Chamberlain WD822KD 1-2 HP User Manual

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

www.chamberlain.com

GARAGE DOOR OPENER

Model WD822KD 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 left side panel of your opener.

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

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 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

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

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

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

Pencil

Hack Saw

Claw Hammer

Wire Cutters

Screwdriver

Stepladder

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

Pliers

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 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.

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

Gap between floor

Safety Reversing Sensor

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

Extension Spring

Torsion Spring

Wallmounted Door Control

Safety Reversing Sensor

Access Door

FINISHED CEILING

Support bracket & fastening hardware is required. See page 16.

Header Bracket

Garage Door Spring

Header Wall

Garage Door

Trolley Stop Bolt

Door Bracket

CLOSED POSITION

Trolley

Straight Door Arm

Curved Door Arm

Motor unit

Belt

Emergency Release Rope & Handle

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).

ONE-PIECE DOOR WITHOUT 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

ONE-PIECE DOOR WITH TRACK

FINISHED CEILI

Support & fastening hard

ware is re

See page 16.

Header Wall

Rail

WARNING

bracket

quired.

Motor Unit

Gap between floor

Safety Reversing Sensor

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

Gap between floor

Safety Reversing Sensor

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

Access Door

Safety Reversing Sensor

Access Door

Safety Reversing Sensor

Wall-mounted Door Control

Header Wall

Trolley Stop Bolt

Header Bracket

Door Bracket

CLOSED POSITION

Header Bracket

Curved Door Arm

Door Bracket

Garage Door

CLOSED POSITION

Belt

Rail

Straight Door Arm

Garage Door

Trolley

Belt

Straight Door Arm

Trolley

Curved Door Arm

Emergency Release Rope & Handle

Rail

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

(2)

SECURITY✚® 3-Button Remote Control

Trolley

SECURITY✚® Keyless Entry

2-Conductor Bell Wire White & White/Red

Idler Pulley

LIGHT

Multi-Function Door Control Panel

Door Bracket

Belt

Rail Front (header) Section

Motor Unit with 2 Light Lenses

Safety Sensor Bracket (2)

Hanging Brackets

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

Rail Center/Back Sections

Belt Cap Retainer

“U” Bracket

Header Bracket

Curved Door

Arm Section

Straight Door Arm Section

Safety Labels

and

Literature

Hardware Inventory

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

ASSEMBLY HARDWARE

INSTALLATION HARDWARE

Spring/Trolley Nut (1)

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

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

Lock Nut 1/4"-20 (2)

Trolley Threaded Shaft (1)

Wing Nut 1/4"-20 (2)

Lock Washer 3/8" (1)

Ring Fastener (3)

Nut 5/16"-18 (8)

Master Link (2)

Nut 3/8" (1)

Idler Bolt (1)

Handle

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

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

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

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

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

Screw 6ABx1-1/4" (2)

Drywall Anchors (2)

Clevis Pin 5/16"x1" (1)

Lock Washer 5/16" (7)

Insulated Staples (30)

Screw 6-32x1" (2)

Rope

Spacer (2)

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

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.

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 stop, insert a screwdriver into the hole 10" (25 cm) 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.

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.

CAUTION

Screwdriver

KEEP LARGER HOLE ON TOP

FRONT RAIL (TOP)

Tapered End

Ta bs

Tapered End

Inner Trolley

Outer Trolley

Tapered End

Back Rails (TO MOTOR UNIT)

Trolley

Window Cut-Out

Idler Pulley Hole

Front Rail (TO DOOR)

Wear Pads

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

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.

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.

WARNING

HARDWARE SHOWN ACTUAL SIZE

CAUTION

Bolts

"U" Bracket

Bolt

Cover Protection Bolt Hole

SLIDE RAIL TO STOPS ON TOP AND SIDES OF BRACKET

Lock Nut

Motor Unit Sprocket

Lock Nut

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

1/4"-20

Idler

Bolt

Lock Washer 3/8"

Screwdriver

Nut 3/8"

Pulley

Trolley Connector

Bolt

Nut

Inside Pulley

Rail

Washer

Grease

Idler Pulley

Trolley Stop Hole

Idler Pulley

Bolt

Lock Nut

Idler Bolt

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

Lock Nut 1/4"-20

Nut 3/8"

Lock Washer 3/8"

ASSEMBLY STEP 4

Install the Belt and Attach the Belt Cap Retainer

1. Pull the belt around the idler pulley and toward

the 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, then

connect it to the flat end of 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.

5. Insert the trolley threaded shaft through the hole

in the trolley. Be sure the belt is not twisted, and

the ribbed side faces the rail.

6. Hold the belt at the trolley shaft as you thread the spring nut by hand onto the shaft until finger tight 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.

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

• ALWAYS keep hand clear of sprocket while operating opener.

• Securely attach sprocket cover BEFORE operating.

WARNING

HARDWARE SHOWN ACTUAL SIZE

Hex Screw 8x3/8"

Spring/Trolley Nut

Master Link Clip-On Spring

Master Link Cap

Idler Pulley

Spring Nut

Trolley Connector

Retaining Slot

Pin Notch

Trolley Threaded Shaft

Round Hole

Belt Cap Retainer

Master Link Bar

Hex Screws #8x3/8"

Motor Unit Sprocket

Mounting Plate

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.

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.

INSTALLATION

Nut Ring Slot

Square End

Trolley

Nut Ring

BEFORE AFTER RELEASE

1" 1-1/4"

(2.5 cm)

Nut Ring

(3.18 cm)

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:

• 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.

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 W al l

V ertical Centerlin e of Garage Door

Level (optional)

Header Wall

2" (5 cm)

Highest Point of Travel

Door

Sectional door with curved track

Header Wall

8" (20 cm)

Door

Jamb Hardware

Track

Highest Point of Travel

Unfinished Ceiling

2x4

Header Wall

Door

One-piece door with horizontal track

Header Wall

8" (20 cm)

Door

OPTIONAL CEILING MOUNT FOR HEADER BRACKET

Structural Supports

2" (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 WD822KD 1-2 HP User Manual

TABLE OF CONTENTS

INTRODUCTION

Safety Symbol and Signal Word Review

Preparing your garage door

Tools needed

Planning

ONE-PIECE DOOR INSTALLATIONS

Carton Inventory

Hardware Inventory

INSTALLATION