Merlin MJ3800 Installation Manual

gomerlin.com.au
gomerlin.co.nz

Residential & Light Duty Commercial Door Opener

Installation and Operating Instructions

Owners Copy: Please keep these instructions for future reference

This manual contains IMPORTANT SAFETY information

DO NOT PROCEED WITH THE INSTALLATION BEFORE READING THOROUGHLY

MJ3800

START BY READING THESE IMPORTANT SAFETY INSTRUCTIONS

ARNING

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• Failure to comply with the following instructions may result in serious personal injury or property damage.

• Read and follow all instructions carefully.
The garage door opener is designed and tested to offer safe service provided it is installed and

•

operated in strict accordance with the instructions in this manual.

These safety alert symbols mean WARNING : A possible risk to personal safety or
property damage exists.

Keep garage door balanced. Do not let the garage door

pener compensate for a binding or sticking garage door.

o
Sticking, binding or unbalanced doors must be repaired
before installing this opener.

Do not wear rings, watches or loose clothing while
installing or servicing a garage door opener. Wear gloves,
safety goggles and suitable protective clothing where
appropriate.

Frequently examine the door installation, in particular
cable, springs and mountings for signs of wear, damage or
imbalance. Do not use if repair or adjustment is needed
since springs and hardware are under extreme tension
and a fault can cause serious personal injury.

To avoid serious personal injury from entanglement,

remove all ropes, chains and locks connected to the
garage door before installing the door opener.

Installation and wiring must be in compliance with your

local building and electrical codes.

The safety reverse system test is very important. Your
garage door MUST reverse on contact with a 40 mm
obstacle placed on the floor. Failure to properly adjust the
opener may result in serious personal injury from a closing
garage door. Repeat the test once a month and make

any necessary adjustments.

This appliance is not intended for use by persons
(including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction
concerning use of the appliance by a person responsible
for their safety.

Use the Manual Release only for the seperation of the
carriage from the drive and - if possible - ONLY with the
door closed. Do not use the red handle to push the door
up or pull it down. Operation of the emergency release can
lead to uncontrolled movements of the door, if springs are
weak or broken or if the door is unbalanced. Mount the
release handle of the emergency release at a height less
than 1.8 m from the floor.

The Protector SystemTMmust be used for all installations

here the closing force as measured on the bottom of the

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door is over 400 N (40 kgf). Excessive force will interfere with

the proper operation of the Safety Reverse System or damage
the garage door.

SPECIAL NOTE: Merlin strongly recommends that The
Protector System

After installation, ensure that the parts of the door do not
extend over public footpaths or roads.

Install the wireless wall control (or any additional wall control) in
a location where the garage door is visible, at a height of at
least 1.5 m and out of the reach of children. Do not allow
children to operate push button(s) or transmitter(s). Serious

personal injury from a closing garage door may result from
misuse of the opener.

Permanently fasten the Warning Labels in Prominent Places,

adjacent to Wall Controls and on manual release mechanism as
a reminder of safe operating procedures.

Activate opener only when the door is in full view, free of
obstructions and the opener is properly adjusted. No one
should enter or leave the garage while the door is in motion.

Automatic Door- The door may operate unexpectedly, therefore

do not allow anything to stay in the path of the door.

Do not allow children to play near the door, or with door
controls. Keep remotes away from children.

Disconnect electric power to the garage door opener before
making repairs or removing covers.

If the supply cord is damaged, it must be replaced by the
manufacturer, its service agent or similarly qualified persons in
order to avoid hazard.

This opener should not be installed in a damp or wet space
exposed to weather.

To avoid damage to very light doors (such as fibreglass,
aluminium or steel doors), an appropriate reinforcement should
be added. To do so, contact the door manufacturer.

SAVE THESE INSTRUCTIONS

TM

be installed on all garage door openers.

NOTE: If your garage has no service entrance door, a CM1702 outside quick release must be installed.
This accessory allows manual operation of the garage door from outside in case of power failure.

CONTENTS PAGE

SAFETY INSTRUCTIONS . . . . .2

CARTON INVENTORY . . . . . . .3

ACCESSORIES . . . . . . . . . . . 3

SPECIFICATION . . . . . . . . . . .4

TOOLS REQUIRED . . . . . . . . .4

PREPARE & TEST THE DOOR . .4

DOOR REQUIREMENTS . . . . . .5

ASSEMBLY . . . . . . . . . . . . . . .6

INSTALLATION . . . . . . . . .7-10

CONNECT ELECTRIC POWER .10
INSTALL MULTI-FUNCTION DOOR

CONTROL . . . . . . . . . . . . . .10

INSTALL THE PROTECTOR

SYSTEM . . . . . . . . . . . . . . .11

AUTO CLOSE . . . . . . . . . . . .13

ADJUSTMENT . . . . . . . . .14-17

WIRELESS PROGRAMMING 18-19

REPAIR PARTS . . . . . . . . . . .20

DIAGNOSTIC CHART . . . . . . .21

TROUBLESHOOTING . . . . . . .22

CARE OF YOUR OPENER . . . . 23

OPERATION OF YOUR OPENER 23

WARRANTY . . . . . . . . . . . . .24

2

Manual

TM

CM128 Wireless
Wall Button

2 x C945 3ch
rolling code
transmitters

Opener

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Multi function

door control
CM475 Battery
Backup Unit

CARTON INVENTORY

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3

1

10

11

2

4

C840

CM128

760E

CM1702

C77

C940 C943

C945

7

8

9

CM844

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C98

845AML

CM475

our door opener is packaged in one carton which contains the opener and the parts illustrated below.

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Note that accessories will depend on the model purchased. If anything is missing, carefully check the
packing material.

Hardware Inventory
INSTALLATION HARDWARE

Hex Screw #14-10x1-7/8" (4)
Screw #6x-1" (2)
Hex Screw #6x1-1/4” (2)
Carriage Bolt 1/4"-20x1/2" (2)

an Head Screw 1/4"-20x1/2" (2)

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Hex Head Screw #8x1" (2)
Self Tapping Screw #10-32 (2)
Wall Anchor (2)
Wall Anchor (Screw-In) (2)
Handle
Rope
Insulated Staples (10)
Lock Template

ACCESSORIES

PROTECTOR SYSTEM

TM

(IR)

INSTALLATION HARDWARE

Screw 10-32x3/8" (4)
Carriage Bolt 1/4"-20x1/2" (4)
Wing Nut 1/4"-20 (2)
Hex Nut 10-32x3/8" (4)
Hex Nut 1/4-20 (4)
Hex Head Screw 1/4-20x1-1/2" (2)
Hex Head Screw 14-10 x 1-1/2" (4)
Insulated Staple (10)

(1) Model CM844 4 Channel remote control
(2) Model CM128 Wireless Wall Button
(3) Model C940 1 Channel visor remote control
(4) Model C943 3 Channel visor remote control
(5) Model C945 3 Channel mini remote control
(6) Model 845AML Multi-Function Door Control

or Model C98 Motion Detecting Control Panel

(7) Model C840 Keyless Entry System

(8) Model C77 The Protector System

(9) Model CM1702 Quick Release Lock
(10) Model 760E Outside Keyswitch
(11) Model CM475 Battery Backup
(12) Model ANT4X-1 433MHz Antenna, cable and adaptor

3

TM

PREPARING YOUR DOOR

Pliers

Wire Cutters

Claw Hammer

Screwdriver

Adjustable End Wrench

1/4", 5/16" & 3/8" Sockets
and Wrench with 200mm Extension

Drill

Tape Measure

2

1

Stepladder

Pencil

3/16" and 1/8"
Hex Key Wrench

Needle Nose Pliers

5/32", 3/16", 5/16"
and 3/4" Drill Bits

Before you begin:

Disable locks.

•

• Remove any ropes connected to door.

• Complete the following test to make sure your
door is balanced and is not sticking or binding:

. Lift the door about halfway as shown. Release

1

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, 20 Kgf is the absolute
maximum allowable force to raise or lower the
door in any position.

F YOUR DOOR BINDS

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RAINED DOOR SYSTEMS TECHNICIAN

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3. Verify equal cable tension on each side of
door. Cable tension should remain equal
during the entire travel of the door.

TICKS OR IS OUT OF BALANCE

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ALL A

o prevent possible SERIOUS INJURY or DEATH:

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• ALWAYS call a trained door systems technician if
door binds, sticks or is out of balance. An
unbalanced door may not reverse when required.

• NEVER try to loosen, move or adjust 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 the door BEFORE installing and operating the
door opener to avoid entanglement.

• This device is not intended for use by small children

or infirmed persons without supervision.

• young children should NOT be permitted to play

with the opener or transmitters.

To prevent damage to door and opener:

• ALWAYS disable locks BEFORE installing and
operating the opener.

Sectional Door

Tools needed

During assembly, installation and adjustment of
the opener, instructions will call for hand tools as
illustrated below.

Specifications

Volts: 230-240 ~ V 50 Hz
Power: 145 Watts
Rated Load: 10Nm

Fmax: 40Nm
Max door height: 4.2m (14’)
Max door width: 5.5m
Max: area 16m

2

Please note this opener contains both imperial and metric fasteners.

Torque Meter (not shown)

4

Safety
Reversing Sensor

Safety
Reversing
Sensor

Torsion Spring

Opener

Wireless wall button

Access Door

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

Powered
Door Lock

Cable Tension
Monitor

Drum

DOOR REQUIREMENTS

Survey the 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 as you proceed with the

nstallation of your opener.

i
Depending on your requirements, there are several

installation steps which may call for materials or

ardware not included in the carton.

h

This opener is compatible with:

• Doors that use a torsion bar, springs and a door
no more than 4.2m (14’) high.

• 100mm - 150mm drums (4” to 6”), NOT TO BE
USED on tapered drums over 150mm (6”).

• High lift and standard lift sectional doors up to

4.2m (14’) high.

• Doors up to 5.5m (18’) wide.

2

• Doors up to 16m

• 25mm (1”) torsion bar only.

• Review or inspect proposed installation area.
Opener can be installed on left or right side of
door. Select the side that meets the
requirements listed below.

• Must have minimum of 64mm (2 1/2”) between

the wall and the center of the torsion bar.

• Must have minimum of 76mm (3”) between the

ceiling and the center of torsion bar.

(170 sq ft)

• Must have minimum of 203mm (8”) between the
ide wall (or obstruction) and the end of torsion

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bar.

• The torsion bar must extend at least 25mm to

00mm (1” to 4”) past the bearing plate.

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• An electric outlet is required within 1.8m (6’) of

the installation area. If outlet does not exist,

ontact a qualified electrician.

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• Depending upon building’s construction,

extension brackets or wood blocks may be
needed to install safety reversing sensors.

M

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• A model CM475 EverCharge

Standby Power
Unit (SPU) is strongly recommended if there is
no access door to the building, as this opener
cannot be used in conjunction with an external
emergency release mechanism.

• Any gap between the floor and the bottom of the
door must not exceed 6mm (1/4”). Otherwise
the safety reversal system may not work
properly.

NOTE: Inspect the torsion bar while the door is raised
and lowered. It is important that there is no noticeable
movement up and down or left and right. If this type of
movement is not corrected, life of this opener will be
greatly reduced.

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ASSEMBLY STEP 1

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Socket Wrench

RIGHT

WRONG

Screw
#10-32

HARDWARE SHOWN ACTUAL SIZE

Attach the Collar to the Opener
To avoid installation difficulties, do not run the door

pener until instructed to do so.

o

• Loosen the collar screws.

• Attach collar to either the left or the right side of the
opener. Depending on Left or Right hand installation
ensure that the collar is seated all the way on motor
shaft until stop is reached (Figure 1).

• Position the collar so that the screws are accessible
when attached to the torsion bar.

• Tighten both sides of collar screws equally (Figure 2) to
secure collar to the opener (16Nm-19Nm of torque).

• Do not tighten set screws as yet.

To prevent possible SERIOUS INJURY or DEATH,

he collar MUST be properly tightened. The door

t
may not reverse correctly or limits may be lost
due to collar slip.

NOTE: Nylon Patch has been added to the collar
screws, so it is normal for some thread resistance to
be evident.

ASSEMBLY STEP 2

Attach Mounting Bracket to Opener

• Loosely attach slotted side of mounting bracket
to the same side of the opener as the collar,
using self-threading screws provided.

NOTE: Do not tighten until instructed. Illustrations
shown are for left side installation.

Right hand

installation

Figure 1

Figure 2

Left hand

installation

Alternate Mounting Kit (NOT SUPPLIED):

This kit allows model MJ3800 to be
mounted below the torsion bar in the
case where the torsion bar is not
round or the normal mounting area
is obstructed.

G480LM

6

INSTALLATION

Staple

Torsion Bar

WARNINGWARNING

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

1. READ AND FOLLOW ALL INSTALLATION
WARNINGS AND INSTRUCTIONS.

2. Install door opener ONLY on properly balanced and
lubricated the 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 the door BEFORE installing opener to avoid
entanglement.

5 Mount emergency release handle no higher than 1.8m

above floor.

6. NEVER connect the door opener to power source
until instructed to do so.

7.NEVER wear watches, rings or loose clothing
while installing or servicing opener. They could be

caught in the door or opener mechanisms.

8. Install wall-mounted door control:

• within sight of the door.

• out of reach of children at minimum height of

1.5 m.

• away from ALL moving parts of the door.

9. Place entrapment warning label on wall next to multi
function door control.

10.Place manual release/safety reverse test label in plain
view on inside of the door.

11.Upon completion of installation, test safety reversal

system. Door MUST reverse on contact with a 40mm
(1 1/2”) high obstacle placed on the floor.

INSTALLATION STEP 1

Position the Opener

1. Close the door completely.

2. Slide the opener with collar over the end of the torsion
bar. Ensure that the collar does not touch the bearing
plate. Check to make sure the mounting bracket is
located on a solid surface such as wood, concrete or
door/flag bracket. Snug collar screws to help assure
proper alignment of opener. Mark the bracket holes. It
may be necessary to cut the torsion bar if it is too long
or damaged.

3. Loosen collar screws from torsion bar and remove the
opener. Drill 5mm (3/16”) pilot holes at the marked
locations. Drill through steel plate if needed.

4. Reinstall the opener by sliding the collar over the torsion
bar until pilot holes align with bracket. Securely tighten
collar screws that attach to the torsion bar to 16Nm­19Nm of torque. Securely tighten both set screws firmly,
without damaging the opener.

5. Fasten bracket securely with 14-10x1-7/8" screws.
Tighten all mounting bracket hardware.

NOTE: The opener does not have to be flush to wall,
but it is essential it is mounted perfectly square to the
torsion bar. This will ensure smooth operation with
minimum stress at the connecting collar mount.

6. Use a staple to secure the antenna wire to prevent
antenna from being entangled in a door roller.

To prevent possible SERIOUS INJURY or DEATH:

• Concrete anchors MUST be used if mounting bracket
into masonry.

• NEVER try to loosen, move or adjust the door,
springs, cables, pulleys, brackets or their hardware,
ALL of which are under EXTREME tension.

• ALWAYS call a trained door systems technician if the
door binds, sticks or is out of balance. An unbalanced
door might not reverse when required.

• Opener MUST be mounted at a right angle to the
torsion bar to avoid premature wear on the collar.

7

Staples

Lock Screw
1/4-20 x 1/2" (2)

Lock Template

Roller

Garage
Door Track

TOP

DRILL8mm

DRILL19mm

DRILL8mm

132A2505

TOP

DRILL5/16"

DRILL3/4"

DRILL5/16"

132A2505

Approx. 7.6cm

(3”)

Overhand
K

not

Emergency
Release Handle

Overhand
K

not

Rope

Opener

E

mergency

Release Cable

01

6+

%'

Warning Label

WARNING

INSTALLATION STEP 2

Attach the Emergency Release Rope and
Handle

• Thread one end of the rope through the hole in
the top of the red handle so “NOTICE” reads
right side up as shown. Secure with an overhand
knot at least 25mm (1") from the end of the

ope to prevent slipping.

r

• Thread the other end of the rope through the
loop in the emergency release cable.

• Adjust rope length so the handle is no higher
than 1.8m (6’) above the floor. Secure with an
overhand knot.

NOTE: If it is necessary to cut the rope, heat seal the
cut end to prevent unraveling.

INSTALLATION STEP 3

Install powered door lock

The lock is used to prevent the door from being
manually opened once the door is fully closed.

1.Select a door roller to mount the lock above.
Check for clearance. If possible select a roller on
the same side of the door as the opener. The
second roller up from the bottom is ideal in most
installations.

2.Ensure the door track surface is clean and
adhere lock template with bottom edge just
above the highest point on the roller (Figure 1).

3.Drill holes as marked on the template.

4.Fasten powered door lock to the outside of the
door track with hardware provided.

5.Run bell wire up wall to opener. Use insulated
staples to secure wire in several places.

6.Plug connector into the opener (Figure 2).

NOTE: Lock must be mounted within 3m (10') of the
power head.

To prevent possible SERIOUS INJURY or DEATH
from a falling door:

If possible, use emergency release handle to

•
disengage door ONLY when door is CLOSED.
Weak or broken springs or unbalanced door
could result in an open door falling rapidly
and/or unexpectedly.

• NEVER use emergency release handle unless
the doorway is clear of persons and
obstructions.

Figure 1

HARDWARE SHOWN ACTUAL SIZE

Figure 2

8