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

Assembly Step 5
Tighten the Chain & Cable
. Spin the inner nut and lock washer down the
threaded shaft, away from the trolley.
. To tighten the chain, turn outer nut in the direction
shown. As you turn the nut, keep the chain
from twisting.
. When the chain is approximalely 112" above the
base of the T-rail at its midpoint, relighten the
inner nut to secure the adjustment.
Sprocket noise can result if chain is either too
loose or too tight.
When installation is complete, you may notice some
chain droop with the door closed. This is normal. lf
the chain returns to the position shown when the
door is open, do not re-adiust the chain'
NOTE: During future maintenance, ALWAYS pull
the manual release handle to disconnect trolley
before adjusting chain.
Lock
Outer Nut Washer lnner Nut
To Tighten
Outer Nut -.- To Tighten
lnner Nut
Trolley
Chain
Base of T-rail
1tz',
you have now finished assembling your garage door opener. Please read the following
warn¡ngs before proceed¡ng to the installation sect¡on:
¿þwnRNINc
IM PORTANT INSTALLATION INSTRUCTIONS
WARNING
To reduce the risk of severe injury or death to persons:
1. READ AND FOLLOW ALL INSTALLATION INSTRUGTIONS.
2. lnstall only on a properly balanced and lubricated garage door' An improperly balanced door
could result in severe in¡ury or death. Repairs to cables, spring assemblies and other hardware
must be made by a professional service person before installing opener'
3. Disable all locks and remove all ropes connected to the garage door before installing the opener
Ropes connected to a garage door can cause entanglement and death.
4. lf possible, install door opener 7 feet or more above floor with the manual release handle
mounted 6 feet above the floor.
5. Do not connect the opener to power source until instructed to do so.
6. Locate the Door Control within sight of the door at a minimum height of 5 feet where small
children cannot reach and away from all moving parts of the door'
7. lnstall the User Safety lnstruction Label on the wall adjacent to the control button and the
Maintenance lnstruction Label in a prominent location on the inside of the garage door'
g. Upon completion of the installation, the door must reverse when it comes in iontact with a
one-inch trigtr oU¡ect (or a2x4laid flat) on the floor'
g. Do not wear watches, rings or loose clothing while installing or servicing an opener' Jewelry or
loose clothing can be caught in the mechanism of the garage door or the opener'
11
Nortek, Exhibit 1012

lnstallation Step I
Determine Header Bracket Location
lnstallation procedures vary according to garage
door types. Follow the instructions which apply to
your door.
lnstallation Section: Pages 12 - 27
- Header -
Vertical
Guideline
F¡nished
Ceiling
Wall . Close the door and mark the inside
vertical centerline of the garage door.
. Extend the line onto the header wall
above the door.
Remember, you can fasten the
header bracket within 2 feet to the
left or right of the door center only il
a torsion spring or center bearing
plate is in the way; or You can attach
it to the ceiling (refer to Page 14)
when clearance is minimal.
lf you need to install the header bracket
on a 2x4 (on wall or ceiling), use lag
screws (not supplied) to securely fasten
the 2x4 to structural supports as shown
here and on page 13.
2x4 Structural
Supports
A*oRNrNc
lf the header bracket is not rigidly fastened to
a structural support on the header wall or
ceiling, the safety reverse system may not
work properly (see page 30). The door might
not reverse when required, and could cause
serious injury or death.
The garage door springs, cables, pulleys'
brackets and their hardware are under extreme
tension. Do not attempt to loosen, move or
adjust them yourself. Serious personal iniury
or death could result. Call for garage door
service.
Verticaì
. Open your door to the highest
point of travel as shown. Draw
an intersecting horizontal line
on the header wall 2" above
the high point. This height will
provide travel clearance for the
top edge of the door.
Ceiling
Header
Wall
2" Track
Highest Point
of Travel
Door
Sectional door
with curved track
Header
-Wall
'- 2', Track
Highest Point
of Travel
Doo
One-piece door
with horizontaltrack
Proceed to Step 2, Page 14.
12
Nortek, Exhibit 1012

ck:'.''t',
Read the Safety tnstructions on page 12.They also apply to doors without tracks.
Header Wall
. Close the door and mark the
inside vertical centerline of
your garage door. Extend the
line onto the header wall
above door.
lf headroom clearance is
minimal, you can installthe
header bracket on the ceiling.
See page 14.
. If you need to install the
header bracket on a 2x4 (on
wall or ceiling), use lag screws
(not supplied) to securelY
fasten the 2x4 to structural
supports as shown.
Vertical
Centerline 2x4
OPTIONAL CEILING MOUNT
FOR HEADER BRACKET
Header Wall
Highest Point
of Travel
I
Ë
o
.9
Door
Jamb
Hardware
One-piece door without track
jamb hardware
. Open your door to the highest point of travel as
shown. Measure the distance from the top of the
door to the floor. Subtract the actual height of the
door. Add B" to the remainder. (See Example.)
. Close the door and draw an intersecting horizontal
line on the header wall at the determined height.
lf the total number of inches exceeds the height
available in your garage, use the maximum
height possible, or refer to page 14 for ceiling
installation.
One-piece door without track
pivot hardware
Example
Distance from top of door
(at highest point of travel) to floor.......'..."
Actual height of door
Remainder..
Add.............
Bracket height on header wa11................'.
(Measure UP from top of CLOSED door.)
....92"
...-88"
....4u
..+8"
=12"
Unfinished -
Supports
Centerline of
Garage Door
Vertical
Highest Point
of Travel
-l
Header
Wall
î
I
Ë
ñ
.q
o
Door
Pivot
Proceed to SteP 2, Page 14
13
Nortek, Exhibit 1012

lnstallation Step 2
lnstall the Header Bracket
You can attach the header bracket either to the
wall above the garage door, or to the ceiling.
Follow the instructions which will work best for
your particular requirements.
Fasten the Header Bracket to the Wall
. Center the bracket on the verlical guideline with
the bottom edge of the bracket on the horizontal
line as shown (with the arrow pointing toward
the ceiling).
Header
Wall
Structural
Supporl
. Mark either set of bracket holes (do not use the
holes designated for ceiling mount). Drill 3/16" pilot
holes and fasten the bracket securely to a structural
support with the hardware provided.
Wall
Mounting Holes
Lag Screws
5/1 6"x1 8x1 -7l8"
2x4 Door
1
z',
L
Spring
_ Garage -
The nail hole is for positioning
only. You must use lag screws to
mount the header bracket. Optional
Wall l\ilounting
Holes
Hardware Shown Actual Size
Lag Screw
5/ 1 6'11 8x1 -7l8"
llr tlr
,1
H¡ghest
Dôor
Point of Travel
(of Garage Door) Vertical
Center
Line
0
H
Bracket
Vertical
Center
Line
Fasten the Header Bracket to the Geiling
. Extend the vertical guideline onto the ceiling as
shown.
. Center the bracket on the vertical mark, no more
than 6" from the wall. Make sure the arrow is
pointing toward the wall. The bracket can be
mounted flush against the ceiling when clearance
is minimal.
. Mark holes designated for ceiling mount only. Drill
3/16" pilot holes and fasten bracket securely to a
structural support with the hardware provided.
Ceiling Mounting Holes
The nail hole is for positioning only.
You must use lag screws to mount
the header bracket.
Finished
Ceiling
Vertical
Center Line
J:
lvlaximum -J
Door Screws
1 8x1 -7l8"
Sprìng
Header
Wall
_Garage_
Door
r Line
14
Nortek, Exhibit 1012

lnstallation Step 3
Attach the T-rail to the Header Bracket
Ø
Ø
Ring Fastener
T+ail
@'-'-
Bracket
Header
Bracket
Clevis Pin
5116"x2-314" Cable
Pulley
Garage
Door
Header Waìl
. Position the opener on the garage floor below the
header bracket. Use packing material as a
protective base.
lf the door spring is in the way you'll need help.
Have someone hold the opener securely on a
temporary support to allow the T-rail to clear
the spring.
. Position the cable pulley bracket against the header
bracket.
. Align the bracket holes and join with a clevis pin
as shown.
. lnsert a ring fastener to secure.
Header
Bracket
Cable
Pulley
Bracket
T+aìl
Temporary
Support
Hardware Shown Actual Size
Clevis Pin
5116"x2-314" Ring Fastener
o
15
Nortek, Exhibit 1012

Installation Step 4
Position the Opener
Follow instructions which apply to your door type
as illustrated ACAUTION
To prevent damage to steel, aluminum,
fiberglass or glass panel doors, do not rest the
opener on the door without using a 2x4.
A 2x4laid flat is convenient for setting an ideal
door-to-T-rai I distance.
. Raise the opener onto a stepladder.
You witl need help at this point if the ladder is
not tall enough.
. Open the door all the way and place a 2x4laid llat
on the top section beneath the T-rail.
tf the top panel hits the trolley when you raíse
the door, pull down on the trolley release arm to
disconnect the inner and outer sections. The
trottey can remain disconnected until Step 12 is
completed.
Trolley
Release Arm
Trolley
T-rail 2x4 Laid Flat
Header
Bracket
Top of Opener
. With the door fully open and parallel to the floor,
measure the distance from the floor to the top of
the door.
. Using a stepladder as a support, raise the opener
to the same distance as the door from the floor (it
will be at a slight angle as shown).
. The top of the door should be level with the top of
the opener. Do not position tlre opener more than
2" above this point.
Top of Door
16
Stepladder
Nortek, Exhibit 1012

lnstallation Step 5
Hang the Opener
Two representative installations are shown.
Yours may be different. Hanging brackets should
be angled, Figure 1, to provide rigid suppott. On
finished ceilings, Figure 2, attach a sturdy metal
bracket to structural supports before installing the
opener. The bracket and fastening hardware are not
supplied.
. Measure the distance 'from each side of the opener
to the structural suPPort.
. Cut both pieces of the hanging bracket to required
lengths.
. Drill 3/'16" pilot holes in the structural supports.
. Attach one end of each bracket to a support with
5116"x1-7 lB" lag screws.
. Fasten the opener to the hanging brackets with
5t16"-18x7l8" hex screws, lock washers and nuts'
. Check to make sure the T-rail is centered over the
door (or in line with the header bracket if the
bracket is not centered above the door).
. Remove lhe 2x4. Operate the door manually' lf the
door hits the rail, raise the header bracket.
Grease the top and underside of
the rail surface where the
trolley slides with rail
grease.
AWARNING
The opener could fall and iniure someone íf it
ís not properly secured. Fasten the opener
securely to structura! supports of the garage.
Figure 1
5/16"-18x7/8" Screw
5/16" Lock Washer
5/16"-18 Nut
Figure 2
Hidden
Support
Structural
Supports
Lag Screws
5116"x1-718
- Finished Ceil¡ng -
(Not Supplied)
5/16"-18x7l8" Screw
5/1 6" Lock Washer
5/16'118 Nut
Measure
Distance
A
--\
-t-
Bracket
(Not Supplied)
5/16"-18x7l8" Screw
5/1 6" Lock Washer
5/16'118 Nut
Hardware Shown Actual Size
Lag Screw
5/1 6"-1 8x1 -7l8"
Hex Screw
5116"-18x7 18" Nut 5/16"-18 Lock Washer 5/16"
17
Nortek, Exhibit 1012

lnstallation Step 6
Install the Door Control WARNING
Children operating or playing with a garage
door opener can injure themselves or others'
The garage door could close and cause
serious iniury or death.
lnstall the Door Gontrol (or any additional push
buttons) out of the reach of children and away
from all moving parts of the door and door
hardware, but where the garage door is visible.
Do not allow children to operate the push
button(s) or the remote control transmitter(s)'
A moving garage door could iniure someone
under íf. Activate the opener only when the
door is properly adjusted, you can see it
clearly, and there are no obstructions to door
travel.
. Strip 114" of insulation from one end of the bell
wire; connect the wire to the two screw terminals
on the back of the Door Control: white to 2 and
white/red to 1.
. Locate the Door Control within sight of the
door at a minimum height of 5 feet where small
children cannot reach, and away from all
moving parts of the door and door hardware.
Fasten the Lighted Door Control Button securely
with 6ABx1-1/2" screws. The Multi-Function Door
Control Panel uses 6ABx'1" screws. lf installing
into drywall, drill Sl32" holes and use the anchors
provided.
. Run the bellwire up the wall and across the ceiling
to the opener. Use insulated staples to secure the
wire in several places. Be careful not to pierce the
wire with a staple, thereby resulting in a shot't'
. Receiver terminal screws and the antenna are
located on the back panel of the opener' Position
the antenna wire as shown.
. Tlren connect the bell wire to the opener terminal
screws: white to 2 and white/red to 1.
. Remember to affix the User Safety lnstruction
label to the wall near the door control, and the
Maintenance lnstruction Label in a prominent
location on the inside of the garage door.
lf the label adhesive will not adhere to your garage
wall surface (or becomes loose with time) use tacks
to secure the label alongside the Door Control.
Page 32 explains how to operate the opener using
the Door Controls and the Lock and Light features
available on the Multi-Function Door Control Panel.
Lock Button
Do NOT connect the power and operate the
opener at this tíme.The trolley will travel to the
fulr open position but will not return to the
close position until the sensor beam is
connected and properly aligned. See Safety
Reversing Sensor lnstructions beginning on
page 21.
Outside Keylock Accessory Connections:
To opener terminal screws: white to 2 & white/red to 1
All models except 5100/5100-2 Models 5100 & 5100'2
2-Conductor
Bell Wire
Door
Control Button
Terminal Screws
Back Pânel
Multi-function
Door Control Panel
Terminal Screws
Opener
Terminal
Screws
2-Conductor
Bell Wire
Lighted
Door Control
Button
Multi-Function
Door Controì Panel
Bell Wire
Light Button
Door Control
Push Bar
fl
oo
Hardware Shown Actual Size
6ABx1 -112" Screw
Lighted Door Control Button lnsulated Staples
Dry Wall Anchors
ffi
Mulli-Functìon Door Conlrol Panel
6ABxl" Screw
18
of Opener
Antenna
Nortek, Exhibit 1012

lnstallation Step 7
Install the Light(s) & the Lens(es) Figure 1
lnstall the Light(s)
. lnstall a 75 watt maximum light bulb in (each)
socket. The light(s) will turn ON and remain lit for
approximately 4-112 minutes when power is
connected. Then the light(s)will turn OFF.
. lf a bull¡ burns out prematurely due to vibration,
replace with a standard-neck "Garage Door
Opener" bulb.
tnstall the Lens (Models 3000 & 2100)
. See Figure '1.
. Locate and loosen (approximately 1/8")the two
screws near top of opener front panel. Position
lens against panel with slotted tabs directly below
screws. Slide lens up to seat tabs behind screws.
Snap bottom tabs of lens into panel slots.
Retighten top panel screws to secure lens'
lnstal! the Lens(es) (All Other Models)
(Except Model 1100 - No Lens)
. See Figure 2.
. Slide lens into guides. Snap bottom tabs into
lens slots.
. Reverse the procedure to remove the lens(es).
Overhand
Trolley
Rope
Manual
Overhand
Screw
Lens Slot
Watt Max.
Light Bulb
Lens Tab
Figure 2
Lens Only)
Lens
Slot
75 Watt
(Maximum)
Light Bulb
. 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.
The knot should be at least l" from the end of the
rope to prevent sliPPing.
. Thread the other end of the rope through the hole in
the release arm of the outer trolley.
. Adjust rope length so the handle is 6 feet above the
floor. Secure with an overhand knot.
lf it is necessary to cut the rope, heat seal the cut
end with a match or lighter to prevent unraveling.
AwARNTNG
Do not use the red handle to pull the door open
or closed. The rope knot could become untied
and you could fali. Use the manual release only
to disengage the trolley and, if possible, only
when the door is closed.
Garaqe doors are heavy' lf the door is open
when-the handle is pulleð, the door could close
inadvertently if it is not properly'bala.nced.
Serious injury may result to persons under the
door. Maké sure the doorway is clear of persons
and obstructions before pr"rlling handle when
door is open.
Light
)Lens
Tab
Knot
Knot
lnstallation Step B
Attach the Manual Release
Rope & Handle
Release Handle
19
Nortek, Exhibit 1012

lnstallation Step 9
Electri ca I Req u ireme nts To prevent electrocution or fire, installation
and wiring must be in compliance with local
electrical and building codes'
To reduce the risk of electric shock, your garage
door opener has a grounding type plug with a third
grounding pin. This plug will onlyfit into a grounding
type outlet.
lf the plug doesn't fit into the outlet you have,
contact a qualified electrician to install the proper
type outlet.
To avoid installation difficulties,
do not run the opener at this time.
Right Wrong
. Do not change the plug in any way.
. Do not use a 2-wire adapter.
. Do not use an extension cord.
tf permanent wiring is required by your local code, refer to the following procedure:
A*oRNtNG
To prevent electrocution, remove power from
the garage door opener and from the circuit
you þtan to use for the permanent connection.
. To make a permanent connection through the
7/8" diameter hole in the top of the opener
(according to local code):
. Remove the opener cover screws and set the
cover aside.
. Remove the attached 3-prong cord'
. Connect the black (line) wire to the screw on the
brass terminal; the white (neutral) wire to the
screw on the silver terminal; and the ground wire
to the green ground screw. The opener must be
grounded.
. Reinstallthe cover.
To avoid installation difficulties'
do not run the oqener at this time.
Permanent Wiring
Connection
Ground Tab
Green
Ground Screw
Ground Black
White BlackWire
20
Nortek, Exhibit 1012