clean and free of debris while you are working.

NOTE: During assembly, avoid pulling the rail section housing the trolley rack away from the screw rod. The rack is factory set about 9" (23 cm) from the end of the screw rod to the center of the rack.

If the plastic liner slides part way out during assembly, simply push it back in.

Straight Door Arm

CAUTION

Rail Support Braces

Rail Assembly Carton

Remove Cardboard Packing

Extend End Rails Outward

Rail Assembly Hardware Bag

Center Rail

Trolley Rack

Sprocket End Rail

Remove Cardboard Packing

Chassis Assembly Hardware Bag

Trolley Rack

Door End Rail

Rail Sprocket

Rotate

Center Rail

Assemble the Rail (Continued)

4. Beginning with the sprocket end, straighten the two rail sections so that the screw rod is in a straight line at the joint. (Avoid handling the joint, which may have sharp edges.)

5. Carefully slide the pins at the top edge of the rail into the openings on the adjacent rail. It is

essential that the rail assembly be on a level surface to achieve proper alignment and to avoid damage to the pins.

6. Insert two 1/4"-20x1-3/4" bolts through the center holes of a brace, and place its open length against the rail at the joint, aligning the holes as shown. Position another brace on the opposite side of the rail over the bolts, add 1/4"-20 lock nuts, and hand tighten. Insert two additional bolts and hand tighten.

7. Keeping the rail straight and on a level surface, grasp the screw rods on each side of the remaining joint and pivot into a straight line. Repeat steps 5 and 6.

8. With a 7/16" wrench, tighten bolts until snug, beginning with the center holes. Do not

overtighten.

Center Rail

Slide end rail toward center rail

Rail Support Brace

Lock Nuts

Center Rail

Rail Pin

Alignment Hole

Rail Support Brace

Rail Pin

Alignment Hole

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

Lock Nuts

End Rail

Door End (Front)

Sprocket End (Back)

Slide end rail toward center rail

HARDWARE SHOWN ACTUAL SIZE

Bolt 1/4"-20x1-3/4" (8)

Lock Nut 1/4"-20

ASSEMBLY STEP 2

Fasten the Rail to the Motor Unit and Install the Trolley

NOTE: To aid in assembly and installation, replace the foam packing around the motor unit. Remove it after Installation Step 4.

• Working on a level surface, align the rail assembly with the motor unit, as shown.

• Slip the coupling over the rail sprocket.

• Slide the rail through the motor unit bracket until the coupling fits securely over the motor unit sprocket.

• Align the two bolt holes in the rail with those in the motor unit bracket. Insert two 1/4"-20x5/8" hex bolts and lock nuts. Tighten securely with a 7/16" socket wrench.

Slide the trolley onto and along the bottom of the rail until it snaps firmly in place. Be certain to

install it facing correctly: the trolley release arm must be horizontal (lock position), with its arrow pointed away from the motor unit.

Rail Sprocket

Rail Assembly

Trolley

Coupling

Motor Unit Bracket

Lock Nuts 1/4"-20

Motor Unit Sprocket

Foam Packaging

Hex Bolts 1/4"-20x5/8"

Release arm

Arrow must point toward garage door

HARDWARE SHOWN ACTUAL SIZE

Hex Bolt 1/4"-20x5/8"

Lock Nut 1/4"-20

INSTALLATION

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

WARNING

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.

ASSEMBLY STEP 3

Attach the Rail Brackets

• Align rail brackets to end of rail assembly, as shown.

• Insert two 1/4"-20x5/8" hex bolts and lock nuts. Tighten securely with a 7/16" socket.

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

HARDWARE SHOWN ACTUAL SIZE

Rail Brackets

Lock Nuts 1/4"-20

Hex Bolts 1/4"-20x5/8

Rail

Hex Bolt 1/4"-20x5/8"

Lock Nut 1/4"-20

WARNING

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:

• 3" (7.5 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.

WARNING

Header Wall

Vertical Centerline of Garage Door

Level (optional)

Header Wall

3" (7.5 cm)

Highest Point of Travel

Door

Sectional door with curved track

Header Wall

Door

Jamb Hardware

Track

8" (20 cm)

Highest Point of Travel

Unfinished Ceiling

OPTIONAL CEILING MOUNT FOR HEADER

2x4

Door

One-piece door with horizontal track

Door

BRACKET

2x4

Header Wall

8" (20 cm)

Structural Supports

3" (7.5 cm)

Highest Point of Travel

Pivot

Track

One-piece door without track: jamb hardware

One-piece door without track: pivot hardware

+ 28 hidden pages

Chamberlain PD460-2K, PD420, PD420-2, PD460-2 User Manual

TABLE OF CONTENTS

INTRODUCTION

Safety Symbol and Signal Word Review

Preparing your garage door

Planning

Carton Inventory

Hardware Inventory

INSTALLATION