Merlin prolift 230T Installation Manual
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Important safety instructions for
installation
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.
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 does not
accept responsibility for damage or injury resulting from installing this opener. Unless you have
appropriate training, refer door adjustments to the door manufacturer.
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 40mm (50mm for UK) 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.
CE compliance after installation (EC countries only)
It is the responsibility of the installer of the opener to ensure that the forces measured at the
leading edge of the door are within the guidelines of BSEN 60335-2-95:2001. This may require
adjustment of the drive and may also require adjustment of the door. Specialised measurement
equipment may be required. Contact Merlin for assistance if necessary. If the measured forces
exceed the guidelines then Merlin M102 non-contact sensors must be fitted.
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Site Requirements
Electrical Power Supply
The opener is for 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 overhead garage door up to 6 m wide, either sectional or
one-piece tilting. Using the standard length pole and chain it is suitable for door heights up to 2.2
m. Alternative poles and chains are available to suit door heights up to 2.4 m and 3.1 m. Contact
Merlin for solutions to suit door heights up to 4.5 m.
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).
For one piece tilt doors over 4.5 m in width built out of cedar or ply it is advisable to use the smaller
15 tooth sprocket.
A properly sprung sectional door will either close of its own accord for the last 500mm 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. Springs can only be adjusted safely by a trained professional.
If in doubt about whether the door is suitable for automation consult Merlin.
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 100mm.
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 depends on the length of pole fitted. The overall
length is 400mm more than the length of the pole.
Clear space of around 600mm is required behind the fully open door.
Sectional door clearance guidelines
For sectional doors using torsion springs the minimum allowable height from the top of the closed
door to the ceiling is 200mm.
For sectional doors using tension springs the minimum allowable height from the top of the closed
door to the ceiling is 280mm.
The header bracket is to fit 200-300mm 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 depends on the length of pole fitted. The overall
length is 400mm more than the length of the pole.
Clear space of around 600mm is required behind the fully open door.
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Door Locks
Existing door locks must be removed or disabled. (The opener or the door can be damaged if you
try to use it to open a locked door).
One Piece doors opening over footpaths
Ensure parts of the door do not extend over public footpaths or roads.
Contents of the package
Opener Light cover
Header bracket
Return pulley Trolley
Hardware pack
Door arm
Chain pack
L arm
Wall box pack
Visor clip
Transmitter
Battery
Door bracket
STEP 2:
If your door is greater than 3 m tall or if your door is greater
than 2.5 m tall and you will use the 15 T sprocket :
Switch the TALL DOOR option on the control panel into the ON position. This will allow the opener
to run for 40 seconds instead of 30.
If you have a sectional door and you want to have auto-closing:
Select the timing of your choice from the autoclose option switches on the control panel. The
options are off, 30 seconds, 60 seconds and 90 seconds.
For a 30 second delay: autoclose short ON
For a 60 second delay: autoclose long ON
For a 90 second delay: both short and long ON
NOTE Auto-closing will only work if the beam sensors are correctly fitted, correctly functioning and unobstructed.
WARNING Merlin does not recommend auto-closing of one piece tilt doors because
beam sensors will not prevent the door from hitting an object close to the outside of
the door.
STEP 1: Check the contents of the package.
Your package should contain: this manual, a warranty
sheet, one or more remote control transmitters, wall box
pack (some models only), 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) and one assembled door
opener.
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.
Preparing the opener
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Assembly of pole,
return pulley,
power head and
trolley
Pole into powerhead
Trolley onto pole
Pole into return pulley
Attaching
mounting
strapping
Chain threading
300-500mm
Connecting the chain
Chain hangs no lower than the pole
Additional setup for trackless tilt doors (jamb fittings) only
The pole should be shortened for
a trackless tilt door.
STEP 3: Assemble the trolley and
header bracket to the pole. Slip the
pole into the return pulley assembly. Slide
the trolley over the pole.
Slip the pole into the power head. The return
pulley should be aligned with the sprocket.
STEP 4: Remove the sprocket cover from the power
head.
Additional setup for trackless tilt
doors (jamb fittings) only
Use the Chain on the smaller of the two sprockets.
STEP 5: Thread up the chain. The threaded end of the torpedo should
now be pointing back toward the power head.
Additional setup for trackless tilt
doors (jamb fittings) only
The chain will need to be shortened to suit the choice of pole
length and sprocket size.
STEP 6: Connect the two ends of the chain.
Slide the trolley over the torpedo and flip the release lever up to en-
gage the trolley with the torpedo. The trolley should be 300 to 500mm
from the power head.
STEP 7: Tension the chain.
STEP 8: Attach mounting strapping to the power head. Black 1/4” machine screws for the rubber
mounting bushes are in the hardware pack. Attach your mounting strapping using these screws.
Place a washer between the rubber bush and the strapping.
NOTE: The sprocket cover must be attached to the opener
using the screws provided.
Rotate adjuster Lock nutLock nut
Correct chain tension
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