Chamberlain PD612EV User Manual

1/2 hp Chain Drive Garage Door Opener

Models

• PD612EV

• HD420EV

FOR RESIDENTIAL USE ONLY

■ 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

properly aligned.

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

■ The model number label is located on the left side panel of your garage

door opener.

■ This garage door opener is compatible with MyQ

■ Only enable the Timer-to-Close* or MyQ

door opener is installed on a sectional door. (*Not available on all models)

Write down the following information for future reference:

remote operation feature* when the garage

is connected and

and Security✚ 2.0™ accessories.

Preparation .............................. 1-4

Assembly ................................. 5-9

Installation ............................ 10-19

Install the Door Control .............20-21

Install the Protector System® ...... 22-25

Power .................................. 26-27

Adjustments .......................... 28-30

Operation.................................. 31

Features ................................... 32

Door Control ..........................33-34

Remote Control ...................... 34-35

To Erase the Memory .................... 35

To Open the Door Manually ............36

Maintenance .............................. 37

Troubleshooting ...................... 38-39

Accessories ............................... 40

Warranty .................................. 41

Repair Parts .......................... 42-43

. .

Model Number:

Serial Number:

Date of Purchase:

www.chamberlain.com

The Chamberlain Group, Inc.

845 Larch Avenue

Elmhurst, Illinois 60126-1196

Torsion Spring

Extension Spring

Preparation

Safety Symbol and Signal Word Review

Thisgarage door opener has been designed and tested to offer safe service provided it is installed, operated, maintained and tested in strictaccordance with the instructions and warnings contained in this manual.

When you see these SafetySymbols and Signal Words on the following pages, they will alert you to the possibilityof serious injuryor death if you do not complywith the warnings thataccompany them. The hazard may come from something mechanical or from electric shock.Read the warnings carefully.

Mechanical

Electrical

When you see thisSignal Word on the following pages, it will alert you to the possibilityof damage to your garage door and/or the garage door opener ifyou do not complywith the cautionary statementsthat accompanyit.Read them carefully.

Check the Door

To prevent possible SERIOUSINJURYorDEATH:

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

• NEVER tryto loosen, move or adjustgarage door, door springs, cables, pulleys,bracketsor their hardware, ALLof which are under EXTREMEtension.

• Disable ALLlocksand remove ALLropes connected to garage door BEFORE installation and operating garage door opener to avoid entanglement.

To prevent damage to garage door and opener:

• ALWAYS disable locksBEFORE installing and operating the opener.

• ONLY operate garage door opener at120 V, 60 Hz to avoid malfunction and damage.

1. Disable locksand remove any ropes connected to the garage door.

2. Liftthe door halfwayup. Release the door. Ifbalanced,it should stayin place, supported entirely by itssprings.

3. Raise and lower the door to check for binding or sticking.Ifyour door binds,sticks,or is out of balance, call a trained door systems technician.

4. Checkthe seal on the bottom of the door.Any gap between the floor and the bottom of the door mustnot exceed 1/4 inch (6 mm). Otherwise,the safetyreversal systemmay not work properly.

5. 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 (1.2 m) to the left or right of the door center. See page 13.

3/16

7/16

1/2

5/32

5/16

5/8

9/16

1/4

7/16

Preparation

Additional Items You May Need:

Survey your garage area to see if you will need any of the following items:

(2) 2X4 PIECES OF WOOD

Maybe used to fasten the header bracketto the structural supports.Also used to position the garage door opener during installation and for testing the safetyreversing sensors.

SUPPORT BRACKETANDFASTENING HARDWARE

Mustbe used if you have a finished ceiling in your garage.

EXTENSION BRACKETS (MODEL 41A5281) OR WOOD BLOCKS

Depending upon garage construction, extensionbracketsor wood blocksmay be needed to install the safetyreversing sensor.

FASTENING HARDWARE

Alternate floor mounting of the safetyreversing sensor will require hardware not provided.

OUTSIDEQUICKRELEASE (MODEL 7702CB)

Required for a garage with NO access door.

DOOR REINFORCEMENT

Required if you have a lightweightsteel,aluminum, fiberglass or glass panel door.

RAIL EXTENSIONKIT

Required if your garage door is more than 7 feet (2.13 m) high.

Tools Needed

Preparation

Carton Inventory

Your garage door opener is packaged in one carton which contains the motor unit and all parts illustrated below.Accessoriesvary depending on the garage door opener model purchased.Depending on your model, other accessories may be included with your garage door opener. Instructions for these accessories will be attached to the accessoryand are notincluded in this manual. Ifanything is missing, carefullycheck the packing material. Hardware for assemblyand installation is shown on the next page. Save the carton and packing material until the installation and adjustment is complete.The images throughout this manual are for reference only and your productmay look different.

A. Header bracket

B. Pulley C. Door bracket D. Curved door arm

E. Straight door arm (Packagedinside front rail section)

F. Trolley

NOTE: Be sure to assemble the trolley before sliding onto rail.

G. Emergency release rope and handle H. Rail (1 front and 4 center sections)

I. Hanging brackets (2) (Packaged inside the front rail section)

J. Garagedoor opener (motor unit)

K. Chain spreader with screws

L. “U” bracket M. Chain and cable N. Door control O. Remote control

P. The Protector System

Safetyreversing sensors with 2 conductor white and white/black wire attached: Sending Sensor (1), Receiving Sensor (1), andSafety Sensor Brackets (2)

NOTSHOWN

White and red/white wire Owner's manual

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

Lock Nut 1/4"-20

Bolt

Nut 3/8" Lock Washer 3/8"

Master Link

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

Ring Fastener (3)

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

Lock Washer 5/16"-18 (5)

Nut 5/16"-18 (6)

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

Clevis Pin 5/16"x1"

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

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

Wing Nut 1/4"-20 (2)

ASSEMBLY HARDWARE INSTALLATION HARDWARE

Screw 6ABx1" (2)

Drywall Anchors (2)

Screw 6-32x1" (2)

DOOR CONTROL HARDWARE

Insulated Staples (N

ot Shown)

Lag Screw 5/16"-9x1-5/8" (4)

Threaded Shaft

Preparation

Hardware Inventory

Assembly

To garage door opener (TO MOTOR UNIT)

Front Rail Section (TO DOOR)

“U” Bracket

Outer Trolley

Inner Trolley

Wear Pads

Rail Tab

Trolley

Window Cut-Out

SLIDE TO STOPS ON TOP AND SIDES OF “U” BRACKET

Idler Pulley Hole

STEP 1 Assemble the rail and trolley

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

To avoid installation difficulties, do not run the garage dooropeneruntilinstructed to do so.

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

1. Removethe straight door arm and hanging bracketpackaged inside the front rail and set aside for Installation Step 5 and 9. NOTE: To prevent INJURY while unpacking the rail

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

2. Align the rail sectionson a flat surfaceas shown and slide the tapered endsinto the larger ones. Tabs along the side will lock into place.

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

4. As a temporary stop,insert a screwdriver into the hole 10" (25 cm) from the front end ofthe rail, as shown.

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

6. Slide the trolley assemblytoward the screwdriveras shown.

7. Slide the rail onto the “U” bracket,until it reaches all the stopson the top and sides of the “U” bracket.

Assembly

(Mounted in the

Bolts

garage door

opener)

HARDWARE

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

Lock Nut 1/4"-20

“U” Bracket

Bolts

Hex Screws 8-32x7/16

SLIDE RAIL TO STOPS ON TOP AND SIDES

Cover

Protection

Bolt Hole

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

Lock Nut 1/4"-20

STEP 2 Fasten the rail to the motor unit

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

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

2. Removethe bolts fromthe top of the motor unit.

3. Usethe carton to support the front end of the rail.

4. Place the “U” bracket,flat side down onto the motor unit and align the bracketholes with the bolt holes.

5. Fasten the “U” bracket with the previously removed bolts;DO NOT use any power tools. The use of power toolsmay permanently damage the garage door opener.

6. Attach spreader to the motor unit with twoscrews.

Assembly

HARDWARE

Bolt

Nut 3/8"

Lock Washer 3/8"

Screwdriver

Rail

Idler Pulley

Grease Inside Pulley

Bolt

Lock Washer 3/8"

Nut 3/8"

Rail Tab

CORRECT

INCORRECT

Rail Tab

STEP 3 Install the idler pulley

1. Lay the chain/cable beside the rail, as shown. Grasp the end with the cable loop and pass approximately 12" (30 cm) ofcable through the window.Allow it to hang until AssemblyStep 4.

2. Removethe tape from the idler pulley.The inside center should be pre-greased. Ifdry, regrease to ensure proper operation.

3. Place the idler pulley into the window as shown.

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

5. Rotatethe pulley to be sure it spins freely.

6. Locate the rail tab. The rail tab is between the idler bolt and the trolley in the front rail section. Usea flat head screwdriver and lift the rail tab until the tab is vertical (90º).

Assembly

HARDWARE

ster

Link

Threaded Shaft

Chain Link

Threaded Shaft

Outer Nut

Front Rail Section (TO DOOR)

Inner Nut

Lock Washer

Master

Link

Master Link

Sprocket

STEP 4 Install the chain

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

• ALWAYS keep hand clear of sprocketwhile operating opener.

• Securely attach chain spreader BEFORE operating.

1. Pull the cable around the idler pulley and toward the trolley.

2. Connectthe cable to the retaining slot on the trolley. (a)

a. Push pins of master link bar through cable link and trolley slot. b. Push masterlink cap over pins and pastpin notches.

c. Slide clip-on spring over cap and onto pin notchesuntil both pins are securely

locked in place.

3. Withthe trolley against the screwdriver, dispense the remainder of the cable/chain along the rail toward the motor unit into the slot on the chain spreader, around the sprocketonto the chain spreader and continuing to the trolley assembly and continuing to the trolley assembly. The sprocketteethmust engage the chain. (b)

4. Thread the inner nut and lock washer onto the trolley threaded shaft.

5. Insertthe trolley threaded shaftthrough the hole in the trolley. Be sure the chain is not twisted.(c)

6. Loosely thread the outer nut onto the trolley threaded shaft.

7. Removethe screwdriver.

Assembly

Outer Nut

Lock Washer

Trolley Threaded Shaft

Inner Nut

To Tighten Inner Nut

To Tighten Outer Nut

Base of Rail

Mid length of Rail

Chain

1/4" (6 mm)

STEP 5 Tighten the chain

1. Spin the inner nut and lock washer down the trolley threaded shaft,awayfrom the trolley.

2. To tighten the chain, turn the outer nut in the direction shown.

3. When the chain is approximately 1/4" (6 mm) above the base of the rail at it's midpoint,retighten the inner nut to secure the adjustment.

Sprocketnoise can result if the chain is too loose. When installation is complete, you may notice some chain droop with the door closed. Thisis normal. If

the chain returns to the position shown when the door is open, do not re-adjustthe chain.

NOTES:During future maintenance, ALWAYS pull the emergency release handle to disconnect the trolley before adjusting the chain.

You may notice loosening of the chain after AdjustmentStep 3 (Test the Safety Reversal System). Check for proper tension and readjustchain if necessary.Then repeat Adjustment Step 3.

You have now finished assemblingyourgarage dooropener.Please read the followingwarnings beforeproceeding to the installationsection.

Installation

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

1. READ ANDFOLLOW ALL INSTALLATIONWARNINGS AND INSTRUCTIONS.

2. Install garage door opener ONLY on properly balanced and lubricated garage door. An improperly balanced door may NOTreverse when required and could result in SEVERE INJURYor DEATH.

3. ALL repairs to cables, spring assembliesand other hardware MUSTbe made by a trained door systems technician BEFORE installing opener.

4. Disable ALL locksand 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 the emergencyrelease within reach,but at least 6 feet (1.83 m) above the floor and avoiding contactwith vehicles to avoid accidental release.

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

8. NEVERwearwatches,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 minimumheight of 5 feet (1.5 m).

• away from ALL moving partsof the door.

10. Placeentrapment warning label on wall next to garage door control.

11. Placemanual release/safetyreverse testlabel inplain view on inside of garage door.

12. Upon completion of installation,testsafetyreversal system.Door MUST reverse on contact witha 1-1/2" (3.8 cm) high object(or a2x4 laid flat) on the floor.

13. To avoid SERIOUS PERSONAL INJURY or DEATH from electrocution,disconnectALL electricpower BEFORE performing any serviceor maintenance.

14. DO NOT enable the Timer-to-Close functionality if operating either one-piece or swinging garage doors. To be enabled ONLY when operating a sectional door.

Installation

Header Wall

Vertical Centerline of Garage Door

2x4

Structural Supports

Level (Optional)

Unfinished Ceiling

2x4

OPTIONAL CEILING MOUNT

FOR HEADER BRACKET

Sectional door with curved track

Header Wall

Track

2" (5 cm)

Highest Point of Travel

Door

One-piece door with horizontal track

Header Wall

Track

2" (5 cm)

Highest Point

of Travel

Door

One-piece door without track: jamb hardware

Header Wall

8" (20 cm)

Highest Point of

Travel

Door

Jamb

Hardware

One-piece door without track: pivot hardware

Header Wall

8" (20 cm)

Highest Point of

Travel

Door

Pivot

STEP 1 Determine the header bracket location

To prevent possible SERIOUSINJURY 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 NOTinstall header bracket over drywall.

• Concreteanchors MUST be used if mounting header bracketor 2x4 into masonry.

• NEVER tryto loosen, move or adjustgarage door, springs, cables,pulleys,brackets,or their hardware, ALL of which are under EXTREME tension.

• ALWAYS call a trained door systemstechnician 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 ofthe garage door.

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

You can fasten the header bracket within4 feet (1.22 m) of the left or right of the door center only if a torsionspring or center bearingplate is in the way; or you can attach it to the ceiling when clearance is minimal.(It may be mounted on the wall upside down if necessary, to gain approximately 1/2" (1 cm).

Ifyou need to install the header bracket on a2x4 (on wall or ceiling), use lag screws(not provided) to securely fasten the 2x4 to structural supports.

3. Open your door to the highest point of travel as shown.Draw an intersecting horizontal line on the header wall 2" (5 cm) 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 maximumheight possible, or refer to page 12 for ceiling installation.

Installation

HARDWARE

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

Wall Mount

Optional Mounting

Holes

Vertical Centerline of Garage Door

(Header Wall)

Header Bracket

2x4 Structural Support

Door Spring

(Garage Door)

Highest Point of Garage Door Travel

Horizontal Line

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

(Header Wall)

Ceiling Mounting

Holes

(Finished Ceiling)

Vertical Centerline of Garage

Door

Header Bracket

6" (15 cm) Maximum

Door Spring

(Garage Door)

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

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 installthe header bracket over

drywall. If installingintomasonry,use concrete anchors (not provided).

OPTION A WALL INSTALLATION

1. Centerthe bracket on the verticalcenterline with the bottomedge ofthe bracketon the horizontal line as shown.

2. Mark the vertical set of bracketholes. Drill 3/16" pilot holes and fasten the bracketsecurely to a structural support withthe hardware provided.

OPTION B CEILING INSTALLATION

1. Extend the vertical centerline onto the ceiling as shown.

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

3. Mark the side holes.Drill 3/16" pilot holes and fastenbracket securely to a structural support withthe hardware provided.

Installation

HARDWARE

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

Ring Fastener

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

Ring Fastener

Connected Disconnected

One-piece door without

tracks

All other door types

STEP3 Attach the rail to the header bracket

1. Align the rail with the header bracket. Insert the clevis pin through the holes in the header bracketand rail. Secure with the ring fastener.

NOTE: Use the packing material as a protective base for the garage door opener.

STEP 4 Position the garage door opener

To prevent damage to garage door,rest garage door opener rail on 2x4 placed on top section of door.

1. Removethe packing material and lift the garage door opener onto a ladder.

2. Fully open the door and place a 2x4 (laid flat) under the rail. For one-piece doors without tracks,lay the 2x4 on it's side.

NOTE: A 2x4 is ideal for setting the distance between the rail and the door. Ifthe ladder is not tall enough you will need help atthis point. Ifthe door hitsthe trolley when itis raised, pull the trolley release arm down to disconnectthe inner and outer trolley. Slide the outer trolley toward the garage door opener. The trolley can remain disconnected until instructed.

+ 30 hidden pages

Chamberlain PD612EV User Manual

CONTENTS

Preparation

Safety Symbol and Signal Word Review

Check the Door

Tools Needed

Carton Inventory

Hardware Inventory

Assembly

STEP 1 Assemble the rail and trolley

STEP 2 Fasten the rail to the motor unit

STEP 3 Install the idler pulley

STEP 4 Install the chain

STEP 5 Tighten the chain

Installation

STEP 1 Determine the header bracket location

STEP 2 Install the header bracket

OPTION A WALL INSTALLATION

OPTION B CEILING INSTALLATION

STEP 4 Position the garage door opener