Merlin Powerlift User Manual
EDR4 1169 G 10/03
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Toll free helpline
Please have your serial number and
model name available before calling.
Australia 1800 638 234
New Zealand 0800 653 667
United Kingdom 0800 073 0112
www.merlingo.com
Professional installation
While this unit is suitable for
'do-it-yourself' installation, using
a qualified Authorised Installer has
the additional benefit of an on-site
warranty and ensures a quality
installation. Telephone for your
nearest Merlin Authorised Installer.
Installation and user manual
remote control openers
making life easier
powerlift
garage door opener for sectional and tilt doors
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Index
Welcome
Thank you for purchasing the Merlin Powerlift sectional or tilting door opener. This product
combines convenience with security.
You can operate the door from a remote control radio transmitter or from a push-button
inside your garage. One touch of the remote control button or internal push button will activate the opener and the door will open (or close) automatically. The door may be stopped in
any position during the opening cycle by simply depressing either button. You may close the
door by depressing the button again.
This ruggedly built garage door opener will provide years of safe and dependable service.
Please take a moment to complete and send in the warranty card included with this product.
Also please note your serial number and purchase details. We are proud of our product and
want to provide the best after sale service possible. Please feel free to contact us if you have
any suggestions or comments.
Important safety instructions for operation
It is vital for the safety of persons to follow all instructions. Save these instructions.
WARNING Do not allow children to play with door controls. Keep remote
controls away from children. The appliance is not intended for use by young
children or infirm persons without supervision.
Watch the moving door and keep people away until the door is completely
opened or closed.
Use caution when operating the manual release with the door open since
it may fall rapidly due to weak or broken springs or an imbalanced door.
Do not use the manual release cord to pull the door open. The cord or
release may break under load.
Frequently examine the installation, in particular cables, springs and mountings, for signs of wear damage or imbalance. Do not use if repair or adjustment is needed since a fault in the installation or an incorrectly balanced
door may cause injury.
Each month check that the drive reverses when the door contacts a 40mm
(50mm for UK) high object placed on the floor. Adjust if necessary and
recheck since an incorrect adjustment may present a hazard.
Disconnect electric power to the garage door opener before making any
repairs or removing any side covers.
To prevent fire or shock hazard, do not expose the opener to rain or moisture.
To avoid electrical shock do not open the cabinet without disconnecting
the opener from the mains.
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Contents
Safety Instructions 2 & 3
Site requirements 4
Preparing the opener 5
Installing the opener 7
Setting door travel limits 11
Setting the force sensitivity 12
Setting up wireless controls 13
Adding the Merlin M102
non-contact beam sensor 14
Improving door security 14
Manual operation 14
Operating from a remote 15
Troubleshooting 15
Optional accessories 17
Specifications 17
Warranty 18
Merlin Service Centres 20
Important safety instructions for
installation
WARNING Incorrect installation can lead to severe injury. Follow all installation
instructions.
Garage doors are under great spring tension. Do not attempt to adjust spring tension. Do not
loosen any brackets under spring tension. Do not remove springs from the door. Merlin Garage Openers Limited do not accept responsibility for damage or injury resulting from installing this opener. If you have any concerns please consider having the opener installed by an
Authorised Merlin Installer.
To avoid difficulty during installation, do not connect the opener to the mains or run the door
opener until instructed to do so.
Do not use force sensitivity adjustments to compensate for a binding or sticking garage door.
Excessive force may damage the garage door.
Before installing the drive remove all unnecessary ropes or chains and disable any equipment, such as locks, that is not needed for powered operation.
Before installing the drive check that the door is in good mechanical condition and that it is
correctly balanced. Check that it opens and closes
properly.
Install the actuating member for the manual release (red handle on a rope) such that it rests at a
height of less than 1.8 m.
Install any fixed control, wired or wireless, within
sight of the door but away from moving parts and
at a height of more than 1.5 m.
Install the drive such that all moving parts (except
the door and the manual release) are at a height
of more than 1.8 m.
Permanently attach the label warning against entrapment in a prominent place, or near any fixed
control.
Permanently fix the label concerning the manual
release adjacent to its actuating member (thread
the cord through the holes in the manual release
warning card).
After installation, ensure that the mechanism is
properly adjusted and that the drive reverses when
the door contacts a 40 mm high object placed on
the floor.
The appliance is not intended for use by young
children or infirm persons without supervision.
If the supply cord is damaged, it must be replaced
by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard.
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Site requirements
Radio interference
Radio interference can reduce the performance of garage door opener remote controls. Garage door remote controls␣ are required to operate in shared radio frequency bands. Regulations permit other users to continuously operate higher powered devices such as baby monitors or wireless headphones in these shared bands. These devices may cause radio interference that reduces the performance of your remote control. Switch off interfering devices if
possible.␣
Remote controls and receivers that operate on alternative frequencies are available at additional cost.
Electrical Power Supply
The opener is for Australian and New Zealand conditions of 220-240 Volts AC - 50 Hz.
There must be an earthed power point within 1.6 metres of the mounting position.
Garage Door
This opener is designed for a residential sectional door to 2.1 metres high or a one piece
tilting door to 2.4 metres high and 6.0 metres wide. For installation on taller doors see your
Merlin dealer.
Check that it is possible to raise the door by hand through the full height of the opening. The
door should operate smoothly, lifting up and down without the door or door mechanism binding. The door must not jam in the tracks.
A properly balanced tilt door will stop of its own accord at about the two thirds closed position. (Springs may need adjustment accordingly).
A properly sprung sectional door will either close of its own accord for the last 500 mm of its
travel or it will require a very light added force. If the door springs back, it is advisable to have
the spring tension adjusted. Do not attempt this yourself. Springs can only be adjusted safely
by a trained professional installer.
If in doubt about whether the door is suitable for automation consult an Authorised Merlin
Installer.
Tilt door clearances
The opener has been designed to fit most existing doors. The minimum installation clearance
from the garage ceiling to the top edge of the door during any part of the door’s travel is 100
mm.
The header bracket is to fit as close as practical above the top of the door, in the centre.
The door bracket is to fit at the highest possible point of the door, in the centre. The bracket
may be fixed vertically or horizontally to suit. A solid fixing point is required.
The overall length of the opener when assembled is 3150mm.
Clear space of around 600 mm is required behind the fully open door.
Sectional door clearances
For sectional doors using torsion springs the minimum allowable height from the top of the
closed door to the ceiling is 200 mm.
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For sectional doors using tension springs the minimum allowable height from the top of the
closed door to the ceiling is 280 mm.
The header bracket is to fit 200-300 mm above the top of the door at the centre or directly
above the torsion bar.
The door bracket is to fit in line with the top rollers in the top panel. It may fit vertically or
horizontally. A solid fixing point is required.
The overall length of the opener when assembled is 3150mm.
Clear space of around 600 mm is required behind the fully open door.
Door Locks
Existing door locks must be removed or disabled. (The opener or the door can be damaged if
you try to open a locked door).
Hardware pack
Pole & strapping
Preparing the opener
STEP 1: Check the contents of the package. Your package should contain: this
manual, a warranty sheet, one remote control transmitter (with clip andbattery included), wall box pack, hardware pack,
chain pack, trolley, header bracket, door
bracket, door arm, L arm, return pulley assembly, light cover, red release rope (with
manual release warning card), one heavy
angle, two light angles and one assembled
door
Your hardware pack should contain: one
long clevis pin, one short clevis pin, two
clevis pin clips, three M8 bolts, one M8 hex
nut, three M8 nylok nuts, two black
1
/
4
pan
head screws, two long
1
/
4
coach bolts, two
short
1
/
4
machine screws, four
1
/
4
flanged
nuts, one
1
/
4
hex nut, one
1
/
4
square nut,
four
5
/
16
lag screws, two
1
/
4
flat wash-
ers.
CAUTION Do not plug in the power
head to test it before installation. The
power head is shipped with the limit
switches set for a door in an open position. Operation before the correct
point in the installation process can
lead to a damaged door or opener.
Contents of the package
Opener Light cover
Header bracket
Return pulley
Door bracket
Trolley
Bulb
Door arm
Chain pack
L arm
Visor clip, battery
transmitter
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Pole Assembly for trackless tilt doors
Additional setup for trackless tilt doors (jamb fittings) only
The assembled pole should be one segment shorter for a trackless tilt door. A shorter pole
flexes less during the opening and closing of the door. (Due to the lack of restraining tracks
the momentum of the moving door will tend to flex the pole.)
STEP 3: Assemble the trolley and header bracket to the pole.
Slip the pole into the return pulley assembly until the pole reaches the restraining
tab.
Slide the trolley over the pole, ensure that the arrow points towards the return
pulley assembly.
Slip the assembled pole into the power head until the pole reaches the restraining
tab. Take care to protect the power head from scratching on the floor of the garage. You can use blocks of styrofoam packing or a sheet of cardboard for this.
Twist the pole until the return pulley is aligned onto the same plane as the power
head drive sprocket.
STEP 4: Remove the sprocket cover from the power head.
Removing the sprocket cover
The pole that is supplied with this unit is in five sections.
Use only four sections for trackless tilt doors. Omit one
of the poles which is reduced in diameter at one end.
Assembly of pole, return pulley,
power head and trolley
Pole into powerhead
Trolley onto pole
Pole into return pulley
Pole Assembly
Four poles reduced in diameter at one end
and one plain pole.
Insert reduced end into plain end.
After assembly, approx 2750mm long
Three poles reduced in diameter at one end and one plain pole
After assembly, approx 2215mm long
STEP 2: Assemble the poles. Gather the 5 pole sections and assemble them as in the
sketch. It may be necessary to force the poles together by knocking the ends with
a block of wood. If you have a trackless tilt door, read the following before assembling the poles.
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