Wayne-Dalton IDRIVE 9100 User's Manual
Contents
1. s n Wan OPENER POWER 16a Disconnect Installation HEAD O S HOOK 4 INSTALLED Attach the loose disconnect cable located in operator hardware bag to the opener power head with S hook Close both ends of S hook to lock assembly together Thread the disconnect cable through hole in right hand end bracket and remove all slack between power head and right hand end bracket Mark location on right door jamb six feet above the ground to mount disconnect handle Thread disconnect cable through handle bracket and then handle Align top of handle bracket with mark on wall Remove all cable slack between the power head and top of handle bracket Insert and tighten 6 20 x 1 2 screw until snug and then tighten screw to 1 1 2 additional turns to secure cable in handle Trim off excess cable from bottom of handle Holding handle bracket remove all remaining slack between E CABLE 6 20 X 1 2 HANDLE HANDLE 6 a BRACKET to bottom of door 1 4 X 1 1 2 LAG SCREW x E G a D power head With slack removed secure bottom of handle bracket with 1 1 4 x 1 1 2 lag screw CAUTION Pull handle just enough to remove the cable slack Pulling the cable more could cause the opener power head to disconnect from the torque tube Rotate disconnect handle to one side exposing upper mounting hole in handle bracket Secure2. handle bracket with a second 1 4 x 1 1 2 lag screw Apply emergency disconnect label next to the mounted bracket Use mechanical fasteners if adhesive will not adhere LABEL HANDLE
3. the drum and flag angle Close front half of the drum wrap around drum engage inboard snap and press firmly until a distinct snap is felt Outboard catch must be engaged as shown Confirm both snap and catch are fully engaged by lightly tugging against them Repeat for the left side Refer back to the main door manual and continue door installation at the REAR SUPPORT INSTALLATION REAR SUPPORT INSTALLATION Step 18 Step 19 in the Single Spring TorqueMaster Installation Instructions PERFORATED After door installation is completed refer to the idrive owner s manual ANGLE NOT starting at the PRE OPERATION INSTALLATION section to complete SUPPLIED the opener installation i HORIZONTAL ee TRACK F NOTE Refer to the main door manual for counterbalance adjustments 8 13 Drum Installation Shake the torque tube gently to extend the winding shafts out about 5 on each side For single spring applications there will be no left hand winding shaft in the torque tube Lift the torque tube and rest on top of flagangles Orient torque tube so that back of opener is flat against header spring pad See Figure 12 Cable drums and torque tube are cam shaped to fit together only one way To install the cable drum slide the drum over the winding shaft until the drum seats against the torque tube The winding shaft must extend past the drum far enough to expose the splines and the groove Align the winding shaft groove with
4. the round notch in the flagangle Repeat for opposite side NOTE On single spring applications take care in handling the loose winding shaft left side so that it does not slide back into the torque tube TORQUE TUBE Single Spring Applications Insert the left hand loose winding shaft into the left hand drum prior to sliding the drum over the torque tube __ ly WO TORQUE TUBE LOOSE WINDING SHAFT WINDING SHAFT GROOVE DRUM h SPLINES FLAG ANGLE 140 Drive Gear End Bracket Installation Ensure that torque tube is centered and level with door Beginning with the right hand side lubricate entire circumference of the drive gear with the oil provided in the packet Slide the drive gear onto the winding splines until it touches the flagangles NOTE No drive gear is required for the left side on single spring applications WINDING SHAFT OIL PACKET DRIVE GEAR INSTALLED Using the emergency disconnect pull disconnect handle downwards and place it in the manual door operated position Use disconnect label for reference Motor will be rotated 90 from its packaged position NOTE If motor does not pivot 90 see troubleshooting section in the idrive main installation manual 16b Cable Adjustments Adjust the counter balance cables by rotating the drum until the set screw faces directly away from the header Loosen the set screw no more than 1 2 turn Pull on the end of the cable to remove all
5. TorqueMaster amp idrive 9900 9600 9200 9 100 INSTALLATION INSTRUCTION SUPPLEMENT When installing an idrive opener with this door use this supplement to the main door instructions as follows 1 Begin with Step 1 of the main door instructions 2 Replace Step 8 of the main door instructions with Step 8 of the attached supplement 3 Replace Steps 12 through 17 of the main door in structions with the Steps 12 through 17b of the attached supplement Supplement replaces Steps 12 18 on single spring doors Copyright 2002 Wayne Dalton Corp 1 Part No 301528 New 07 02 TorqueMaster amp fMdrive 9900 Thermowayne www wayne dalton com 9600 Thermogard 9200 9100 Foamcore INSTALLATION INSTRUCTIONS INSERT Follow the corresponding steps in this insert with the steps in the installation manual provided with the door These modifications are designed to accommodate the new idrive garage door opener 8 Top Bracket Installation To install the L shaped top brackets align the top holes in the top bracket with the first set of holes in the endcap for 9900 Thermowayne doors and second set of holes for 9600 Thermogard doors and 9200 9100 Foamcore doors Fasten using 4 1 4 20 x 5 8 self tapping screws Secure the top bracket slide to the bracket using 2 1 4 20 x 5 8 carriage bolts and nuts Insert rollers see Fig 1 NOTE To differentiate between a 9900 Thermowayne 9600 Thermo
6. ating the winding bolt clockwise until snug Tightening of the lock nut prevents spring from unwinding Repeat for opposite side if necessary Door Height Spring Turns 6 0 Door Height 14 1 2 turns Double Spring and 15 turns Single Spring 6 3 Door Height 15 turns 6 5 Door Height 15 1 2 turns 6 6 Door Height 15 1 2 turns 6 8 Door Height 16 turns 6 9 Door Height 16 turns T 0 Door Height 16 1 2 turns T 3 Door Height 17 turns T 6 Door Height 17 1 2 turns T 9 Door Height 18 turns 8 0 Door Height 18 1 2 turns IMPORTANT Adjustments to the recommended number of turns may be required AFTER REAR SUPPORT ASSEMBLY IS COMPLETE located in main door manual instructions check door balance If door raises off of floor under spring tension alone then reduce turns until door will rest on floor A hot door such as this can cause idrive operation problems Slide the right hand end bracket over the drive gear Attach end bracket and the flagangle to the jamb with 2 5 16 x 1 5 8 lag screws see Fig 11 14b Counter Installation m ti END BRACK COUNTER i F a ie i JI i gt ha E j i ni Fj a rh k a Begining with the right side install the counter gear with the missing tooth toward the outside away from the end bracket Press the counter gear onto the end bracket until snaps engage Select the right hand counter cove
7. cable slack Check to ensure the cable is aligned and seated in the first groove of the cable drum Snug the set screw then tighten an additional 1 1 2 turns Cut off excess cable 17a Wind Counterbalance Springs Clamp locking pliers onto both vertical tracks just above third roller This is to prevent garage door from rising while winding counterbalance springs IMPORTANT DO NOT USE IMPACT GUN TO WIND SPRING S Beginning with the right hand side Press and hold in the canoe clip Ensure the cable is in the first groove of the drum Using an electric drill high torque gear reduced to 1300 RPM preferred with a 7 16 socket carefully rotate right hand winding bolt clockwise until counter shows 2 3 turns This will keep the counterbalance cable taut while adjusting the left hand side counterbalance cable Repeat for left side on double spring TorqueMaster systems Single spring applications will require no spring pre winding Ensure counterbalance cable tension is equal for both sides prior to fully winding spring s to appropriate number of turns Carefully rotate the winding bolt head clockwise until the counter show the correct number of turns for your door See the chart below Repeat for the opposite side on double spring TorqueMster systems If door raises off of floor remove 1 2 1 full turn from each spring before proceeding After spring is wound hold the lock nut stationary with a 7 16 wrench while rot
8. gard and 9200 9100 Foamcore door mod els look for the following characteristics 1 9900 Thermowayne 2 9600 Thermogard right below will have painted hard will have galvanized hardware with ware top brackets bottom brack a steel backing on the sections ets end caps etc with a steel 2 CARRIAGE BOLTS 15T SET OF HOLES ON 3 9200 9100 Foamcore 9900 THERMOWAYNE d Lean TOP below will have galvanized hard BRACKET ware with a laminated soft back E SLIDE ing on the sections 2X SET OF HOLES ON 9600 THERMOGARD Pe TOP AND 4 a BRACKET 9200 9100 FOAMCORE A 2 HEX NUTS 4 SELF TAPPING SCREWS The idrive garage door opener is best installed in combination with the door installation steps Refer to this idrive installation insert when you reach Step 12 TorqueMaster installation in the main door installation instructions and owners manual When instructed to slide the center bracket bushing onto the torque tube replace that step with the follow ing instructions below which will provide the steps necessary to install the TorqueMaster system as well as the preliminary installation steps for the idrive garage door opener 12 Power Head Assembly Lay the torque tube on the floor inside garage in front of the door with the labeled end to the left NOTE Opener will not slide over a torque tube label Attempting to slide opener over the left end of the
9. r assembly and align the hex of the counter cam with the end of the winding shaft Also align the 0 on the counter cover with the raised rib on the end bracket Press the counter cover assembly against the counter gear until it locks into place Repeat the Drive Gear End Bracket Installation and Counter Installation sections for the left hand side installation NOTE No drive gear counter gear or counter cover assembly is required on left hand side for single spring applications Only an end bracket is needed IMPORTANT At this time do not wind counter balance springs 15 Power Head Support Bracket Installation Locate the spring pad The spring pad is a vertical running board directly above the door Remove 2 1 4 20 flange nuts from bottom of opener power head NOTE Do not discard flange nuts Place the support bracket underneath opener power head to the right side of motor centered on spring pad Level the torque tube to the top of the door section with the idrive resting on the support bracket Once torque tube is level secure support bracket to the spring pad with 2 1 4 x 2 lag screws OPENER SPRING PAD POWER HEAD BRACKET Lift and slide the opener power head over the support bracket aligning the mounting studs with the bracket slots Loosely fasten to mounting studs with the 2 1 4 20 flange nuts NOTE Do not tighten 1 4 20 flange nuts to power head studs at this time i i POWER HEAD
10. torque tube can damage the internal electronics NOTE Hold opener by the main body Do NOT hold by the motor Look into the opener s left side to ensure the left hand bearing and the internal black sleeve are aligned with the torque tube profile Once aligned slide the opener power head onto the right hand end of the torque tube As the right end of the torque tube enters the internal black sleeve rotate the opener back and forth slightly to help aid alignment NOTE Do not force the opener onto the torque tube if misalignment occurs OPENER POWER HEAD TORQUE TUBE AND BEARINGS PROFILES ALIGNED Continue sliding the opener power head onto the torque tube Align the right hand bearing with the torque tube and slide the opener power head completely onto the torque tube until the torque tube exits the opener power head s right hand bearing Continue sliding the opener power head to the center of the torque tube and plug the motor into the Opener power head IMPORTANT Right and left hand are always determined from inside the garage looking out LEFT HAND BEARING OPENER POWER HEAD RIGHT HAND BEARING PLUG MOTOR m INTO THE OPENER SMIDE Ope POWER HEAD g OWER HEAD TORQUE TUBE INSERT THIS END FROM LEFT SIDE OF OPENER FIG 5 FRONT HALF INBOARD SNAP FLAGANGLE APPLY PRESSURE Locate right hand drum wrap Slide back half of the drum wrap behind drum placing the right end wall between
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