Chamberlain HD200DM User Manual

®

The Chamberlain Group, Inc. 845 Larch Avenue

Elmhurst, Illinois 60126-1196

www.chamberlain.com

®

GARAGE DOOR OPENER

Model HD200DM • 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 and
install the idler pulley..................................................		9
Install the chain/cable...............................................		10
Tighten the chain.......................................................		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 light ..........................................................		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

INTRODUCTION

Safety Symbol and Signal Word Review

Adjustment	27-29
Adjust the travel limits ..............................................	27
Adjust the force ........................................................	28
Test the safety reversal system................................	29
Test The Protector System®......................................	29
Operation	30-34
Operation safety instructions....................................	30
Using your garage door opener ...............................	30
Using the wall-mounted Door Control ......................	31
To open the door manually.......................................	31
Care of your garage door opener.............................	32
Having a problem? ...................................................	33
Diagnostic chart........................................................	34
Programming	35-36
To add or reprogram a hand-held remote control .... 35
To erase all codes ....................................................	35
3-Button Remotes ....................................................	35
To add, reprogram 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

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

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

Support bracket & fastening hardware is required.

See page 16.

Slack in chain tension is normal when garage door is closed.

Extension Spring

Motor Unit

OR

Torsion Spring

	Wall-mounted
	Door	Access
	Control
—		Door	Header	CLOSED POSITION
	Vertical
—			Bracket
	Centerline
			Trolley
—
	of Garage Door				Trolley
			stop bolt
— — —	Safety
	Reversing					Chain
—	Sensor		Garage
			Door	Straight
—
			Spring			Emergency
				Door
						Release
	Gap between floor and bottom of door			Arm
						Rope & Handle
	must not exceed 1/4" (6 mm).
Safety Reversing Sensor				Curved
		Header		Door
		Wall		Arm
		Garage	Door Bracket
		Door

4

Access

Door

Safety Reversing

Sensor

Gap between floor

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

Access

Door

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.

Rail

Header Wall

Slack in chain tension is normal when garage door is closed.

Wall-mounted

Door Control

Safety Reversing Sensor

Motor Unit

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

ONE-PIECE DOOR WITH TRACK

Safety

Reversing Sensor

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

	CLOSED POSITION
	Trolley Stop Bolt	Cable	Chain
Header
Wall	Header	Curved
			Rail
	Bracket	Door Arm
	Door		Emergency
		Straight	Release
	Bracket
			Rope &
		Door
			Handle
	Garage	Arm
	Door

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.

Idler Pulley

	Lighted Door Control Button	SECURITY ®
		Single-Button Remote Control

SECURITY ®

Keyless Entry

Chain Spreader

Trolley

Motor Unit with a Light Lens

Rail

Center/Back

Sections

Door Bracket

Chain and Cable in

Dispensing Carton

Header Bracket

2-Conductor Bell Wire

White & White/Red

Rail
Front (header)
Section
	Hanging Brackets
	Curved Door
	Arm Section	Straight Door
	"U" Bracket
		Arm Section
	The Protector System®
	(2) Safety Reversing Sensors	Safety Labels
	(1 Sending Eye and 1 Receiving Eye)	and
	with 2-Conductor White & White/Black	Literature
Safety Sensor	Bell Wire attached
Bracket (2)

6

Hardware Inventory

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

ASSEMBLY HARDWARE

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	Lock Washer	5/16" (7)	Insulated
5/16"-9x1-5/8" (2)		5/16"-18x7/8" (4)			Staples (30)
Lag Screw		Screw
5/16"-18x1-7/8" (2)		6ABx1-1/4" (2)		Screw 6-32x1" (2)
					Rope
Self-Threading Screw		Drywall Anchors (2)			Spacer (2)
1/4"-14x5/8" (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" (25 cm) away from the front 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

		Tapered
	KEEP LARGER	End
	HOLE ON TOP
	FRONT RAIL	Back Rails
	(TOP)
		(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 onto the motor unit and align the bracket hole 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.

•Attach spreader to the motor unit with two screws.

HARDWARE SHOWN ACTUAL SIZE

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

ASSEMBLY STEP 3

Install the Idler Pulley

•Lay the chain/cable beside the rail, as shown. Grasp the end of the cable and pass approximately 12" (30 cm) of cable through the window. 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.

Hex Screws 8-32x7/16"

	Chain
Bolts	Spreader

Motor Unit

Sprocket

"U" Bracket

Bolt

Cover

Protection

Bolt Hole

Lock Nut

Chain and

Cable

SLIDE RAIL TO STOPS ON TOP AND SIDES OF BRACKET

Bolt

Pulley

Rail

Nut

Washer

Idler	Screwdriver Trolley
Bolt

Bolt

Trolley

Stop Hole

	Grease
	Inside Pulley
Lock	Idler
Washer	Pulley
3/8"	Nut 3/8"
	Cable Link

Lock

Idler Nut

Pulley

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 Chain/Cable

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

2.Connect the cable to the retaining slot on the trolley, as shown (Figure 1):

•From below, push pins of master link bar up through cable link and trolley slot.

•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.

3.With the 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 sprocket onto the chain spreader and continuing to the trolley assembly. The sprocket teeth must engage the chain (Figure 2).

4.Check to make sure the chain is not twisted, then connect it to the threaded shaft with the remaining master link.

5.Thread the inner nut and lock washer onto the trolley threaded shaft (Figure 3).

6.Insert the trolley threaded shaft through the hole in the trolley. Be sure the chain is not twisted (Figure 4).

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

8.Remove the screwdriver.

Figure 2

Chain
Spreader	Motor Unit
"U" Bracket	Sprocket
Bolt

Figure 4

Trolley

Threaded

Shaft

Round

Hole

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

•ALWAYS keep hand clear of sprocket while operating opener.

•Securely attach chain spreader BEFORE operating.

Dispensing Carton

Leave Chain and Cable

Inside Dispensing

Carton to Prevent Kinking.

Keep Chain and Cable

Taut When Dispensing

Figure 1
Master Link
Clip-On Spring	Master
	Link Cap

	Master Link
	Clip-On Spring	Master
		Link Cap
		Trolley	Pin
	Cable	Threaded
		Shaft	Notch
	Link
			Master
		Round
			Link Bar
	Idler	Hole
		Slotted
	Pulley	Hole
	Cable	Master
		Link Bar

Figure 3

	Trolley
	Threaded
	Shaft
	Inner Nut
Lock	5/16"
Washer
5/16"

10

ASSEMBLY STEP 5

Tighten the Chain

•Spin the inner nut and lock washer down the trolley threaded shaft, away from the trolley.

•To tighten the chain, turn outer nut in the direction shown (Figure 1).

•When the chain is approximately 1/4" (6 mm) above the base of the rail at its midpoint, re-tighten the inner nut to secure the adjustment.

Sprocket noise can result if chain is too loose.

When installation is complete, you may notice some chain droop with the door closed. This is normal. If the chain returns to the position shown in Figure 2 when the door is open, do not re-adjust the chain.

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

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

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

Figure 1	Lock	Trolley
Outer		Threaded
Nut	Washer	Shaft
To Tighten Outer Nut
	Inner Nut
	To Tighten
	Inner Nut

Figure 2

Chain

1/4" (6 mm)

Base of Rail

Mid length of Rail

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