Overhead door 55A Assembly instructions

MODEL 55A
GARAGE DOOR OPENER SYSTEM
'. l;·I
'/
. I'
',,
105376-1
4-15-83
ASSEMBLY
1
INSTALLATION
AND
OPERATING INSTRUCTIONS
--------
-· __.------------·
Printed in U.S.A.
Page 1

TABLE OF CONTENTS
HOW TO USE THIS BOOK ______ _ 2
TOOLS NEEDED ___________ 2
GENERAL NOTES ___________ 3
ASSEMBLY INSTRUCTIONS 4-7
HOW TO USE THIS BOOK
1. Use tools indicated by silhouettes
at top of instruction.
2. Perform the instruction according
to the words and iI lustration.
3. Put a check in box after completion
of instruction.
4. Proceed to next step.
ASSEMBLY DRAWING ________ _
INSTALLATION INSTRUCTIONS ____ _
WIRING ______________ _
7
8-15
16-18
Adjust drive chain-cable.
OPERATION AND ADJUSTMENT ____ _
TROUBLE SHOOTING GUIDE _____ _
PARTS AND SERVICE---------
PARTS LIST ____________ _
ILLUSTRATED PARTS BREAKDOWN __ _
WIRING DIAGRAM-----------
WIRING SCHEMATIC----------
TOOLS NEEDED
19-20
21
23
22
22
23
23
EXAMPLE
You will need the tools shown below to assemble and install this operator.
ELECTRIC DRILL
5/32 BIT
1 /4 BIT
,.., : 0
CARPENTER
LEVEL
A
STEP LADDER
6-0
(.., __ _..[\HACK SAW
.,., ••• .,.ADJUSTABLE
<lllf END WRENCH
Page 2
NEEDLE NOSE
PLIERS
" D
-=C
END WRENCH
•
TAPE MEASURE
7/16 & 9/16
•
STRAIGHT EDGE
SLOTTED
SCREWDRIVER
•
PENCIL
WIRE
•
POCKET
KNIFE
CUTTERS
OR
WIRE STRIPPERS
•
NUTDRIVER
1/4
1

GENERAL NOTES
The following procedures must be performed before operator can be installed. Failure to
complete the
fol lowing procedures can cause operator failure and/or hazardous conditions
which could cause personal injury.
l. Check working condition of door. Door should operate freely without sticking or binding.
Lubricate door rollers and hinges with
SAE 30 wt. o.il. Replace damaged or broken
rollers and hinges. Tighten all bolts and screws.
2. Check for broken counterbalance springs and worn or broken lift cables. Replace any
defective parts.
CAUTION
Repairs and adjustments to cables and springs can be hazardous
and should be performed by qualified door service
people.
3. Counterbalance should be set so that door does not have to be held up or down.
4. If door is equipped with a locking device, make it inoperative by permanently securing
the locking bar in an unlocked position.
CAUTION
Remove any lift or pull rope if door is so equipped.
If adding
11
Door Minder" accessory kit; see
instructions supplied with kit for installation
WARNING
TO REDUCE THE RISK OF INJURY TO PERSONS -
USE THIS OPERATOR ONLY WITH A SECTIONAL DOOR.
CAUTION
Do not use lighted-type pushbutton,
WARNING
DO NOT CONNECT ELECTRICAL POWER TO
UNIT UNTIL INSTRUCTED TO DO SO.
Page 3

ASSEMBLY
10
Lay powerhead and boom on workbench or
floor. Assemble boom (3 sections).
30
Insta 11 boom into boom bracket •
Page 4
20
Position carriage over tapered end of boom.
BOOM
CARRIAGE
40
-
TO
POWER HEAD
Install header pulley assembly on end of boom.
HEADER
PULLEY
ASSEMBLY

ASSEMBLY
50 or
····-··· ~
Remove gear guard and sprocket cover. Check
to see that chain is correctly routed around
sprocket
and drive gear,
COVER
SCREWS
HEX. HD.SLOT
6-32 x 1/4
y
70~
Install retainer clips on connecting links.
A B C
@§)• 1n)• @=§)
CONNECTING LINK
CHAIN
CABLE
ASSEMBLY
60
Insert carriage engagement cylinder into
carriage. Wrap cab le end of drive chain-
cable around header pulley and back to
carriage. Connect chain and cable to car-
riage engagement cylinder using connect-
ing links.
CONNECTING LINK
CHAIN
CARRIAGE
8 D ~4'-m•
Adjust drive chain-cable.
CHAIN CABLE
ASSEMBLY
1-
BOOM
Reinstall gear guard and sprocket cover.
9/ 16 WRENCH
ADJUSTING
TO INCREASE TENSION
IMPORTANT
HEADER PULLEY
ASSEMBLY
BOOM
With carriage near header end of boom,
chain should not sag below center line of
boom more than 3
'.4-
11
•
Page 5

ASSEMBLY
90
100
or •
...... ~. 1.
• 4
Correctly installed: - Header pulley assembly. Remove front screws
from operator cover
and swing open.
ADJUSTING
ADJUSTING
NUT
SOLT HEADER PULLEY
~LY
0 fr. .
110
Page 6
Make initial adjustments to limits switches
by
plugging operator in and using transmitter to
run operator. Refer to page 20 for instructions
on how to set Iimit switches. The "Down" Iimit
switch should be set so that the carriage stops
approximately 7" from end of header pulley.
The
11
Up
11
limit switch should be set so that
the carriage stops approximately 18
11
from the
powerhead.
UP LIMIT
TRAVEL NUT
WARNING
Keep hands and objects clear of powerhead when
operator is running. Unplug operator when making
adjustments
to limit switches.
RETAINING ROD

(
ASSEMBLY
120
1
•••ti-••• 4
or
130
Re-install cover.
CHECKLIST
IMPORTANT
D
Make sure antenna is
ANTE~ ~~~ended through D
D
D
D
CIRCUIT BOARD
ASSEMBLY ORA WING
CONNECTING
LINKS
60684-1
CARRIAGE CYLINDER
SLIDE
-102350-1
-11/ir-'J.. 1=:.d,J RJJa;
f!fu ~ /O!f7ft./. 3
HEADER PULLEY ...}
ASSEMBLY
104159-1
CARRIAGE
THREE PIECE
BOOM
104036-1 *
104036-2
DASH ONE ( 1) PART NUMBER FOR 7 FT. DOORS.
* DASH TWO (2) PART NUMBER FOR 6 FT. DOORS.
DASH THREE
(3) PART NUMBER FOR 7 FT. DOORS.
**DASH FOUR (4) PART NUMBER FOR 6 FT. DOORS.
Header pulley assembly is positioned
correctly.
Drive chain is seated in drive sprocket
and limit switch
sprocket.
Drive chain is not twisted.
Cable is seated in header pulley.
Limit switches set to initial dimensions.
ONE PIECE
BOOM
1g:g~:=: **
AND 102104-1
CABLE ASSEMBLY
DRIVE CHAIN ~'V 8crt~D
/
104061-3** • SPROCKET
•
102104-1
104061-4~COVER
' SUPPORT
I
BRACKET
102106-1
Page 7

INST ALLA Tl ON
140
Measure width of door to determine center.
ATTACHMENT FOR DOOR BRACKET
FOR DOORS WITHOUT CENTER STILE
If header does not have suitable woodwork where
header bracket will be installed, then such will
have to be made.
It is suggested that a wood
2
11
x6
11
be secured to nearby existing woodwork.
If door does not have a center stile or suitable
attachment for attaching door bracket then
door must be re-inforced with wood or steel
at mounting point.
160
,., : 0
Raise door untiI top section reaches its highest
arc of travel. Mark header on center line at
point where level touches header.
DOOR
OPENING
CARPENTERS LEVEL
-- ..
HIGH ARC OF
DOOR
TRAVEL
DOOR TRACK
DOOR SECTIONS
IT IS RECOMMENDED THAT OPERATOR
BE MOUNTED A MINIMUM OF 7 FEET
ABOVE FLOOR.
Page 8
150
Mark center Iine on door and header.
----------- CEILING
·~
l OF DOOR
HEADER
DOOR
170
Mark horizontal center line of header bracket
three
(3) inches above high arc of door travel.
HIGH ARC OF
DOOR
TRAVEL
DOOR
1-5/8" minimum head room required above
high arc of door travel •
\

INSTALLATION
180 190
Mark horizontal center line of header bracket. Position header bracket on center line and
mark mounting hole locations on
center line.
HEADER
CENTERLINE OF
HEADER BRACKET
2oor
CEILING
Drill 5/32
11
diameter holes at marked locations.
CEILING
HEADER
CENTER LINE· OF
HEADER BRA
CKE.!. \\\
)._
CENTER LINE I
OF DOOR
I
I
DOOR
CEILING
HEADER
21D '>-' -0°~
Secure header bracket to header.
<X1\\\\\\\\\\\\\\\\\\\\%\\\\\\\\\o
1/4 x 1-3/4
LAG SCREW
HEADER
1/4 x 1-3/4 -«'\:.~
LAG SCREWS
HEADER
BRACKET
I
CENTER LINE --4
OF DOOR
CEILING
Page 9

INSTALLATION
220 A
Rest header end of boom on top edge of top door section and powerhead on top of step ladder.
EXTENSION SPRING DOOR
OR
Rest header end of boom on torsion spring and powerhead on top of step ladder.
TORSION SPRING DOOR
Page 10

INSTALLATION
230 '!11~-mn
Attach header pu 11 ey assembly to header bracket.
CEILING
250
Continue raising door until fully open.
PROTECTIVE~ ::C!
----i9--7,..J_l.
POWERHEAD
STEP
LADDER
240
To raise powerhead: raise door slowly.
PROTECTIVE
PAD •
=:____~,,,........
POWERHEAD ~
-.-f .~--__J'/t::====.
Carriage should be Jocated near powerhead
when raising
operator.
260
Position a wood 2x4 on edge between top
door section and boom.
Use center line of
door to correctly align boom.
<j) CENTER LINE
OF DOOR
=
DOOR IN FULLY OPEN POSITION
Page 11

INSTALLATION
27 D r L\ ,...- , o,~
l. Shown are examples of various installation configurations. Determine the configuration which
best suits your requirements.
2. If necessary, span ceiling joists with wood 2 x 4's sufficient enough to support operator.
3. Hold ceiling mounting angle in mounting position. Using holes in angle as a guide, dril I
3/16" diameter pilot holes in ceiling joists or 2 x 4 framing.
4. Using 1/4" x 1-3/4" lag screws, secure ceiling mounting angle to ceiling joists or 2 x 4 framing.
5. Notch operator end of vertical angles (Detail A).
6. Using 1/4"- 20 x 1/2" hex head bolts and lock nuts, secure angle brackets to operator.
7. Using 1/4"- 20 x 1/2" hex head bolts and lock nuts, secure vertical mounting angles to ceiling
angle. Vertical angles may be bent at notch if necessary (Detail B).
LENGTHWISE CEILING JOISTS
ON CENTER
CEILING JOIST
SHEET ROCK
9"
IT IS RECOMMENDED THAT OPERATOR BE MOUNTED
A MINIMUM
OF 7 FEET ABOVE FLOOR.
LOCK NUT
OPERATOR
Page 12
NOTCH ANGLE
WITH HACKSAW
CUT LINE
DETAIL A
DETAIL B
(
\

INSTALLATION
LENGTHWISE CEILING JOISTS
CROSSWISE CEILING JOISTS
CEILING JOIST
2x4
SHEET ROCK
30"
15'
0
OFF-CENTER
CEILING JOIST
30"
SHEET ROCK
6"
SWAY
BRACE
9"
0
CROSSWISE CEILING JOISTS
HIGH CEILING
rCEILING JOIST
~-- ~ -==-
---.-· ----- --
SHEET ROCK
~-tt<>+-- 1 O" SWAY BRACE
20"
0 0
or
as required
0
0
0
0
Page 13

INSTALLATION
280
Drawbar bracket should be mounted in line with
top fixture roller and secured to top rail and
cen-
ter stile of doors so equipped. If door strut inter-
feres with this position; move bracket below strut.
DO NOT CUT OR MODIFY STRUT IN ANY WAY.
Position back angle of bracket on door centerline
and mark mounting hole locations.
ORAWBAR
BRACKET
Position back
angle on the
centerline.
.
~CENTERLINE
OF DOOR
290 ,,.-
Dri 11 1/4
11
diameter holes through door
at locations marked.
Page 14
If necessary raise door to
avoid dri
11 ing into header.
TOP RAIL
DOOR
PANEL
SECTION THAU
PANEL DOOR
ORAWBAR
BRACKET
If operator is to be installed on Steel or Fiberglass
doors, use Attachment Kit P
/N 105383-1
Secure drawbar
bracket to door using
1/4
11
-20 x 2- 1/4
11
carriage bolts.
M\\\\\\\\\\\\\U ~
1/4-20 x 2-1/4
CARRIAGE BOLT LOCKNUT
DRAWBAR BRACKET
Install bolts thru front of door.

INSTALLATION
310 'J
Attach yokes to drawbar bracket. Tighten
locknut but do not compress yokes to
bracket.
Yokes must move freely.
DRAWBAR
111--.-~ YOKES (2)
~
DRAWBAR~
BRACKET 119'
104432-1 \ p 3. /8-16 x 3/4
·~"""' BOLT
. ..
,.._ ~ ~~
@~ ~ "'::::-.DRAWBAR
3/8 ~- YOKES
LOCKNUT 76557
330
Route pu 11 cord through reI ease I ever.
Install pull knob on pull cord approximately
six
(6) feet from floor.
RELEASE LEVER
~
DRAWBAR
77089-1
320
1
After pinning drawbar into carriage, move
carriage toward header unti I drawbar can be
connected to drawbar vokes.
Drawbar yokes shou Id be in a vertical position.
Align two (2) holes in drawbar arm with two
holes in drawbar yokes and
secure.
0
0
0
0
Jiil 0 1/4-20 x 1"
~ v BOLTS (2)
~ r 1/4 NUTS (2)
~---;~o .. (
(
EMERGENCY
RELEASE
DECAL
(
Remove protective backing from EMERGEN-
CY
RELEASE decal and install on door, near
drawbar
bracket.
340
CHECKLIST
D
D
D
D
D
D
D
D
Header bracket secure.
Door bracket-yoke pivot bolt secure,
but not too tight.
Header pulley assembly pivot bolt secure
but not too tight.
Hanging bracket bolts tight.
Drawbar to yoke bolts tight.
Drive chain-cable is tight (tensioned
correctly).
Carriage engagement cylinder is
engaged with carriage.
Make fine adjustments on
11
UP
11
and
11
DOWN
11
limit switches • (See page 20~
Page 15

WIRING
350
Separate end of push button wire.
Use only wire supplied with operator
or equivalent gauge.
370
Remove insulation.
Page 16
360
Carefully cut insulation around wire.
DO NOT cut wire.
380
This procedure is best perfonned
by using wire
strippers.
Twist ends of wire strands together.

WIRING
390----.
Shape wire leads like a hook, and
connect leads to operator terminals.
410
Insta 11 push button on wa 11 near house
entrance door approximately six (6) feet
from floor.
Button shou Id be out
of reach of children.
a·-o·
Peel backing off "PUSHBUTTON OPERATION"
decal and attach to wall near pushbutton.
400
Route push button wire from powerhead
along ceiling to house entrance door.
Staple wire as necessary to prevent
entanglement or contact with moving objects.
CAUTION
Be careful not to pierce wire insulaton
with staples
Shape wire leads like a hook,
and
connect leads to push button terminals.
PUSH BUTTON
420
Install I ight bulb.
Depress ends of Ii ght Iens to insta II
or remove lens.
IMPORTANT
USE MAXIMUM 60 WATT BULB.
Page17

WIRING
430
WARNING
It is important that electrical power to operator be cut off when powerhead cover is
removed. Electrical power must remain disconnected while making electrica I con-
nections and limit switch adjustments. Keep hands and objects clear of powerhead
if electrica I power is re-connected with cover off.
Operator is equipped with a factory installed
power cord and must be plugged into a
115 volt,
60 hertz, grounded electrical outlet.
CAUTION
For maximum safety it is essentiaI that
operator be properly grounded.
If a convenient electrical outlet has to be instal-
led it is recommended that such work be perform-
ed by a licensed
electrician. Use of an extension
cord
is NOT RECOMMENDED.
When installing a
convenient electrical outlet, it
is suggested that an electrical switch be installed
to foci
litate emergency power cutoff.
44.D
If local electrical codes require permanent
wiring,
it is recommended that such work
be performed by a licensed
~lectrician.
Remove cover (4 screws).
Remove and discard strain
relief bushing
and
adapter.
Remove wire nuts and disconnect power
cord lead
wires.
Make conduit connection to chassis.
Connect permanent wiring leads to power-
head leads and re-install wire nuts.
Re-install
cover.
Page 18
115 VOLT
60 HERTZ
GROUNDED
ELECTRICAL
OUTLET
WIRE NUTS
- - -1
BLACK, WHITE AND
GREEN
POWER LEADS

OPERATION & ADJUSTMENT
450-...--
For transmitter operation and frequency code
setting, see Instructions enclosed with operator.
Operator is furnished with "TRINARY
DIGITAL
11
radio controls. Make sure
Frequency Code Switches are set the same
on operator circuit board as those in trans-
mitter.
The cover will have to be removed to set Fre-
quency Code on operator circuit board.
CAUTION
Make sure electrical power has been dis-
connected from operator before removing
cover.
To set transmitter
Frequency Code,
remove snap out
cover as shown.
470
Both
11
UP
11
and
11
DOWN
11
sensitivity must be ad-
justed to insure proper operation of door. Ad-
justments must be made in 1/2-turn increments.
Turning adjusting screws •••
- clockwise, decreases sensitivity.
- counter-clockwise, increases sensitivity.
Door should open fully without stopping.
Door should close completely without reversing.
Door should reverse ONLY when it contacts an
obstruction in "CLOSE" cycle.
Door should stop ONLY when it contacts an ob-
struction in "OPEN" cycle.
Test safety reverse by putting empty carton in
doorway
and start operator to close door. Door
should not crush empty
carton before reversing.
Adjust as necessary.
460
TO START OPERATOR:
Press transmitter button l time.
Press push button 2 times within 3 seconds. (Door
will
automatically stop in "fully opened" or "fully
closed
11
position.)
TO STOP OPERATOR:
Press transmitter button l time.
Press push button l time.
TO RESTART OPERATOR:
Press transmitter button l time.
Press push button 2 times. (Door will move in op-
posite direction.)
TO TURN LIGHT ON:
Press push button l time. (light comes on after
a brief delay.)
TO TURN LIGHT OFF:
Press push button l time. (light goes off after
a brief delay.)
MORE () LESS
SENSITIVITY SENSITIVITY
Page 19

OPERATION AND ADJUSTMENT
480
Page 20
Adjustments to the limit switches are made by loosening the wing nuts and moving
the retaining rod away from the travel nuts. Adjust travel nut "A
11
for the
11
UP
11
limit and travel nut
11
B
11
for the
11
DOWN
11
limit. Moving a travel nut one full
turn toward its switch will
cause the carriage to move approximately 4 inches
less in
that direction and 4 inches more if the travel nut is moved away from Its
switch.
TRAVEL NUT
(A)
RETAINING ROD
After each adjustment of a travel nut and before starting
the operator , make sure that the retaining rod is properly
seated in the slots of the travel nuts and that the wing nuts
are securelytightened.
WARNING
Keep hands and objects clear of powerhead when
operator is running. Unplug operator when making
adjustments
to Iimit switches.