Merlin prolift 230T User manual

EDR4 1179 G2.16 10/03
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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 in-
structions.
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 cor-
rectly 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
Transmit-
ter
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 func-
tioning 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 posi-
tion. Operation before the correct point in the in-
stallation 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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Maximum height
marking on header
Header
Mark highest point
onto header
Installing the opener
WARNING Garage doors are under great spring tension. Do not remove the springs.
Merlin does not accept responsibility for damage or injury resulting from installing
this opener. Please read this manual fully before attempting installation.
STEP 1:
Check that there is a power point available and that there is adequate clearance to mount the
opener onto the door. Check that the door is in good mechani-
cal condition, correctly balanced and opens properly.
STEP 2: Close the door.
STEP 3: Mark the centre line of the door using a tape meas-
ure and pencil. Mark on the header above the door and mark
the door itself at the top edges.
STEP 4: Check the installation height of the opener. Slowly
open the door and observe the point at which the top edge of
the door is closest to the ceiling. Measure the height of the top
edge of the door from the floor of the garage at this point. You
may have to clamp the door in position or use blocks to hold it.
STEP 5: Close the door again and mark this maximum door
height onto the header above the top edge of the door. (On tilt
doors with tracks, this maximum height might be as low as the
top edge of the closed door.) If a sectional door torsion bar or
spring is in the way, mark the next clear space on the wall above.
Extend the door centre line up to intersect with the new height line.
Additional setup for trackless tilt doors (jamb fittings) only
Mark a horizontal line 300mm above this maximum door height line. If there is insufficient space
above to allow the line to be 300mm above the maximum height, then draw the line 80mm below
the ceiling. Extend the door centre line up to intersect with the new height line.
STEP 6: Fit the header bracket to the header above
the top of the door. The header bracket must be at-
tached to a rigid part of the garage such as a beam,
with the bottom edge of the bracket no lower than
the height line that has just been marked. The cen-
tre line of the door must align with the centre line of
the header bracket.
STEP 7: Place the opener assembly in the centre
of the garage floor, resting on its styrofoam or card-
board packing to protect the power head from
scratching by the garage floor. Header bracket mounting
Header bracket
Max door
travel height
Door
opening
centre line
Two lag screws

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STEP 8: Lift the return pulley assem-
bly up to the header bracket and attach
by pushing the clevis pin through both
the header bracket and the return pul-
ley assembly. Fit the clevis pin clip to
secure the clevis pin.
STEP 9: Lift the power head end of the
opener to the ceiling. Add temporary
support so that the pole is level to the
garage floor. Open the door.
STEP 10: Line up the centre of the
pole with the marked centre line of the
door.
STEP 11: Locate a ceiling joist in the
area where the straps will attach to the ceiling.
STEP 12:
Before attaching the
straps to the joists, set
the level of the opener.
Check that the door
does not hit the pole
when manually open-
ing and closing. Allow
a minimum of 25mm
clearance between the top
edge of the door and the bottom of the pole.
Attaching the return pulley assembly to the
header bracket
Centre line of pole to
line up with centre line
of open door
Move until
pole lines up
with door
centre mark
Clevis pin & clip
Door closed
Protective cardboard
Correct angle to mount the opener for
a trackless tilt door
Maintain at least 25mm
clearance from moving door
At an
angle to
the floor
Additional setup for
trackless tilt doors
(jamb fittings) only
It is better to mount the opener at
an upward facing angle for track-
less tilt doors. Allow the opener to
hang at the lowest possible point
that maintains at least 25mm
clearance between the pole and
the top edge of the closing door.

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STEP 13: Fasten the straps solidly to the joists.
STEP 14: Close the door manually.
STEP 15: Attach the door bracket to the door.
Door arm examples
Door bracket,
lock nut,
trolley and clevis pin
Preferable for
sectional doors
Preferable for
tilt doors
OK for
tilt doors
Mounting strap methods
STEP 16: Connect one end of the straight door arm to the trolley. Attach to the trolley using the
short clevis pin and its clip.
Usually the straight arm is all that is required on tilting doors. Usually the L arm is attached between
the door and the straight arm for use with sectional doors. You may have to shorten or re-drill the
door arm.
You may need to use the L-arm to prevent fouling of the door in
the fully open position.
CAUTION When the door is fully closed the door arm
must not ever become vertical. The door arm must
remain at less than a right angle to the pole.
Disengage the trolley.
Connect the free end of door arm assembly to the door
bracket.
Top of door
Angle iron
Door Bracket mounting
Top of door
Door
Centre line of
door
Top of door
150mm
Either
Door bracket

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STEP 17:
If a wall control box is included in
your opener then locate a conven-
ient position to mount the wall con-
trol box. The garage door should be
visible from this location. There
should be no moving parts of the
door or opener within 1.8 metres of
this box and the box should be
placed higher than 1.5 metres from
the floor.
Connect the wire to the manual con-
trol accessory terminals on the rear
of the power head. Take care to keep
frayed wire ends from shorting
across terminals.
Route wire from the power head to the location for the wall control box. Allow some slack in the
wire to the power head. Connect the wire to the two terminals inside the wall control box. Mount
the box to the wall.
CAUTION Keep the push button cable at least 60mm clear of mains power cables if it is
parallel to them. Do not run the push button wiring through the same cavities in the wall as
the mains power. Mains and low voltage wiring can cross with no problems.
STEP 18: Remove or disable any door locking mechanism. Remove unnecessary ropes or chains
STEP 20: Fit the light cover into position and lock the cover securely.
STEP 21: Manually raise the door and re-engage the trolley.
STEP 22: Attach the red release rope through the hole in the trolley release lever. The handle
must be fitted at a height of less than 1.8 metres.
Ensure the release cord is threaded through the manual release warning card.

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Setting the door travel limits
NOTE Repeated operation of the opener in a short
period of time during setup may trigger the ther-
mal cutout of the motor. In this case you will have
to wait for approximately five minutes for the mo-
tor to cool sufficiently to continue the installation
process. If the unit has overheated you will hear
the relays clicking in response to the transmitter
or pushbutton but the motor will not operate. After
cooling down, normal operation is able to resume.
The limit adjustment screws are inside the lamp cover and
are marked as up limit and down limit. One full turn of either
screw results in around 250mm of trolley travel.
STEP 1: Plug the opener into an earthed three-pin 220-240V outlet and switch on the power.
The opener’s courtesy lamp may turn on, or may flash for five seconds.
STEP 2: Remove the lamp cover by turning the catch on its underside. Remove the green control
panel cover to expose the setup controls. Observe
the red and green indicator LEDs. The red LED will
stay on continuously at the fully closed position. The
green LED will stay on continuously at the fully open
position. Identify the green operate button.
Ensure the door is engaged on the trolley.
STEP 3: Press and hold the green operate button
to move the door up and down into the required
fully open or fully closed positions. Each time the
operate button is pressed the door will stop or move
in the opposite direction.
STEP 4: When the door is at the fully closed posi-
tion, turn the down-limit screw (located adjacent to
the courtesy lamp) until the red close-LED stays
on continuously.
STEP 5: When the door is at the fully open posi-
tion, turn the up-limit screw (located adjacent to
the courtesy lamp) until the green up-LED stays
on continuously.
STEP 6: If the door can not be moved sufficiently
far then look at the red and green LEDs. If one of
these is on continuously then the door has stopped
at a limit point. Adjust that limit to allow more travel.
One turn of a limit adjustment screw results in
250mm of door travel.
exit delay
Light door
roller: L
tall door
auto-
close
on
on
R
on
short
long
open auto
open
force
operate
learn delete
close
auto
close
force
program
remove
for setup
manual
control
Door travel
limit adjustments

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Additional setup for trackless tilt doors (jamb fittings) only
The aim of these steps is to make the opener push in the direction that the door edge is moving.
Preferably the door edge is being forced upward slightly as the closing cycle begins.
You must adjust the top limit of travel so that if you sight along the fully open door the sight line
intersects the pole in front of the trolley - not behind the trolley.
If the door does not open far enough after setting the top limit of travel correctly then it will be
necessary to make some in-
stallation changes. You will
need to try some or all of: rais-
ing the location of the header
bracket further, lowering the
power head further or increas-
ing the length of the door arm
further.
WARNING The door
is not safe for unsu-
pervised operation until the
force sensitivity has been be
set. Opener position and open door po-
sition for trackless tilt door
Sight line intersects pole
in front of the trolley
Setting the force sensitivity
STEP 1: Remove the lamp cover by turning the catch on its underside. Remove the green control
panel cover.
STEP 2: Identify the green and the red control knobs marked open-force and close-force.
Note: The opener can be set to either determine its own safe operating force level, or it can be set
to allow a deliberately greater amount of force to be applied to the door.
STEP 3: To set the force levels automatically, press the program button and turn the control knobs
fully anticlockwise. Ensure that the door is engaged to the opener. Then operate the opener to
move the door in a single unobstructed movement from one limit position to the other. If no ob-
struction was sensed during this cycle then the opener will save the settings to memory. Operate
the opener to move the door back to the original limit position. Again, if no obstruction is sensed,
the settings will be stored in memory.
STEP 4: To set the force levels at some higher level, rotate the control knob to some position
clockwise from the auto-setting point.
STEP 5: If a very light door is being operated, and if a very gentle closing force is required, then
set the option switch marked ‘Light door’ to the ON position. Note that on a heavier door this
option switch position may result in unintended detections of obstructions.
NOTE: To reset the adaptive and automatic force settings at any time, press the program button
once.

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Setting up wireless controls
Wireless controls can operate the opener, or the opener’s courtesy lamp, by sending coded radio
signals. These coded signals use high-security code-hopping.
Wireless controls can be hand-held or fixed to walls, such as a wireless keypad, or a wireless wall-
switch.
Up to 20 Merlin wireless controls can be learned by the opener. After this, the 20th wireless control
is over-written in the opener’s memory.
All wireless controls can be deleted from the opener’s memory.
There is a learn button on the underside of the opener inside the lamp cover. The small button on a
Merlin M-122 wired wall-switch can also be used as the learn button.
If a setting is enabled in the opener, then it is possible to use any existing learned wireless control
as a learn button. (See separate section following.)
Remove the lamp cover by turning the catch on it’s underside. Remove the green control panel
cover to expose the setup controls. Identify the red learn button.
To learn a remote button to operate the opener:
Press the learn button for 1-2 seconds, until the courtesy lamp begins to flash slowly.
Press the desired remote button, wait 1 second, press the desired remote button again. The cour-
tesy lamp will stop flashing once learning is complete.
To learn one remote button to operate the opener and another to operate the lamp:
Press the learn button for 1-2 seconds, until the courtesy lamp begins to flash slowly.
Press the desired remote button for control of the opener, wait 1 second, press the desired remote
button for control of the courtesy lamp. The courtesy lamp will stop flashing once learning is com-
plete.
To delete all remote controls from the opener’s memory
Press and hold the Learn (or setup on some models) button for eleven seconds, until the courtesy
lamp stops flashing. After six seconds it will flash fast as a warning. If you release the learn (or
setup) button during this warning period then the memory will not be wiped.

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Remote transmitter learning
Remote Transmitter Learning (RTL), when enabled, allows any existing learned wireless control to
be used as a learn button for the learning of additional wireless controls. Note that this feature
trades convenience for security. If it is chosen to disable RTL (the default setting at manufacture is
enabled) then the level of security is increased. It is recommended that after use this feature be
disabled.
To enable or disable RTL:
Remove the lamp cover by turning the catch on its underside. Remove the green control panel
cover to expose the setup controls. Identify the red learn button and the black program button.
Hold both of the these buttons down for three seconds until the courtesy lamp begins to flash.
Release both buttons.
Six flashes confirms that RTL is now enabled.
Four flashes confirms that RTL is now disabled.
To place the opener in learn mode using RTL:
Select any two or four button Merlin hand held remote control that is already learned in to the
opener. Call this the master remote.
Press the North and the South buttons together for 2-3 seconds.
The courtesy lamp on the opener will begin to repeat a cycle of flashing three times and pausing. If
you have several openers that operate from this master remote, then all these openers will begin to
flash their courtesy lamps.
Press the button on the master remote that would normally operate the opener that you want to
learn another remote into. Now that opener will go into learn mode, and any other openers that
were flashing will return to their normal standby state.
The courtesy lamp on the opener that is in learn mode will begin to flash slowly. If no signals are
received for 20 seconds, the opener will revert to its normal standby state.
To learn a button to operate the opener:
Press the desired remote button, wait 1 second, press the desired remote button again. The cour-
tesy lamp will stop flashing once learning is complete.
To learn one remote button to operate the opener and another to operate the lamp:
Press the learn button for 1-2 seconds, until the courtesy lamp begins to flash slowly.
Press the desired remote button for control of the opener, wait 1 second, press the desired remote
button for control of the courtesy lamp. The courtesy lamp will stop flashing once learning is com-
plete.
Improving the door security
If there is a clear gap above the top of the closed door it is possible in some cases for people to
gain unauthorised access to the garage after an opener is fitted. You can improve the security by
adding a strip of metal or wood over any gap to block access to the manual release rope.

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Adding the Merlin M102
non-contact beam sensor (Optional)
Non-contact Near-Infra-Red beam sensors are optional but may be required in EC countries. Mer-
lin strongly suggests they be fitted for increased levels of safety.
If sensors are fitted the opener will only close when the sensors are fully functional and where their
beam is unobstructed.
The sensors should be placed either side of the door opening, within 300mm of the door’s open-
ing, and within 100mm of the floor. Choose positions that will protect the sensors from accidental
impact or water. If one sensor is marked ‘receiver’ then do not place that sensor where it will be
subjected to bright direct sunlight. The high level of Infra Red light in bright sunlight may temporar-
ily prevent normal operation of the opener.
Switch off the power to the opener. Run the pair of cables from each sensor back to the accessory
terminals on the rear of the opener.
There is no need to connect the cables with any particular polarity.
Switch the power to the opener back on. Aim the sensors at each other using the adjustments
provided. When correctly aligned and unobstructed the sensor LEDs will stop flashing and stay on
continuously.
The door can open regardless of the sensor beam. Only the closing operation is affected by the
state of the beam. If the beam is obstructed or if the sensors are not functioning then the door may
still be closed by holding the manual control button down for at least two seconds, and keeping it
held until the door is closed.
NIRLightbeam
Max7metres
Non contact beam sensor

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Specifications
Replacement light bulb E27 45mm Round, 40W maximum, RC preferred
Mains power required 220V to 240 V, 50 Hz, single phase AC, earthed
Suitable for sectional doors, one piece tilt doors. Note that counterweight
type doors are not suitable for automating
Stand-by power consumption 3 W
Operating power consumption 900 W
Net weight 15kg (installed using typical pole and strapping)
Trolley speed depending on sprocket and load: 75 to 135mm/sec
Rated force 770N
Standard pole length 2750mm to suit chain supplied
Standard assembled overall length pole length + 400mm = 3150mm
Standard trolley travel pole length - 275mm = 2480mm
Minimum headroom required 100mm between the top edge of the door and the ceiling
while the door is closing or opening
Minimum backroom required 600mm back from the rear edge of a fully opened door,
depends on door arm chosen.
Ambient operating temperature +50C to +400C.
3150 (Standard)
Minimum 453 Minimum 215
170
205
80
65
Overall dimensions

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27
Merlin does not accept responsibility for damage or injury resulting from installing this opener.
Merlin reserves the right to change the design and specification without prior notification. Some
features or accessories may not be available in certain markets or areas. Please check with your
distributor.
Merlin service centres
New Zealand
Auckland phone [phone]
Phone toll free 0800 653 667 or 0800 MERLIN
Fax toll free 0800 653 663
Australia
NSW, Vic, Qld, WA
Phone toll free 1 800 638 243
Fax toll free 1 800 640 243
England
Phone toll free 0800 073 0112
Fax toll free 01709 514 534
www.merlingo.com