Linear LCO75 installation instructions Serious injuries or death, Cord and Outlet Connection

LINEAR LLC (760) 438-7000 USA & Canada (800) 835-5666 & (800) 421-1587

Toll Free FAX (800) 468-1340 www.linearcorp.com

MODEL LCO75

LIGHT-DUTY CHAIN-DRIVE COMMERCIAL GARAGE DOOR OPERATOR RESIDENTIAL BELT-DRIVE/CHAIN-DRIVE GARAGE DOOR OPERATOR

INSTALLATION INSTRUCTIONS

3 Locate the Header Bracket Position

1	Close the door.
2	From inside the garage, use a pencil to mark the
	vertical centerline of the door on the header wall and
	on the top panel of the door.
3	Examine the area above the center of the door on the
	door header wall for a header bracket mounting location.
4	Open the door to the high-rise point (the point where
	the top edge of the door is highest above the fl oor) and

MARKING THE CENTERLINE	MARK THE CENTERLINE
	OF THE DOOR ON THE
	HEADER AND THE TOP
	DOOR PANEL

7 Install the Wall Station

WARNING

Children operating or playing with a garage door operator can injure themselves or others. The garage door could cause serious injury or death. Do not allow children to operate the remote control(s) or the wall station. Install the wall station out of reach of children and away from all moving parts of the door. The door must be clearly visible from the wall station. A moving garage door could injure someone under it. Only activate the door when it is properly adjusted, when it can be seen clearly and when there are no obstructions to the door travel.

9 Install the Door Bracket and Door Arm

1	Fully close the door. Hold the door bracket against the
	inside of the door’s top panel. Align the top edge of the
	bracket 2” to 4” below the top edge of the door; or, if
	there is a structural support across the top of the door,
	place the top edge of the bracket directly below the
	support. Align the vertical centerline drawn on the door
	with the center of the bracket. See the fi gure for details.
	Mark the left and right holes of the bracket.
2	Drill ¼” holes at marks and insert two ¼-20 x 2”

INSTALLING THE DOOR BRACKET

DOOR		CAUTION! LIGHTWEIGHT SECTIONAL DOORS
		NOT DESIGNED FOR USE WITH A GARAGE
BRACKET		DOOR OPENER MUST BE EQUIPPED WITH A
		DOOR REINFORCEMENT KIT (CHECK WITH
		THE GARAGE DOOR MANUFACTURER)
			ALIGN THE DOOR BRACKET
			ON THE CENTERLINE 2" TO 4"
		DOOR	BELOW THE TOP EDGE
			OF THE DOOR, OR DIRECTLY
	STRUCTURAL
			BELOW ANY DOOR
		SUPPORT
			STRUCTURAL SUPPORT

For Sectional Type Doors

IMPORTANT SAFETY NOTES

Please read the instructions carefully! This garage door	THE FOLLOWING FORMATS ARE USED FOR
	SAFETY NOTES IN THESE INSTRUCTIONS.
operator is designed to provide safe and reliable service
if installed and tested as described in these instructions.	WARNING
A garage door is the largest mechanical appliance in a
	This type of warning note is used to indicate
residence. Care must be taken to prevent injury or death
during installation and operation of the garage door and	possible mechanical hazards that may cause
garage door operator.	serious injuries or death.

measure the distance to the fl oor.

5 Close the door and use a pencil to mark the header

wall 1” above the measured high-rise point.

➤NOTE: In some installations, the header bracket location will be higher than the door header. This will require adding a 2x4 (or larger) cross piece to the wall studs to provide a mounting location for the header bracket. Use lag screws (not supplied) to attach the 2x4 to the studs.

6On doors with low headroom, the header bracket can be attached to the ceiling up to 6” back from the header wall (see next step).

MARKING ABOVE THE HIGH-RISE POINT

MARK HEADER

1" ABOVE

HIGH-RISE POINT

SECTIONAL DOOR

➤NOTE: 22 AWG 2-conductor wall station and safety beam wire is supplied with the operator, Use this wire or the installation’s pre-wiring. For additional wire, contact Linear for information regarding the 24-pack Model HAE00009 wire and wire clip kit.

➤UL NOTE: All low voltage Class 2 cable used with this operator must be UL Listed Type CL2, CL2P, CL2R, or CL2X or other cable with equivalent or better electrical, mechanical, and fl ammability ratings.

1 Strip back ½” of insulation and connect a wire to each

of the two terminals on the back of the wall station.

CONNECTING AND LOCATING THE WALL STATION

CONNECT PUSHBUTTON WIRES

TO WALL STATION'S TERMINALS

MOUNT WALL STATION

AT LEAST 5 FEET ABOVE

THE FLOOR LEVEL

	carriage bolts (not supplied) from outside of door
	through the door bracket.
3	Secure door bracket with two ¼-20 keps nuts (not
	supplied). Tighten with a 7/16” socket.
4	Slide the 5/16” x 1-3/8” clevis pin through one hole on
	door bracket; then the single hole on the curved door
	arm; then through the other hole on the door bracket.
	Secure the clevis pin with the hitch pin.
5	Insert the single hole end of the straight door arm into
	the slot in the trolley. Slide the 1-1/8” clevis pin through
	the hole and secure it with a hitch pin.

DRILL TWO 1/4" PILOT HOLES
USE TWO 1/4-20 x 2" CARRIAGE BOLTS AND
NUTS (NOT SUPPLIED) TO ATTACH THE DOOR BRACKET
CONNECTING THE DOOR ARM TO THE DOOR BRACKET
	CONNECT
INSTALL	SINGLE-HOLE
	END OF
HITCH PIN
	DOOR ARM

CURVED

DOOR

ARM

1-3/8"

CLEVIS PIN

WARNING	CAUTION
This type of warning note is used to indicate	This type of warning note is used to indicate
possible electrical shock hazards that may	the possibility of damage to the garage door or
cause serious injuries or death.	garage door operator.

IMPORTANT INSTALLATION SAFETY INSTRUCTIONS

WARNING

TO REDUCE THE RISK OF SEVERE INJURY OR DEATH TO PERSONS, REVIEW

THESE INSTALLATION SAFETY STEPS BEFORE PROCEEDING

1 READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2 Install only on a properly balanced garage door. An improperly balanced door could result in severe injury or death. Repairs to cables, spring assemblies, and other hardware must be made by a qualified service person before installing the operator.

3 Remove all pull ropes and remove, or make inoperative, all locks (unless mechanically and/or electrically interlocked to the power unit) that are connected to the door before installing the operator. Ropes connected to a garage door can cause entanglement and death.

4	Install the Header Bracket	ATTACHING THE HEADER BRACKET
1	Hold the header bracket on the center line drawn	1/2" SOCKET	CENTERLINE OF DOOR
	above the door with the bottom edge of the bracket on
	the line marked above the high-rise point.	ATTACH HEADER
2	Use a pencil to mark the two bracket holes.
		BRACKET WITH
3	Drill two 3/16” pilot holes about 2” deep.	TWO 5/16" x 2"	1 INCH (SECTIONAL)
		LAG SCREWS
4	Use a ½” socket to fasten the bracket with two 5/16” x 2”
	lag screws.
			HIGH-RISE POINT
			OF DOOR
5 Connect the Rail to the Header Bracket
1	Place assembled operator on the empty carton on the	CONNECTING THE RAIL
	fl oor with rail towards the door.
2			2-3/8" LONG
	Insert the end of the rail into header bracket.		CLEVIS PIN
3	Insert the 5/16” x 2-3/8” clevis pin through header	INSERT HITCH PIN
	bracket and rail.	INTO CLEVIS PIN

4 Secure the clevis pin with the hitch pin.

2	Use the screws provided to mount the wall station near
	an access door at a minimum height of fi ve feet. SEE
	IMPORTANT WARNING ABOVE!
3	For non-prewired installations, route the wire to
	the back of the operator. Use insulated staples (not
	supplied) to secure the wire. Staples must straddle
	both wires to avoid electrical shorts.
4	Cut the wall station wire about 6” longer than needed to
	reach the operator terminals. Strip back ½” of insulation.
5	Connect either wire to the operator’s PUSHBUTTON
	terminal and the other wire to the operator’s COMMON
	terminal.
6	Apply the User Safety Instruction Label (residential) to
	the wall next to the wall station in a prominent location.
	Use staples or tacks to help the label remain in place
	over time.
7	Install the Entrapment Warning Placard and Duty
	Rating Label (commercial) on the wall next to the door.
	Use screws to secure the placard to the wall.

➤IMPORTANT! DO NOT PLUG THE OPERATOR IN AT THIS TIME! More installation is required.

MOUNTING THE WALL STATION		USE MACHINE SCREWS
	USE WOOD SCREWS	WHEN MOUNTING TO
		A SINGLE-GANG BOX
	WHEN MOUNTING
ROUTE WIRE	DIRECTLY TO WALL
THROUGH
SLOT IN
CASE

PUT HOLE

PLUGS IN

TO HIDE

SCREWS

CONNECTING THE WALL STATION WIRES

WIRES TO THE

WALL STATION

CONNECT THE WALL STATION

WIRES TO PUSHBUTTON AND

COMMON TERMINALS (EITHER

WIRE TO EITHER TERMINAL)

6	Flip the trolley release lever to disconnect the trolley.
7	Rotate the curved door arm upward to meet the
	straight door arm connected to the trolley. Align the
	two door arms so that the holes in both arms overlap.

➤NOTE: The straight door arm should be slightly angled toward the operator head.

8Line up door arms until trolley is positioned as shown. Connect the arms together using two 5/16-18 x 1” bolts inserted in the highest and lowest matching holes, secure the bolts with two 5/16” keps nuts, tighten with a ½” socket.

CONNECTING THE DOOR ARM TO THE TROLLEY

TROLLEY

SLIDE IN THE

1-1/8" CLEVIS PIN

INSTALL THE

HITCH PIN

STRAIGHT DOOR ARM

CONNECTING THE DOOR ARMS

12"

(APPROXIMATELY)

LINE UP DOOR ARMS UNTIL

TROLLEY IS POSITIONED

AS SHOWN

	CONNECT ARMS WITH
	TWO 5/16-18 x 1" BOLTS
2" TO 4"	IN THE HIGHEST AND
	LOWEST MATCHING HOLES

4 If possible, install door operator 7 feet or more above the floor with the manual release handle mounted 6 feet above the floor. Instruct the end user on the operation of the manual release.

8 Install the Safety Beam

SAFETY BEAM BRACKET OPTIONS

10 Connect the Operator to Power Source

5 Do not connect the operator to the power source until instructed to do so.

6 Locate the wall station within sight of the door at a minimum height of 5 feet so that small children cannot reach it. Locate the wall station away from all moving parts of the door.

7 Residential Installations: Install the User Safety Label on the wall adjacent to the wall station. Commercial Installations: Install the Entrapment Warning Placard and Duty Rating Label in a prominent location visible in the area of the door.

8 Upon completion of the installation, the door must reverse when it comes in contact with a 1-1/2” high object (or a 2x4 laid flat at the center of the door) on the floor and when the infrared safety beam is blocked.

9 Do not wear watches, rings or loose clothing while installing or servicing an operator. Jewelry or loose clothing can be caught in the mechanism of the garage door or the operator.

10 DISCONNECT THE ELECTRIC POWER FROM THE GARAGE DOOR OPERATOR BEFORE MAKING ANY REPAIRS OR REMOVING THE COVER.

11 Commercial Installations: The rate of operation must not exceed 13 cycles of opening and closing per hour.

1 Check the Door Balance
		CHECKING THE DOOR BALANCE
1	From outside the garage, slowly open the door all the
	way, and then close it all the way. Notice if there is
	any binding, sticking or rubbing. The door should move
2	smoothly in both directions.
	Raise the garage door about halfway up. Carefully
	release the door and see if the door balances. It should
	stay in place. Close the door.		THE DOOR SHOULD
➤ IMPORTANT: If the garage door is unbalanced or			BALANCE WITHOUT
			GOING UP OR DOWN
	the door travel isn’t smooth, have a qualifi ed garage
	door professional adjust or repair the door.

6 Hang the Operator

Installation requirements vary with garage construction. Hanging brackets should be angled to provide rigid support. Hanging material is not provided. Angle iron and lag screws are recommended. DO NOT USE NAILS. Following are typical operator hanging methods. Certain installations will require improvised methods.

1 Raise the operator head and set it on top of a stepladder (use extra spacers on top of ladder if it isn’t tall enough).

2	Carefully open the door to the full up position. Lay a
	2x4 across the top section of the door as a spacer.
	Adjust the operator height until the rail touches the
	spacer. The rail should be close to level.
3	Center the operator head and rail with the centerline
	mark on the top of the door.
4	For fi nished ceilings only: An angle iron cross piece
	between the two closest joists above the operator will
	be required. Mark mounting hole locations, drill pilot
	holes and attach the piece with two lag screws (not
	supplied).
5	Measure the distance from each of the operator’s
	hanging tabs to the ceiling joists or angle iron cross piece.
6	Cut two angle iron pieces to the required lengths for
	hanging brackets. Bend brackets if required.
	• For unfi nished ceilings: Hold each bracket in place
	and use a pencil to mark the locations where they will
	be attached to the joists, drill pilot holes and attach the

PREPARING TO HANG THE OPERATOR

ADJUSTING OPERATOR HEIGHT

PLACE A 2x4 SPACER

BETWEEN THE DOOR AND RAIL

ADJUST HEIGHT

AS REQUIRED

WARNING

Persons, particularly children, could be killed by a closing garage door without a properly installed and adjusted safety beam optical obstacle sensing system.

➤NOTE: The safety beam’s infrared light beam must not be obstructed by the door, or by any part of the door hardware. Use wooden spacers between the beam brackets and wall if necessary to create proper clearance.

1Assemble the two safety beam brackets from the four L-shaped brackets using two ¼-20 x ¾” bolts and ¼-20 keps nuts (one nut & bolt for each bracket).

WARNING

To protect small children, do not install the safety beam higher or lower than instructed.

2Position the assembled brackets on each side of the door so the center line of the safety beam lenses will be 6” above the floor. Use the index marks on the brackets to make the bracket assemblies equal lengths. Mark the locations for the bracket mounting screws (the brackets can be wall or fl oor mounted).

➤NOTE: The safety beam receiver (the unit with two indicators) should be located on the “shady” side of the door to prevent sunlight from shining directly into the receiver’s lens.

ASSEMBLE BRACKETS
WITH 1/4-20 x 1/2" BOLTS
AND KEPS NUTS
	BRACKET
	INDEX
	MARKS
WALL MOUNTING	FLOOR MOUNTING

MARKING THE CORRECT BEAM BRACKET HEIGHT

LOCATE THE SAFETY BEAM

BRACKETS SO THE BEAM

CENTERLINE IS 6" ABOVE THE FLOOR

INSTALLING THE BEAMS

WARNING

To prevent electrocution or fire, installation and wiring must be in compliance with local electrical and building codes.

Cord and Outlet Connection

The operator should be connected to a grounded receptacle on the ceiling or near the operator head. If none is available which will accept the grounded operator plug, one should be installed by a qualifi ed electrician. Do not use an extension cord.

1Plug the operator into a grounded receptacle.

2When the operator is plugged in, a click should sound in the operator and the lights should turn on. If the lights do not turn on, check the power source and light bulbs.

Permanent Wiring

SOME LOCAL ELECTRICAL CODES REQUIRE PERMANENT WIRING BETWEEN THE OPERATOR AND THE POWER SOURCE THROUGH A CONDUIT. IT IS RECOMMENDED THAT YOU HAVE A LICENSED ELECTRICAL CONTRACTOR FOLLOW THESE STEPS ONLY IF PERMANENT WIRING IS REQUIRED.

1	BE SURE POWER CORD IS UNPLUGGED.
2	Cut the power cord about 2” above the strain relief
	bushing on the operator.
3	Remove the four side screws and bottom cover of
	operator.
4	Use pliers to remove the strain relief bushing and

WARNING

To reduce the risk of electric shock, this operator has a grounding pin. This plug will only fit into a grounding type outlet. If the plug doesn’t fit into the outlet, contact a qualified electrician to install the proper outlet. Do not change the plug in any way.

POWERING THE OPERATOR

CEILING

OUTLET

PLUG OPERATOR

INTO GROUNDED

OUTLET

FOR PERMANENT WIRING ONLY!

REMOVING THE POWER CORD

BE SURE THE POWER

2 Attach the Rail to the Operator

1 Place the operator head on the garage fl oor with cardboard underneath it to protect the fi nish.

2 Manually turn the sprocket two full turns counterclockwise to align the trolley approximately 12 inches from the pulley bracket (see figure).

3Align the rail over the center of the operator head.

4Be sure the fl at on the sprocket lines up with the fl at on the drive shaft.

5Slide the sprocket onto the shaft.

6Attach the rail to the operator head by installing four ¼-20 x ¾” bolts.

7Tighten the four bolts in the order shown with a 7/16” socket.

CAUTION

- BELT RAILS HBT7 ONLY! -

TURN THE OPERATOR’S OPEN LIMIT 8 TURNS IN THE DOWN DIRECTION BEFORE OPERATING UNIT.

ATTACHING THE RAIL

INSTALL FOUR 1/4-20 x 3/4"

RAIL-TO-HEAD BOLTS USING A 7/16" SOCKET (SEE TORQUE ORDER BELOW)

PULL THE CHAIN OR BELT

AWAY FROM THE RAIL TO

FIT THE SOCKET ON THE

FRONT BOLTS

HCI-12	NOTE: FOR A 14-FOOT RAIL
12-FOOT
I-RAIL	USE THE HCI+2 EXTENSION KIT

SET TROLLEY LOCATION

SET TROLLEY 12" FROM
PULLEY BRACKET	12"

ALIGNING THE RAIL

LINE UP THE RAIL OVER THE DRIVE SHAFT

ON TOP OF THE OPERATOR HEAD

CHAIN DRIVE

BELT DRIVE

BE SURE THE FLAT ON THE SPROCKET

LINES UP WITH THE FLAT ON THE DRIVE SHAFT

MATING THE SPROCKET AND SHAFT

SLIDE THE SPROCKET

INTO THE SHAFT

CHAIN DRIVE

TABS FIT INTO SLOTS

BELT DRIVE

TIGHTEN THE RAIL-TO-HEAD BOLTS IN THIS ORDER

3

1

2

4

pieces with two lag screws (not supplied).

• For fi nished ceilings with an angle iron cross piece:

Attach the two hanging brackets to the cross piece

with two bolts and two keps nuts (not supplied).

7 Attach operator to hanging brackets using two 5/16-18 x

1” hex bolts and two 5/16-18 keps nuts (supplied). Insert

bolts from the inside of hanger brackets with the nuts on

the outside of the operator. Tighten nuts with a ½” socket.

8 When using a 12-foot or longer I-rail, install the

center rail support bracket at the middle of the rail.

The bracket attaches with a strap (not included) to a

vertical support.

9 Tighten all hanging hardware.

10 Open and close the door manually. The door should

clear the rail by at least 1”.

11 Attach the trolley’s release lever to the red release

handle with the cord supplied so the handle is at least

6 feet from the fl oor. Cut off any excess cord.

12 Press the light cover release tabs in to open the

covers. Install two 100 watt maximum rough service

lamps. Swing the light covers closed, snapping them

shut.

MAXIMUM DOOR AREA (IN SQUARE FEET)

STANDARD SECTIONAL DOORS

DOOR	DOOR CONSTRUCTION
SIZE	Insulated	Non-insulated	Other
(SQ. FT.)
	Steel	Steel	Construction
250			Fiberglass
210		24 Gauge	Aluminum
		22 Gauge
180	24 Gauge	20 Gauge	Wood
120	20 Gauge	16 Gauge
80	16 Gauge

NOTE: On steel insulated doors, a 24 gauge back panel is assumed.

HANGING BRACKET OPTIONS

TYPICAL HANGING BRACKETS

SCREWED DIRECTLY TO JOISTS

TYPICAL HANGING BRACKET

ASSEMBLY USING A CROSSPIECE

HANGING THE OPERATOR

HANG THE OPERATOR

WITH TWO 5/16-18 x 1"

BOLTS AND NUTS

LIGHT COVER

RELEASE TAB

CENTER SUPPORT BRACKET

ATTACH THE SUPPORT	CONNECT SUPPORT
	BRACKET TO A
BRACKET AT THE CENTER
	HANGER STRAP
OF THE RAIL

NOTE: INSTALL

ON 12-FOOT OR

LONGER I-RAILS

3Drill two 3/16” pilot holes for lag screws at marks. Mount the brackets with two ¼” x 1-1/4” lag screws and tighten with a 7/16” socket (or use proper concrete fasteners if fl oor mounting).

4Insert the sender and receiver into the bracket holes so the lenses of the units will face each other. Twist the units until the spring clips lock into a detent mark on the brackets. To protect the units from being bumped after installation, it is recommended to mount the sender and receiver inside the brackets as shown.

5Install the two safety beam protective covers over the beam units to protect them from damage.

➤IMPORTANT: Be careful to route the safety beam wiring away from any moving parts of the door or operator.

6 For non-prewired installations, route the wires from the sender and receiver, up the wall above the door hardware, then over to the center of the door, then along the top of the rail (or ceiling), and back to the operator head. Cut the wires about 6” longer than needed to reach the operator terminals. Strip back ½” of insulation from the ends of the wires.

7 For non-prewired installations, secure all the wires to the wall and ceiling with insulated staples (not supplied). Staples must straddle both wires to prevent shorts. Secure the wire to the top of the rail with wire clips (supplied).

8At the operator, twist one wire from each pair together, then twist the other wire from each pair together.

9Attach either twisted connection to the operator’s BEAM terminal. Connect the other twisted connection to the operator’s COMMON terminal.

INSERT UNIT	TWIST UNIT TO
	LOCK INTO BRACKET
INTO BRACKET
PRE-ADJUSTING THE BEAMS
ADJUST UNITS SO
LENSES POINT
TOWARD EACH
OTHER
SPRING CLIP LATCHES
INTO DETENT MARKS
TO HOLD UNIT'S POSITION
INSTALLING THE BEAM COVERS
COVER SNAPS
ONTO BRACKET
WITH FOUR TABS

THE PROTECTIVE

COVER CAN ATTACH

TO EITHER SIDE

OF THE BRACKET

CONNECTING THE BEAM WIRES

WALLBEAM

STATION WIRES

WIRES

CONNECT THE SAFETY BEAM

WIRES TO COMMON AND

BEAM TERMINALS (EITHER

WIRE TO EITHER TERMINAL)

	discard the bushing.
5	Remove the outer insulation from the power cord and
	strip the white, black, and green wire insulation back
	about ½”.
6	Pull white (neutral), black (hot) and green (ground)
	wires through conduit.
7	Connect the conduit to the operator with the appropriate
	termination.
8	Use wire nuts (not supplied) to connect the wires to the
	matching color wires inside operator head.
9	Secure the wires away from all moving parts with a
	zip-tie as shown in the fi gure.
10 Replace the operator cover and the four side screws.
11 Connect the conduit wires to the power source at
	junction box.
12 When power is applied to the operator, a click should
	sound and the lights should turn on. If the lights do
	not turn on, check the power source, wiring, and light
	bulbs.

CORD IS UNPLUGGED!!

CUT THE CORD ABOUT 2" ABOVE THE STRAIN RELIEF BUSHING

FOR PERMANENT WIRING ONLY!

REMOVING THE BUSHING

REMOVE STRAIN

RELIEF BUSHING

WITH PLIERS

FOR PERMANENT WIRING ONLY!

HARDWIRING THE OPERATOR	CONDUIT
	WIRE
	NUTS
CONNECT CONDUIT
WIRING TO OPERATOR
WIRING WITH
WIRE NUTS

GREEN - GROUND

WHITE - NEUTRAL

BLACK - HOT