Wayne-Dalton 3982 User Manual

Wayne-Dalton Corp.

P.O. Box 67 Mt. Hope, OH 44660

(888) 827-3667

www.wayne-dalton.com

Installation Instructions and Owner’s Manual

EXTENSION

Model 3982 idrive™ Extension Spring Kit.

Use these instructions to install the extension spring kit with idrive™ Models: 3660-372/ 3661-372/ 3662-372/ 3760-372

Covered under one or more of the following U.S. patents: D413,579;D466,141; D472,568; D472,910;D473,573; D473,574;

D474,215; D505,393; D517,580; 5,929,580; 6,078,249; 6,145,570; 6,164,014; 6,253,824; 6,263,947; 6,325,134; 6,326,751; 6,326,754; 6,401,792; 6,561,255; 6,561,256; 6,568,454; 6,588,156; 6,605,910; 6,667,591; 6,739,372; 6,845,804; 6,851,465; 6,873,127; 6,880,609; 6,903,650; 7,053,571; 7,061,197; 7,075,256; 7,109,677; 7,123,128; 7,143,804; 7,173,389; 7,173,514;

7,173,516; 7,183,732; 7,190,266; 7,193,502; 7,207,142; 7,211,975. other U.S. and foreign patents pending

Important Notice!

Use these instructions instead of the manual included with your idrive™. Read the enclosed instructions carefully before installing/operating this garage door opener. Pay close attention to all warning labels and notes. This manual should be attached to the wall in close proximity to the garage door opener.

Part No. 306436

7/6/2007

Table of Contents

System Requirements 2. Important Safety Instructions 3. Package Contents 4. - 5. Tools Needed 6. Available Accessories 6. idrive™ Retro-ﬁ t Installation 7. Extension idrive™ Installation 7. - 14. Pre-Operation Installation 15. - 29. Operation 30. - 32. Maintenance 33. Troubleshooting 34. - 35. Warranty 36. Customer Service Number 36.

System Requirements

WARNING To reduce the risk of severe injury or death,

use this kit only with the following openers:

idrive™ Models 3660-372, 3661-372, 3662-372, 3760-372 or 3760N-372 can be installed on a garage door with an extension spring counterbalance system and standard lift track, ONLY when installed with the Infrared Safety Sensors Accessory; Model 3965.

idrive™ Model 3660-372, 3661-372, 3662-372, 3760-372 & 3760N-372 can be installed on a garage door with an extension spring counterbalance system and standard 6” low headroom track, ONLY with the Low Headroom Kit, Model 3980 (not included).

After installation is complete, fasten this manual near garage door. Perform monthly maintenance (see Maintenance section page 33 of your idrive™ Installation Instructions and Owners Manual) and periodic checks, as recommended.

NOTE:

high.

FCC and IC Statement

FCC Regulatory Information:

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Extension spring kit, model 3982 is designed for garage doors 7’-0” wide to 10’-0” wide and up to 8’-0”

IC Regulatory Information:

Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired

operation of the device.

NOTE: This equipment has been tested and found to comply with limits for a Class B digital device,

pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with these instruction, may cause harmful interference to radio communication; however, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning equipment off and on, user is encouraged to try to correct interference by one or more of the following measures: Reorient or relocate receiving antenna. Increase separation between equipment and receiver. Connect equipment into an outlet on a circuit different from that which receiver is connected. Consult your dealer or/and experienced radio/television technician for help. WARNING: Changes or modiﬁ cations to this unit not expressly approved by party responsible for compliance could void user’s authority to operate this equipment.

IMPORTANT SAFETY INSTRUCTIONS FOR

INSTALLATION AND USE

WARNING: INCORRECT INSTALLATION CAN LEAD TO SEVERE OR FATAL INJURY. FOLLOW INSTRUCTIONS.

READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

Do not connect the opener to a power source until instructed to do so.

Install the entrapment warning label next to the wall station in a prominent location. Install the emergency release marking on or next to the emergency disconnect.

Remove all ropes and remove or make inoperative all locks connected to the garage door before installing the opener.

Do not wear rings, watches or loose clothing when installing or servicing a garage door system.

WARNING: IT IS VITAL FOR THE SAFETY OF PERSONS TO FOLLOW ALL INSTRUCTIONS. SAVE THESE INSTRUCTIONS.

Install only on a properly balanced garage door. An improperly balanced door could cause severe injury. Have a qualiﬁ ed service person make repairs to cables, spring assemblies, and other hardware before installing the opener.

Where possible, install the opener seven feet or more above the ﬂ oor. Mount emergency release six feet above the ﬂ oor.

Locate the wall station: (a) within sight of door, (b) at a minimum height of ﬁ ve feet, so small children cannot reach it, and (c) away from all moving parts of the door.

After installing the opener, the door must reverse when it contacts a 1-1/2” high object (or 2 x 4 board laid ﬂ at) on the ﬂ oor.

Wear safety glasses for eye protection when installing or servicing the opener or door.

Installation and wiring must comply with local building and electrical codes. Connect power cord to a properly grounded outlet. Do not remove the ground pin from power cord.

Package Contents: 3982 idrive™ Extension Spring Kit

RH.

LH.

RH. LH. Flag Brackets

Photoelectric Safety Sensors

W/Hardware

Owners Manual

Cable/Drum

Assembly

Hardware Kit: 3982 idrive™ Extension Spring Kit

RH.

LH.

Drum Wrap Set

(3) Cam Tubes

Cable Loop Tool

(2) 1/4-20 x 9/16”

Track Bolt

(4) 3/8-16 x 3/4” Truss

Head Bolt

(2) Drum Shafts

(2) 1/4-20

Flange Hex Nut

(4) 3/8-16

Hex Nut

(2) 1/2-13 Lock Nut

(2) 3-Hole Clip

(2) 5/16” x 1-5/8” Hex Head Lag Screw

(2) 1/2-13 x 2” Socket Head Cap Screw

(2) Large S-Hook

(4) 1/2” Flat Washer

(4) spacers

(2) Snap Buttons

Grease Packet (1)

idrive™ Package Contents:

Three-button

Transmitter (2)

Wall Station Assembly

6’ Power Cord (1)

Opener

Lock Arm Assembly

Entrapment Label

idrive™ Hardware Kit:

“S” Hook (1)

Disconnect

Handle (1)

Wall Station

Reference Label

Owners Manual

Disconnect Cable (1)

Support Bracket

1/4 x 1-1/2” Hex Head Lag Screws (4)

Light Fixture Assembly

w/ Screw & Diffuser

Jumpers (3)

Emergency

Disconnect Label (1)

Handle Bracket (1)

Cable Clips (4)

M5 x .8 x 12 Phillips Pan Head Screw (1)

(For Lock Arm)

#6-32 x 3/4” Phillips

Pan Head Screw (1)

(For Light Fixture)

#6 x 7/8” Phillips Pan

Head Screws (4)

1/4 x 2” Hex Head Lag Screws (2)

#6-20 x 1/2” Phillips Pan

Head PL Screw (1)

(for disconnect handle)

Tools Needed:

1/8” Drill Bit

3/32” Drill Bit

Power Drill

Pencil

7/16” Socket

1/2” Socket

9/16” Socket

3/4” Socket

7/16” Socket Driver

Safety Glasses

3/8” Hex Wrench

Ratchet

Level

Available Accessories: For idrive™

Tape Measure

Step Ladder

7/16” Wrench

1/2” Wrench

9/16” Wrench

3/4” Wrench

Flat Head Screw-

driver

Phillips Head

Screwdriver

Locking Pliers (2)

3-Button Mini RF Trans-

mitter

Model no: 3973

Part no: 302083

Infrared Safety Sensor

Model no: ML2

Part no: 301674

Power Cord Extender

Model no: 3960M, Part no: 302616

Keyless Entry RF

Transmitter Model no: KEP2 Part no: 302078

5-Button Wall-Station RF

Transmitter

Model no: 3975

Part no: 302090

Low Headroom Kit

Part no: 302883

Deluxe Wireless Light Kit

Model no: 3950-ULDRE

Part no: 302097

idrive™ Retro-ﬁ t Installation

Step 1: Extension Spring Relief

Raise the door to the fully open position and clamp locking pliers to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling (see Fig. 1). By opening the door, you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove the counterbalance cable. Leave extension spring with it’s sheave installed. Repeat for the other side.

WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE RE-

MOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE, EVEN FATAL INJURY.

NOTE: Only remove springs when door is in the up position and visegrip pliers are attached to the

track.

BOTTOM ROLLER

LOCKING PLIERS

FIG. 1

SAFETY CABLE (LEAVE INSTALLED)

CAREFULLY REMOVE THE “S” HOOK AND COUNTERBALANCE CABLE (REPEAT FOR THE OTHER SIDE)

ATTACH LOCKING PLIERS TO BACK LEG OF TRACK BELOW ROLLER (BOTH SIDES)

Step 2: Remove Front Sheave

Disassemble the existing front cable sheaves. Typically the front sheave is secured with a bolt and nut to the horizontal angle. Repeat for other side. (NOTE:

NUT

FRONT CABLE SHEAVE

BOTTOM DOOR SECTION

It may be helpful to refer to the original garage door’s owner’s manual for removing parts from the original door.)

HORIZONTAL ANGLE

Extension idrive™ Installation

Step 3: Lifting Cable Loop

Locate the bottom bracket at the lower edge of the bottom section. The lift cable will be attached to the brackets milford pin. Measure the diameter of the head of the pin and record the measurement. Locate the drum assemblies provided with the kit. They will have a cable attached with a loop formed on the end of the cable. Locate the cable loop tool and install the loop over the shape that corresponds to the milford pin head size you measured. Use the larger size if the milford pin head size is greater than or equal to 1/2”, and the smaller size if the diameter is less than 1/2”. With the cable installed onto the tool, pull the cable tight, forming it around the loop tool. Remove the cable from the tool while holding the cable so it does not slip in the crimp sleeve. Place the crimp sleeve on a hard surface and using a hammer, hit the crimp sleeve until it is squeezed tightly around the cable. Verify the loop has been set securely by pulling

on the loop. Repeat for the other cable. Set the drum/cable assemblies aside until needed.

PULL LIFTING CABLE TIGHT SNUGGING THE CABLE TO SIZE AROUND THE FIXTURE

LOOP TOOL

MILFORD PIN

CRIMP SLEEVE

BOTTOM BRACKET

WARNING FAILURE TO CRIMP SLEEVE SECURELY TO CABLE, CAN CAUSE CABLE

TO SLIP OUT, ALLOWING DOOR TO FALL DURING OPERATION, RESULTING IN SEVERE OR FATAL INJURY.

Step 4: Flag Bracket Installation

RIGHT HAND FLAG BRACKET

There are two ﬂ ag brackets (left and right) provided. The right side bracket has an extended ﬂ ange at the top. Align the left hand ﬂ ag bracket to the existing left ﬂ ag angle, so the top ﬂ ange will be located to the top edge of the existing ﬂ ag angle. Identify two locations that will allow the 3/8” bolts to go through both the ﬂ ag bracket and the existing ﬂ ag

5/16 X 1-5/8” LAG SCREW

DRILL (2) 3/8” DIA. HOLES TO MATCH SLOTS IN FLAG BRACKETS

(2) 3/8” NUTS

FLAG BRACKET

(2) 3/8-16 X 3/4” TRUSS HEAD BOLTS

(2) SPACERS

angle.

FLAGANGLE

NOTE: In some instances there

LEFT HAND FLAG BRACKET

may not be any holes in the existing ﬂ agangles to mount the ﬂ ag brackets. It will be necessary to drill two 3/8” dia. holes that will allow the 3/8” bolts to go through both the existing ﬂ ag angles and the new ﬂ ag

brackets. Once the holes are drilled proceed with the installation of the ﬂ ag brackets as shown in step 4.

BRACKET

INSTALLED

Insert the 3/8” bolts into the previously identiﬁ ed slot in the ﬂ ag bracket, insert a spacer onto the bolt and position the ﬂ ag bracket to the existing ﬂ ag angle. Attach the 3/8” nut and tighten. Secure the second bolt, spacer and nut in the same manner. Make sure that the ﬂ ag bracket is parallel with the existing ﬂ ag angle.

IMPORTANT! Flag brackets must be level and plumb. Secure the top of the ﬂ ag bracket with a 5/16” lag

screw in the slot provided. Repeat the procedure for the right hand bracket.

NOTE: Right and Left hand is determined from inside the garage, looking out.

Step 4A: Track Width

Conformation

For the extension spring torsion

1-3/4”

DOOR WIDTH + 3-1/2”

EXTENSION SPRING

FLAG BRACKETS

1-3/4”

tube to install correctly it is necessary that the distance between the ﬂ ag angles be correct. Measure the

DOOR WIDTH

distance between the existing ﬂ ag angles. The dimension needs to be the width of the door + 3-1/2”. If this is not what the track is set to, then you must adjust the track so that the mounting brackets meet

EXISTING

FLAG ANGLES

the requirment.To move the track it may be necessary to loosen the bolts in the ﬂ ag angles and the brackets mounting it to the jamb. Set the track so it is 1-3/4” from the edge of the door on both sides. Reinstall bolts in the jamb brackets and ﬂ ag angles. Recheck dimensions before go-

ing to the next step.

Step 5: Cable Drum Installation

NOTE: Do not remove shrink wrap from cable

drums until instructed to do so.

1/2-13 X 2” SOCKET HEAD CAP SCREW

DRUM SHAFT

Cable drums are right and left. Be sure to check the identiﬁ cation on each drum to make sure the correct drum is installed on its corresponding side.

Apply grease to both sides and outer diameter of the ﬂ ange of the drum shaft.

Insert the 1/2-13 x 2” socket head cap screw into the drum shaft. Then insert the screw and shaft into the drum so that the screw threads and drum shaft are showing out past the drum bearing.

Install the drum/shaft/screw assembly into the 3/4” hole in the ﬂ ag bracket. Be sure the end of the shaft

is inserted into the hole in the ﬂ ag angle.

Secure assembly with a 1/2” washer and 1/2” lock nut.

Check to make sure the drum will rotate freely on the shaft. If not, loosen 1/2” lock nut until the drum is free to rotate. Repeat for opposite side.

DRUM SHAFT

3/4” HOLE

FLAG BRACKET

1/2” WASHER

APPLY GREASE TO DRUM SHAFT FLANGE

CABLE DRUM

1/2-13 X 2” SOCKET HEAD CAP SCREW

DRUM ASSEMBLY (SHRINK WRAPPED)

Step 6: Bottom Bracket Lifting Cables

Locate the end of the lifting cable where the custom loop was made earlier in the instructions. Carefully pull the cable, bringing the loop to the milford pin located in the bottom bracket on the edge of the bottom section. Secure the cable loop around the milford pin, making sure the loop is over the head of the milford pin and around the smaller diameter. Repeat for the other side.

MILFORD PIN ON BOTTOM BRACKET

1/2” LOCK NUT

LIFTING CABLE

Step 7: Drum Wrap Installation

NOTE: Right and Left hand is determined

from inside the garage, looking out.

Drum wraps are right and left. Take the extension spring cable and unroll it, thread the free end of the cable through the rectangular window of the drum wrap. Position the drum wrap as shown

DRUM WRAP INSTALLED

RECTANGULAR WINDOW

FLAG BRACKET

1/4-20 FLANGE NUT

LEFT HAND DRUM WRAP

EXTENSION SPRING CABLE

CABLE DRUM

1/4-20 X 9/16” TRACK BOLT

Step 8: Extension Spring Counterbalance

NOTE: The door lifting cable and the extension spring cable are

wrapped oppositely on the drum.

Take the end of the extension spring cable, thread it through and around the sheave located on the extension spring, then bring the cable to the front of the track.

COUNTERBALANCE CABLE ON DRUM GROOVES

S-HOOK

3-HOLE CLIP

ADJUST CABLE SO THAT

SPRING STRETCHES 1”, BY RELOCATING S-HOOK OR ADJUSTING THE CABLE IN THE 3-HOLE CLIP

SECURE COUNTERBALANCE CABLE WITH S-HOOK AND 3HOLE CLIP

EXTENSION SPRING COUNTERBALANCE CABLE

CABLE DRUM

COUNTERBALANCE CABLE ON SPRING SHEAVE

SECURED TO FRAMING MEMBERS

REVERSE ANGLE

CABLE DRUM

SHEAVE

Attach the 3-hole clip as shown. Insert the S-hook into the 3-hole clip. Pull the

S-HOOK

3-HOLE CLIP

cables taut ensuring the cable is on the sheave. Connect the cable to the horizontal angle. Repeat Step 8 for the opposite side of the door. After the counterbalance cables are installed on both sides of the track, lift the drum wrap to remove the shrink wrap from the cable drums. Re-insert the drum wrap and match the hole in the drum wrap with the hole in the ﬂ ag bracket.

CABLE

Secure the drum wrap to the ﬂ ag bracket using (1) 1/4-20 x 9/16” track bolt and 1/4-20 ﬂ ange nut (see Fig.7). Repeat for the other side.

SPRING ADJUSTMENTS: Adjust the counterbalance cables so that there is

TIE CABLE THROUGH THE (2) SMALLER HOLES

no more than 1” of spring stretch. This is done by adjusting the cable in the 3hole clip and/or moving the S-hook to another location on the horizontal angle. Be sure that the left and right side counterbalance cables are adjusted to provide the same amount of spring pre-tension on each side.

Step 9: Safety Cable Installation

Ensure that the safety cables installed on your door are not tangled with the extension spring cables. Contact a professional garage door service technician if safety cables are not installed through each of the extension springs on your door.

REAR SUPPORT

SAFETY CABLE

3 HOLE CLIP

Step 10: Lower the Door

Now that the counterbalance system is installed to the garage door, remove the locking pliers and carefully lower the door to the fully closed position. Be sure the door descends uniformly by pulling the door down from the center of the door and using correct gripping points, such as a lift handle or lock handle.

WARNING TO AVOID SEVERE IN-

JURY DO NOT PLACE FINGERS OR HAND BETWEEN SECTION JOINTS.

SHEAVE

EXTENSION SPRING

SPRING TENSION

EQUAL ON BOTH SIDES

Once the door is closed, measure the spring length on both springs and verify the spring tension length is the same for both springs. If they are not, raise the door, re-attach locking pliers and repeat the CABLE ADJUSTMENT process in Step8.

IMPORTANT! Do not try to adjust springs while the door is in the closed (Down) position.

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