Chamberlain Grifco CG3800 User manual

INSTRUCTION MANUAL
Model CG3800
Light Duty Commercial Door Operator
The Chamberlain Group
PO Box 6106
West Gosford NSW
www.chamberlainanz.com
N2966
Optional
Accessory
Available
See Page 11 fortheNew

2
INTRODUCTION
Safety Symbol Review
and Signal Word Review
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 door and/or the door operator if
you do not comply with the cautionary
statements that accompany it. Read them
carefully.
This door operator 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
INTRODUCTION 2-5
Safety symbol review and signal word review . . . . . . . .2
Planning .....................................3
Preparingyourdoor ............................4
Tools ........................................4
Specifications .................................4
Cartoninventory ...............................5
Hardwareinventory .............................5
ASSEMBLY 6
Attach the collar to the motor unit . . . . . . . . . . . . . . . . . .6
Attach mounting bracket to the motor unit . . . . . . . . . . .6
INSTALLATION 7-14
Installation safety instructions . . . . . . . . . . . . . . . . . . . . .7
Positiontheoperator ............................7
Attach the emergency release rope and handle . . . . . . .8
Install the power door lock . . . . . . . . . . . . . . . . . . . . . . .8
Attach the cable tension monitor (Required) . . . . . . . . . .9
Electrical requirements . . . . . . . . . . . . . . . . . . . . . . . . .10
Install the wireless wall control . . . . . . . . . . . . . . . . . . .10
Auxiliaryinputs ...............................11
Mount the EverCharge unit (SPU) (not provided) . . . . .11
Install The Protector System®..................12-13
AD USTMENT 14-17
Program the travel limits . . . . . . . . . . . . . . . . . . . . . . . .14
Settingtheforce ..............................15
Test cable tension monitor . . . . . . . . . . . . . . . . . . . . . .15
Testpowerdoorlock ...........................15
Test the safety reversal system . . . . . . . . . . . . . . . . . . .16
Test The Protector System®......................16
Toopendoormanually .........................17
OPERATION 17-19
Operation safety instructions . . . . . . . . . . . . . . . . . . . . .17
Using your door operator . . . . . . . . . . . . . . . . . . . . . . .18
Careofyouroperator ..........................18
Using the remote control . . . . . . . . . . . . . . . . . . . . . . . .18
Diagnosticschart..............................19
Replacingthebattery ..........................20
PROGRAMMING 20-21
To add or reprogram a hand-held remote control . . . . .20
To erase all codes from motor unit memory . . . . . . . . .20
To program wireless keypads . . . . . . . . . . . . . . . . . . . .21
TROUBLESHOOTIN .........................22
REPAIR PARTS 23
Installationparts ..............................23
Motor unit assembly parts . . . . . . . . . . . . . . . . . . . . . . .23
WARRANTY 24
TABLE OF CONTENTS

Safety
Reversing Sensor
Safety
Reversing
Sensor
Torsion Spring
Motor unit
Wireless wall control
Access Door
Gap between floor
and bottom of door must not exceed 6 mm (1/4”)
Powered
Door Lock
Cable Tension
Monitor
Drum
3
Planning
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 installation of your operator.
Depending on your requirements, there are several
installation steps which may call for materials or hardware
not included in the carton.
This operator is compatible with:
• Doors that use a torsion bar, springs and a door no
more than 3.8m (12.5ʼ) 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 3.8m
(12.5ʼ) high.
• Doors up to 5.5m (18ʼ) wide.
• Doors up to 16m2(170 sq ft)
• 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.
• Must have minimum of 203mm (8”) between the side
wall (or obstruction) and the end of torsion bar.
• The torsion bar must extend at least 25mm to 100mm
(1” to 4”) past the bearing plate.
• An electric outlet is required within 1.8m (6ʼ) of the
installation area. If outlet does not exist, contact a
qualified electrician.
• Depending upon buildingʼs construction, extension
brackets or wood blocks may be needed to install safety
reversing sensors.
• A model CM475 EverChargeTM Standby Power Unit
(SPU) is strongly recommended if there is no access
door to the building, as this operator 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 operator will be
greatly reduced.

4
Preparing your Door
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:
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.
3. Verify equal cable tension on each side of door.
Cable tension should remain equal during the entire
travel of the door.
4. The installer is to ensure that the temperature range
is suitable for the installation.
To prevent damage to door and operator:
• ALWAYS disable locks BEFORE installing and
operating the operator.
To prevent possible SERIOUS INJURY or DEATH:
•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
operator 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 operator or remote controls.
Tools needed
During assembly, installation and adjustment of
the operator, instructions will call for hand tools
as illustrated below.
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
Sectional Door
Torque Meter (not shown)
Specifications
Volts: 230-240 ~ V 50 Hz
Current: 145 Watts
Rated Load: 10Nm
Fmax: 40Nm
Max door height: 3.8m (12.5ʼ),
Max door width: 5.5m
Max: area 16m2
Temperature range: 500C To 400C
Please note hardware accessories are supplied directly from Chamberlain USA,
therefore Tools and Drills are often stated in imperial measures.

5
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)
Pan Head Screw 1/4"-20x1/2" (2)
Hex Head Screw #8x1" (2)
Self Tapping Screw #10-32 (2)
Wall Anchor (2)
Wall Anchor (Screw-In) (2)
Handle
Rope
Lock Template
PROTECTOR SYSTEM (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 (20)
Carton Inventory
Your door operator is packaged in one carton which contains the motor unit and the parts illustrated below. Note that
accessories will depend on the model purchased. If anything is missing, carefully check the packing material.

ASSEMBLY STEP 1
Attach the Collar to the Motor Unit
To avoid installation difficulties, do not run
the door operator until instructed to do so.
• Loosen the collar screws.
• Attach collar to either the left or the right side
of the motor unit. 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
facing up (accessible when attached to the
torsion bar).
• Tighten both sides of collar screws equally to
secure collar to the motor unit (16Nm-19Nm .
of torque)
(Figure 2).
NOTE: For most installations the screws should
be facing up for easy access. Do not tighten set
screws until indicated.
6
CollarScrew
CollarScrew
SetScrew
CollarScrew
CollarScrew
Set Screw
ASSEMBLY STEP 2
Attach Mounting Bracket to Motor Unit
• Loosely attach slotted side of mounting
bracket to the same side of the motor unit as
the collar, using
self-threading screws provided.
NOTE: Do not tighten until instructed.
Illustrations shown are for left side installation.
Socket Wrench
Figure 1
RIGHT WRONG
Figure 2
Screw
#10-32
HARDWARE SHOWN ACTUAL SIZE
To prevent possible SERIOUS INJURY or
DEATH, the collar MUST be properly
tightened. The door may not reverse correctly
or limits may be lost due to collar slip.
Alternate Mounting Kit (NOT SUPPLIED):
This kit allows model C 3800 to be
mounted below the torsion bar in the
case where the torsion bar is not
round or the normal mounting area
is obstructed.
CG480
Left hand
installation
Right hand
installation

7
INSTALLATION
INSTALLATION STEP 1
Position the Opener
NOTE: For additional mounting options see accessories
page.
1. Close the door completely.
2. Slide the operator 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 operator. 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
operator. Drill 5mm (3/16”) pilot holes at the marked
locations. Drill through steel plate if needed.
4. Reinstall the operator 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
16Nm-19Nm of torque. Securely tighten both set screws
firmly, without damaging the motor unit.
5. Fasten bracket securely with 14-10x1-7/8" screws.
Tighten all mounting bracket hardware.
NOTE: The motor unit does not have to be flush to wall.
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.
• Operator MUST be mounted at a right angle to the
torsion bar to avoid premature wear on the collar.
Staple
Torsion Bar
IMPORTANT INSTALLATION INSTRUCTIONS
To reduce the risk of SEVERE IN URY or DEATH:
WARNINGWARNING
1.READ AND FOLLOW ALL INSTALLATION
WARNIN S AND INSTRUCTIONS.
2.Install door operator 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 operator.
4.Disable ALL locks and remove ALL ropes
connected to the door BEFORE installing
operator to avoid entanglement.
5 Mount emergency release handle no higher than
1.8m above floor.
6.NEVER connect the door operator to power
source until instructed to do so.
7.NEVER wear watches, rings or loose clothing
while installing or servicing operator. They could
be caught in the door or operator mechanisms.
8.Install wall-mounted door control:
• within sight of the door.
• out of reach of children at minimum operator of
1.5 m.
• away from ALL moving parts of the door.
9.Place entrapment warning label on wall next to
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 object (or a 2x4 laid
flat) on the floor.

Staples
Lock Screw
1/4-20 x 1/2" (2)
HARDWARE SHOWN ACTUAL SIZE
Lock Template
Roller
Garage
Door Track
TOP
DRILL 8mm
DRILL 19mm
DRILL 8mm
132A2505
TOP
DRILL5/16"
DRILL3/4"
DRILL5/16"
132A2505
Approx. 7.6cm
(3”)
Figure 1
INSTALLATION STEP 3
Install Power 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 motor unit. 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 power door lock to the outside of the door track
with hardware provided.
5. Run bell wire up wall to motor unit. Use insulated
staples to secure wire in several places.
6. Plug connector into the motor unit (Figure 2).
NOTE: Lock must be mounted within 3m (10') of the
power head.
Overhand
Knot
Emergency
Release Handle
Overhand
Knot
Rope
Motor Unit
Emergency
Release Cable
NOTICE
Warning Label
WARNING
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.
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 rope to prevent slipping.
• 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
(6ʼ) above the floor. Secure with an overhand knot.
NOTE: If it is necessary to cut the rope, heat seal the cut
end with a match or lighter to prevent unraveling.
Figure 2
8

WHT/GRN
To insert or release wire,
push in tab with
screwdriver tip
Cable Tension
Monitor
Strip wire (11mm)
WHT/GRN
Cable
Tension
Monitor
Cable Tension
Monitor Roller
Cable
2"-6"
(5 cm-
15 cm)
Drum
Torsion Bar
Opener
1/8"-1/4"
(3 mm-6 mm)
With Door Closed
Preferred Orientation
D
Figure 1
#8 Hex Head Screw (2)
Screw #6 (2)
Wall Anchor(2)
Staples
Figure 3
INSTALLATION STEP 4
Attach the Cable Tension Monitor (Required)
This operator comes standard with the cable tension
monitor. It is supplied as a device to monitor the
cables for ANY slack that may occur and will reverse
the door when excessive slack is detected, eliminating
service calls.
The cable tension monitor
MUST be connected and
properly installed before the door operator will move
in the down direction.
NOTE: The cable tension monitor is shipped for left side
installation. It is preferred that the cable tension monitor
be installed on the same side of the door as the operator.
If required, it can be mounted on the opposite side of door.
Remove the snap-ring holding the roller in place and
reassemble it on the opposite side of the cable tension
monitor.
1. Position the cable tension monitor as shown
(Figures 1 and 2). The cable tension monitor should be
located as close to the drum as possible.
NOTE: There must be no obstructions in the installation
area that prevent the cable tension monitor or the cable
itself from closing completely when slack is detected.
2. Make sure cable tension monitor is located over a wood
support member.
NOTE: If the cable tension monitor can not be mounted
into wood with the lag screws provided, it can be mounted
into 25mm (1”) or greater pasterboard using the wall
anchors (2) and the #8 hex head screws (2) provided in
the hardware bag.
3. Mark and drill 5mm (3/16”) pilot holes for screws (pilot
holes are not required for anchors).
4. Attach the cable tension monitor to the wall using the
hardware provided. Make sure that the roller is on top of
the cable.
5. Run bell wire to motor unit. Use insulated staples to
secure wire in several places.
6. Connect bell wire to the green quick-connect terminals
(polarity is not important) (Figure 3).
NOTE: Cable must have tension through entire travel.
Make sure there is no slack in cable on opposite side of
the door during normal operation. If this condition exists,
adjust cables as required.
3/4" Min.
(18 mm Min.)
Wall
W
Drum
Cable
Figure 2
9

10
INSTALLATION STEP 5
Electrical Requirements
To avoid installation difficulties, do not run the
operator at this time.
To reduce the risk of electric shock, your door operator
has a grounding type plug with a third grounding pin. This
plug will only fit into a grounding type outlet. If the plug
doesn't fit into the outlet you have, contact a qualified
electrician to install the proper outlet.
RIGHT WRONG
To prevent possible SERIOUS INJURY or DEATH from
electrocution or fire:
• Be sure power is not connected to the operator, and
disconnect power to circuit BEFORE removing cover.
• Door installation and wiring MUST be in compliance
with ALL local electrical and building codes.
• NEVER use an extension cord, 2-wire adapter or
change plug in any way to make it fit outlet. Be sure
the operator is grounded.
• If the supply cord is damaged, it must be replaced by
the manufacturer or itʼs service agent or a similiarly
qualified person in order to avoid harzard.
+
+
GRIFCO
Mount the wireless wall control out of the
reach of children at 1.5m
INSTALLATION STEP 6
Installing the Wireless Wall control (CG128)
Control must be mounted out of the reach of children
at a height of 1.5m with an unobstructed view of the
door.
• Ensure you C 3800 operator is switched off whilst
installing your wireless door control to prevent accidental
activation
• Remove the cover from the C 128.
• Mount C 128 as shown using the screws provided if
mounting into a wall box (not provided).
• If mounting directly on the wall use wall anchors
(provided) to fix unit to the plasterboard wall.
• Replace the cover plate and affix the warning label
adjacent the wall controller.
Fix the emergency door release label adjacent to the
operator.
To reduce risk of fire, explosion or chemical burn:
• Replace ONLY CR2032 batteries.
• Do NOT recharge, disassemble, heat above 75°C or
incinerate.