Chamberlain Series 5100 User manual

The Chamberlain GrouP, lnc.
A DUCHOSSOIS ENTERPRISE
845 Larch Avenue
Elmhurst, llllinois 60126-11 96
Complies with UL 325
Regutations effective
January 1, 1993.
Garage Door Opener
OWNER'S MANUAL
For Residential Use Only
Series 5100 - l/2HI
(lncludes Model 7200) Series 4100 - 1l2HP
(lncludes Model 71 OWHC)
Series 2100 - 1/3HP
Series 3000 - 1l2HP Series 1100 - 1l4HP
¡ please read th¡s manual and the enclosed safety materials carefully!
¡ Fasten the manual near the garage door after installation.
r The door WILL NOT CLOSE unless the Protector System@ is connected and
properly aligned
r Periodic checks of the opener are required to ensure safe operation.
r The model number label is located on the front end panel of your opener as
shown.
ooooo
o
ooooo o
oooooo s
ó
Nortek, Exhibit 1012

Contents
A review of safety alert symbols
You'll need too|s.............
Safety information regarding garage door
locks and ropes...........
Testing your garage door for sticking,
binding and balance
lllustration of sectional door installation
lllustration of one-piece door installation
Carton inventory......
Hardware inventory......
Assembly section - pages 8 - 11
Assemble T-rail....
Attach cable pulley bracket........
lnstalltrolley
Fasten T-rail to opener ........'.:.'...'
lnstall chain/cable ...........
Attach sprocket cover...........
Tighten the chain and cable
lnstallation section - pages 11 '27
lnstallation safety instructions..............
Determine header bracket location
Sectional door.............
One-piece door.............
lnstall the header bracket
Attach the T-rail to header bracket........
Position the opener...
Hang the opener.........
lnstall the Door Control
Contents
lnstall the lights and lenses
Attach manual release rope and hand|e............
Electrical requirements
The Protector System'safety reversing sensor
Page
...'',..'2
.........3
information..
lnstallthe safety revers t; ;;;.. .............21
.....22,23
Fasten door bracket (sectional door) .................. "
Fasten door bracket (one-piece door) ..................
Connect door arm to trolley (sectional door)........
Connect door arm to trolley (one-piece door)..'....
Adjustment section - pages 28 '30
Travel limit adjustments .............
Force adjustments..........
Test The Protector SYstem' ....
Test the safety reverse sYstem
Operation safety instructions ......
Care of your opener.
Maintenance schedule......
Operation of your opener.........
Receiver and remote control programming
Having a problem?
Repair parts, rail assemblY
Repair parts, installation ..............
Repair pads, opener assemblY...
Accessories
1ndex...........
How to order repair parts ............
Warranty.....
..24
..25
..¿o
..27
.......8
.......8
.......9
.......9
.....10
.....10
.....11
11
....34,
Start by rev¡ew¡ng these important safety alert symbols
When you see these safety symbols on the following pages, they will alert you to the possibility of
seriouî injury or death if youdo not comply with the corresponding instructions' The hazard may
come from something mechanical or from electric shock. Read the instructions carefully.
WARNINt^
t¡r . ..:.
Electrical
Mechanical
When you see this Safety Symbol on the following pages, it will alert you to the possibility of damage
to youi garage door andior ihe garage door opener if you do not comply with the corresponding
instructions . Read the instructions carefully.
&cAuiloM,r '
This garage door opener is designed and tested to offer safe service provided it is installed, operated,
ma¡ntaineã and tested in strict aècordance with the safety instructions contained in this manual.
2
Nortek, Exhibit 1012

You'll Need Tools
During assembly, installation and adjustment of the opener, instructions will call for hand tools shown below.
H
Pencil
Carpenter's
Level Hack Saw
Tape Measure
ñWire Cutters
Drill 3/16", 5/16" and
5/32" Drill Bits
Claw Hammer
PIìers
Stepladder 1/2" and 7/16" Sockets
and Wrench Screwdr¡ver Adjustable End Wrench
AwnnuNc
An unbalanced garage door might not reverse
when required and someone under the door
could be seriously iniured or killed.
lf your garage door binds, sticks or is out of
balance, call for professional garage door
service. Garage doors, door springs, cables,
pulleys, brackets and their hardware, are
under extreme tension and can cause serious
injury or death. Do not try to loosen, move or
adjust them yourself!
Ropes left on a garage door could cause
someone to become entangled and killed.
Remove all ropes connected to the door before
installing and operating the opener.
ldentify the type and height of your door, any special
conditions that exist, and any additional materials
that may be required. Refer to the lists on page 4 or
page 5.
AcAunoN
To avoid damage to the garage door and
opener, disable locks before installing and
operating the opener. Use a wood screw or nail
to hold locks in the "open" (unlocked) position'
Operation at other than 120V 60 Hz will cause
opener malfunction and damage'
Test Your Door
Before you begin, complete the following test to
make sure your door is balanced, and ís not
sticking or binding:
. Lift the door about halfway as shown' Release the
door. li should stay in place, supported entirely by
its springs.
. Raise and lower the door to see if there is any
binding or sticking.
U
SECTIONAL DOOR
U
ONE-PIECE DOOR
3
Nortek, Exhibit 1012

at
At, II
Before you begín, survey your garage area to
see whether any of the conditions below apply
to your installation.
Horizontal and vertical reinforcement
is needed for lightweight garage doors
(fiberglass, steel, aluminum, door
with glass panels, etc.).
See page 24 for details.
Header Wall
Floor must be ìevel
across width of door
Safety Reversing Sensor
Based on your parlicular requirements, there are
several installation steps which might call for
mater¡als and/or hardware not included in the
carton.
. Step 1, page 12 - Look at the wall or ceiling above
the garage door. The header bracket mustbe
securely fastened to structural supports.
. Step 5, page 17 - Doyou have a finished ceiling in
your garage? lf so, a supporl bracket and
additional fastening hardware may be required.
. Safety reversing sensor, page21- Depending
upon garage construction, wood blocks may need
to be fastened to mounting locations before
sensors are installed.
. Step 10, page 22 - Alternate floor mounting of the
safety reversing sensor will require hardware not
provided.
. Step 11, page 24 -Do you have a steel, aluminum,
fiberglass or glass panel door? lf so, horizontal
and vertical reinforcement is required.
. Look at the garage door where it meets the floor. lt
must close on the floor all the way across' Other-
wise, the safety reverse system may not work
properly. See page 30. Floor or door should be
repaired.
. lf your door is more than 7 feet high, see longer
rails available on page 38.
. The opener can be installed within 2 feet of the left
or right of the door center if there is a torsion spring
or center bearing plate in the way of the header
bracket or door bracket area. lf your door has
extension springs, the opener musf be installed
in the center of the door. See pages 12 and 24'
. Do you have an access door in addition to the
garage door? lf not, Model 7702C8 Outside Quick
Release is required. See Page 38.
You may find it helpful to refer back to this page
as you proceed with the installation of your
opener.
FINISHED CEILING
Support bracket &
fastening hardware
is required.
See page'17.
Sìack in Chain Tension
ìs Normal When
Garage Door ìs Closed
Extension
Spring
OR
Torsion
Spring
Safety
Reversing
Sensor
FÈ
Access Door
t
oGarage
Door
Spring
Rope & Handle
Door Bracket
Chain
Straight
Cable Pulley
BracketTrolley
Cabìe
Curved
Closed Position
Rail Assembly
Header
Bracket
Manual
Release
Door
Arm
Header
Wall
Garage
Door
Door
Arm
Nortek, Exhibit 1012

ôrug-PleCE Door lnstallation "
Before you begin, survey your garage area to
see whether any of the conditions below apply
to your installation' srack in chain Tension
is Normal When
Garage Door ìs Closed
Header
Reversing
floor and bottom Sensor
Safety of must not exceed 1/4"
Reversing Sensor
Based on your particular requirements, there are
several installation steps which might call for
materials and/or hardware not included in the carton'
. Step 1, page 12 - Look at the wall or ceiling above
the garage door. The header bracket must be
securely fastened to structural supports'
. Step 5, page 17 - Do you have a finished ceiling in
your garage? lf so, a support bracket and
additional fastening hardware (not supplied) may
be required.
. Safety reversing sensor, page21 - Depending on
garage construction, wood blocks may need to be
securely fastened to mounting locations before
sensors are installed,
. Step 10, page 22 - Allernate floor mounting of the
safety reversing sensor will require hardware that
is not provided.
. Step 1 1, page 25 - Generally, a one-piece door
does not require reinforcement. lf your door is
lightweight, you can refer to the information
relating to sectional doors on page 24.
. Step 1 1, page 25 - Depending on your door's
construction, you might need additional mounting
hardware for the door bracket.
. Do you have an access door in addition to the
garage door? lf not, Model 7702C8 Outside Quick
Release is required. See Page 38.
. The gap between the bottom of the garage
door and the floor cannot exceed 1/4".
Otherwise, the safety reverse system may not
work properly. See page 30. The floor or the door
should be repaired.
FINISHED CEILING
Support bracket
& fastening
hardware is required.
See page 17.
One-Piece Door without Track
You may find it helpful to refer back to this page
as you proceed with the installation of your
opener.
Wall
5
Access Door
o
T-rail
Header
Bracket
Door
Bracket
Rope & Handle
Closed Position
Cable TrolleY
Cable
Pulley Bracket
Straight Curved
Door Door
Arm Arm
Header
Wall Garage
Door
Manual
Release
One-Piece Door with Track
o
Access
Door
\ Header curued
Bracket DoorArm
Safety
Revers¡ng
Vr'all
ht
Closed Position
Trolley
T-rail
Bracket
Door
Safety
across width of door
must be level
Garage
Door
Belt
Pulley Bracket
Door
Arm
Reversing
Sensor
Nortek, Exhibit 1012

Carton lnventorY
your garage door opener is packaged in one cadon which contains all parts illustrated below. lf anything is
missiñg, cãrefully check the þackrig material. Parts may be "stuck" in the foam. Hardware for assembly and
installation is shown on Page 7.
Models 51 00 (1 ) & 51 00-2 (2) Model 3000 l\lodels 5'100 & 5100-2 lvlodels 41 00, 3000, 21 00,
1100, 4100-2 & 710-2
lvlulti-Function
Remote Control Transmitter SecuritY
Remote Control Transmitter 2-Conductor Bell Wire
Wh¡te & White/Red Multi-Function
Door Controì Panel Lighted Door Control Button with (2) 6A8x1-1/2" screws
Models 4100,3000, 2100, 1100 (1)
41 00-2 & 710-2 (2)
Rail Brace (3) Cable Pulley Door Brackel
Single-Function
Remote Control Transmitter Trolley Bracket
l\¡lodeìs 5100 & 5100-2
[,4odels 4100 & 71 0 (1(2\
)N
Door Bracket
Plate
Light Lens T-rail
End Section (2) T-rail
Center Section
(each) (2) Header Bracket
Model 3000 & 2100 OnlY
Light Lens (1 )Chain and Cable ¡n
D¡spensing Carton Sprocket Cover
Hanging Brackets
Safety Reversing Sensor
Mounling Bracket
With Square Holes (2) "C" Wrap (2) Straight Door
Arm Section
Curved Door
Arm Sect¡on
Safety Reversing Sensor
lVounting Bracket
With Slot (2)
Safety Reversing Sensor (2)
(1) Sending EYe
(1)Receiving Eye
2-Conductor Bell Wire
with Connector (2 Rolls)
White & White/Black
Safety Labels
and
Literatu re
a
ne
6
Nortek, Exhibit 1012

Group all hardware found in all packages contained in the rail and opener cartons into
the three kits illustrated below.
Assembly Hardware Kit 4142848
Ø
æ
Washered Screw
5116"-18x112" (2)
(mounted in opener)
. Hex Screw
5/1 6'11 8x7/8" (3) Nut Carriage Bolt
114"-20x112" (121
5/1ôL18 (5) N/aster Link (2)
!l( (
TrolleY
Threaded Shaft (1 )Lock Washer
5/16" (4) Lock Nut
114"-20x7116" (12\
lnstallation Hardware K¡t 41A3475
Hex Screw
5/'i6"-18x7/8" (4)
Handle Rail Grease
Lag Screw
5h6"-18x1-718" (4)
Nut 5/16'118 (6) Lock Washer 5/16" (6)
Rope
Carriage Bolt
5116"-18x2-112" (2) Screw ftmml-
tU'lrlilTr-
6ABx1 " (2) Dry Wall Anchors (2)
ffi
Clevis Pin
5116"x2-314" (11 lnsulated
Staples (10) Clevis Pin Ring
Fastener (3)
5116"x1" (2\
rll
I
oo
Safety Reversing Sensor
lnstaf lation Hardware K¡t 41A4116
Lag Screw
114x1-112" (4) Carr¡age Bolt
114"-20x112" (4) Lock Nut
1t4',-20 (4) Wins Nut (2)
ffi
Hex Screw Screw
#1 0-32x3/8" (4) Lock Nut
#10x32 (4) lnsulated
Staples (20)
114-20x1-112" (21
7
Nortek, Exhibit 1012

Assembly Step 1
Assemble the T-rail &
Attach the Cable PulleY Bracket
Assembly Section: Pages I - 11
To avoid installation difficulties, do not run the garage door opener until instructed to do so.
T-RAIL BACK
(ro oPENER)
. Align the 4 T-rail sections on a flat surface
exactly as shown. Center sections are
interchangeable. Front and back sections are
also interchangeable for ease of assembly.
. lnsert the carriage bolts so the square bolt
necks seat in the square holes in the T-rail
sections and pass through the round holes in
the rail braces. Assemble lock nuts, ensure
alignment and tighten.
lf T-rail is not assembled
exactly as shown, trolleY
will not travel smoothlY
along length of rail or it
will hit against nuts.
Cable pulley bracket
altaches to FRONT
END of T-rail T+ail
(End Sect¡on)
T-RAIL FRONT
(ro DooR)
. Position the cable pulley bracket on the front end
of the T-rail as shown. Fasten securely with the
hardware shown.
Hex Screws
5/1 6"-1 8x7l8"
Cable Pulley
Brâcket
Lock Washer
5/1 6"
Square Carriage
Bolt Hole
T-ra¡l
(Center Section)
1/4" Lock
T-rail
(End Section)
Carriage Bolt
114"-20x112"
When tightening
the screws, be
sufe to keep
bracket parallel
to the rail.
Otherwise, the
rail may bow
when the opener
is operated.
B
Right
Wrong
Make sure bolt
necks are
seated in the
square holes
and rails are
aligned before
you tighten lock
nuts. (See right
and wrong
views).
lmproper
assembly can
cause jerky
trolley
operation, noise
and/or nuisance
door reversals.
Hardware Shown Actual Size
Lock Nut
114"-20x7116" Carriage Bolt
114"-20x112"
Ir
Hex Screw
5/1 6"-1 8x7l8" Nut
5/1 6'-l ILock Washer
5/1 6"
ttßó\
^ò
Þ\.So"
Right Wrong
Nortek, Exhibit 1012

Assembly Step 2
Installthe Trolley on the T-rail
Hardware Shown Actual Size
Lock Washer
5/1 6" Nut
5/16'11B
. Attach the threaded shaft to the trolley with the
lock washer and nuts as shown.
Outer Nut
5/1 6'
Lock
Washer
5/1 6"
Shaft
Trolley lnner Nut
5/1 6"
Temporary Stop
Screwdriver
. Place the opener on packing material to protect
the cover. For convenience, put a support under
the cable pulley bracket.
. Remove the (2) 5116"-18x112" washered screws
mounted in the toP of the oPener.
. Align the holes in the back section of the T-rail with
the holes in the oPener.
. Fasten the rail with the (2) washered screws
previously removed. Tighten securely.
Remember to use only these screws! Any other
screws will cause serious damage to the opener'
. lnsert a 5116"-18x7l8" hex screw into the trolley
stop hole in the T-rail as shown. Tighten securely
with a 5/16" lock washer and nut' This screw limits
trolley travel in the UP direction.
Trolley
Æ,", Threaded
. As a temporary stop, insert a screwdriver into the
hole in the front end of the T-rail.
. Slide the trolley assembly along the rail to the
screwdriver stoP.
lf trolley hits against the nut on the T-rail, the
bolts and nuts were attached from the wrong
side and must be repositioned. Review Step 1.
Washered Screw
5116"-18x112"
Hex Screw
5/1 6"-1 8x7l8"
Troìley
Stop Hole
T-Rail
(Back Section)
Lock Washer
c/ ¡o
Nut
5/16':18
I
Assembly Step 3
Fasten the T-raíl to the OPener
TYPE AND SIZE
SC
ONLY
I
I
I
To fasten rail, use only those screws mounted
in the top of the opener. Any other screws will
cause serious damage to the opener.
Hardware Shown Actual Size
Hex Screw
5116"-18x7 18" Nut
5/1 6"-1 ILock Washer
5116"
Nortek, Exhibit 1012

A,ssembly Step 4
Install the ChainlCable
& Attach the Sprocket Cover
Dispensing Carlon
Leave Chain and Cable
lnside Dìspensing
Carton to Prevent Kinking
Keep Chain and Cable
Taut When Dispensìng
. Detach the cable loop from the cadon and fasten it
to the trolley tvith a master link from the hardware
bag. See master link procedure, Figure 1.
. With the trolley against the screwdriver, dispense
the cable around the PulleY.
. Proceed baók around the opener sprocket,
Figure 2. Be sure sprocket teeth engage the chain.
Continue forward to the trolley threaded shaft,
Figure 3.
. Use the second master link to connect the
chain to the flat end of the shaft. Check to
make sure the chain is not twisted.
. Remove the screwdriver.
Cable
Cable
Pulley
lnstalì Chain & Cable
ln This D¡rection
Sprocket
Cover Back Tab SIot
Mounting
¡s,WARNING
Serious injury can result if fingers become
entangled in moving opener sprocket' Attach
sprocket cover securely. Never operate opener
while your hand ís near tlre opener sprocket'
Figure 2
Opener
Sprocket
Figure 3
Master Link
Loop
Itrlaster Link
Cl¡p-On Spr¡ng
Master
Link Cap
Flat end
of Trolley
Threaded Shaft
Chain
T-rail
Trolley
Figure 1
Master Link Procedure:
Push pins of master link bar through
cable loop and hole ¡n front end of
trolìey. Push cap over pins and into
notches. Slide clip-on spring over
cap and into notches until both pins
are securely locked.
@_ Master
Link Bar
To attach the sprocket cover:
. lnsert the back tab in the opener slot. Squeeze the
cover slightly and insert the front tab in the slot on
the mounting plate.
Front Tab Slot
Plate
Top of Opener
10
Nortek, Exhibit 1012