Audi Aud S Users Manual 190 113269B Aug 2007

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INSTALLATION AND
OWNER’S MANUAL

AUD-S
AU SERIES WITH SOLID STATE CONTROL CIRCUITRY
DRAWBAR COMMERCIAL VEHICULAR DOOR
OPERATORS

107093

Serial #:
Date Installed:
As of date of manufacture,
meets all ANSI/UL 325
Safety Requirements for
Vehicular door operators

Your Dealer:

READ THIS MANUAL
CAREFULLY BEFORE
INSTALLATION OR USE
SAVE THESE INSTRUCTIONS !

2

TABLE OF CONTENTS
Description ...........................................................................................................Page
Model AUD-S Drawbar Operator Features................................................................ 3
Model AUD-S Applications ........................................................................................ 3
Preparation ................................................................................................................. 4
Figure 1 - Component Identification Pictorial (Unpacking)..................................... 4
Important Installation Warnings (Things To Do Before & During Installation) ...... 5
Table 1 - Component Identification Listing .............................................................. 5
Rail/Chain Assembly Instructions ............................................................................ 6
Installation Instructions........................................................................................ 7-12
Electrical Wiring Instructions.................................................................................. 10
Pneumatic Door Edge Installation .......................................................................... 11
Field Wiring ......................................................................................................11 & 12
Turning on Power to the Operator .......................................................................... 12
Operation and Adjustment Instructions ............................................................ 13-19
Important Safety Instructions for Owner................................................................ 13
Setting the Switch Selectable Operating Modes.................................................... 14
Set-Up Operating Characteristics Instructions`..................................................... 15
Brake Adjustment .................................................................................................... 16
Setting The Limits .................................................................................................... 17
Clutch Adjustment ................................................................................................... 18
Testing ...................................................................................................................... 19
Maintenance ............................................................................................................ 19
Wiring Diagrams/Schematics (Single & Three Phase) ..................................20 & 21
Operator Dimensions............................................................................................... 22
Parts Identification................................................................................................... 23
Operator Specifications........................................................................................... 24
Warranty ................................................................................................................... 24

READ THESE STATEMENTS CAREFULLY AND FOLLOW THE
INSTRUCTIONS CLOSELY.
The Warning and Caution boxes throughout this manual are there to protect you and
your equipment. Pay close attention to these boxes as you follow the manual.

WARNING

CAUTION

WARNING

CAUTION

Indicates a MECHANICAL
hazard of INJURY OR
DEATH. Gives instructions
to avoid the hazard.

Indicates a MECHANICAL hazard
of DAMAGE to your operator or
equipment. Gives instructions to
avoid the hazard.

Indicates an ELECTRICAL
hazard of INJURY OR
DEATH. Gives instructions
to avoid the hazard.

Indicates an ELECTRICAL hazard
of DAMAGE to your operator or
equipment. Gives instructions to
avoid the hazard.

PRODUCT FEATURES
The purpose of this booklet is to provide assembly,
installation and operation information concerning the
Model AUD-S Commercial Vehicular Garage Door
Operators and related Accessory Products.
NOTICE
IT IS IMPORTANT THAT THIS INSTRUCTION
MANUAL BE READ AND UNDERSTOOD
COMPLETELY BEFORE INSTALLATION OR
OPERATION IS ATTEMPTED. IT IS INTENDED
THAT THE INSTALLATION OF THIS UNIT WILL BE
DONE ONLY BY PERSONS TRAINED AND
QUALIFIED IN THE INSTALLATION, ADJUSTMENT
AND SERVICE OF COMMERCIAL OVERHEAD
DOORS AND DOOR OPERATORS AND BY
QUALIFIED ELECTRICIANS.
NOTICE
THE IMPORTANT SAFEGUARDS AND
INSTRUCTIONS IN THIS MANUAL CANNOT COVER
ALL POSSIBLE CONDITIONS AND SITUATIONS
WHICH MAY OCCUR DURING ITS USE. IT MUST
BE UNDERSTOOD THAT COMMON SENSE AND
CAUTION MUST BE EXERCISED BY THE PERSON
(S) INSTAL- LING, MAINTAINING AND OPERATING
THE EQUIPMENT DESCRIBED HEREIN. DO NOT
USE THIS EQUIPMENT FOR ANY OTHER THAN ITS
INTENDED PURPOSE - OPERATING OVERHEAD
COMMERCIAL VEHICULAR GARAGE DOORS.
STANDARD FEATURES:
Solid State Controls: The openers employ solid state
technology with advanced standard features to provide
for a complete commercial door operating system.
Switch Selectable Operating Modes: Six distinct base
operation modes can be selected by resetting the switches
on the motor control board: a standard Open, Close, Stop
(B2, momentary button push); three constant pressure
modes (C2, D1, and E2); two Timer to Close modes (T
and TS). See page 14 for complete description of the
modes.
Switch Selectable Characteristic Modes: Five different
operating characteristics can be activated and/or modified
through the switches on the motor control board: Delay
On Reverse, Close Limit Delay, Mid Stop Travel, Timer
to Close, Maximum Run Timer.
Limit Switches: Driven limit switches, easily adjusted
over a wide range. The motor may be removed without
affecting the limit switch adjustments
Manual Release: Permits manual operation of the door
in the event of a power failure.
Control Circuit: Standard three button open, close and
stop. 5 Volts DC.
Connections For Auxiliary Entrapment Protection
Devices: Use with foam or pneumatic reversing door
edge components or a photoelectric beam (across the
opening).

3

MODEL AUD-S OPERATOR APPLICATIONS:
Drawbar operators are for commercial and industrial
use on sectional overhead doors which use horizontal
track with normal radius. A draw bar operator is not
suitable for doors with high lift exceeding 24 inches or
vertical lift doors. The installation requires a minimum
clearance of 5 inches above the high arc of the door
(the highest point reached by the door at any part of its
travel). For back-room requirement refer to Figure 24,
Page 22. When properly installed a drawbar operator
effectively locks the door in the closed position.
The Model AUD drawbar operators are used in the
following applications:
-Continuous Duty, Medium Cycle Commercial
installations only
-Indoor Use Only
-Up to 22 foot high doors with a maximum area of
480 square feet for 3/4 HP, 280 square feet for 1/2
HP and 200 square feet for 1/3 HP - maximum area
slightly higher for lighter doors - consult factory
-Use with foam or pneumatic reversing edge door
components - REQUIRED where the 3 button
station is out of sight of the door or any other
automatic, remote or manual control is used to
activate the door.

OPTIONAL FEATURES:
Digital Radio Controls: Open, Close and Stop
operation. Radio units are available to control up to 27
doors from one transmitter
Keyless Entry System: Connection terminals provided
for hard wired or wireless keyless entry system.
Brake: Optional on 1/3 & 1/2HP, Standard on 3/4 HP.
Can be added in the field.

4

PREPARATION

WARNING
ELECTRIC DOOR OPENERS ARE DESIGNED
FOR DOORS IN GOOD WORKING CONDITION,
PROPERLY COUNTERBALANCED AND
PROPERLY ADJUSTED IN ACCORDANCE WITH
THE DOOR MANUFACTURER'S INSTALLATION
INSTRUCTIONS.
Before starting the installation of the operator, the door must be in
good working condition and properly counterbalanced. Inspect the
door and track for loose or missing hardware. Test the door
manually for balance and ease of operation. Lubricate door hinges
and rollers. If necessary, adjust the springs for proper
counterbalance of the door.
Before removing the operator powerhead from the shipping carton,
inspect the nameplate on the cover of the operator control box to
verify that it is the correct model for the intended application and
that the voltage and phase are in accordance with electrical power
provided at the job site.

The rails and drawbar chain/hardware package are shipped
separately from the powerhead. Warning: Rope off the area
to keep personnel and vehicles clear of the door and floor
space in the vicinity of the operator during the
installation.

WARNING
SPRINGS ARE SUBJECT TO VERY
HIGH FORCES AT ALL TIMES AND
ADJUSTMENTS MUST BE MADE ONLY
BY A QUALIFIED PROFESSIONAL
DOOR INSTALLER.

WARNING
REMOVE OR DISABLE ANY LOCKING
DEVICES FROM DOOR AND REMOVE
ALL ROPES

COMPONENT IDENTIFICATION PICTORIAL
107100

Figure 1

IMPORTANT INSTALLATION WARNINGS

WARNING

5

TO REDUCE THE RISK OF SEVERE INJURY
OR DEATH: READ AND FOLLOW ALL
INSTALLATION INSTRUCTIONS!

Install only on a properly balanced garage
door. An improperly balanced door could cause
severe injury. Have a qualified service person
make repairs to cables, spring assemblies and
other hardware before installing the opener.
• Remove all ropes and remove or make
inoperative all locks (unless mechanically and/or
electrically interlocked to the power unit) that are
connected to the garage door before installing the
opener.
• Lightweight doors (fiberglass, aluminum etc.)
must be reinforced to avoid door damage. Check
the door manufacturer’s instruction manual for a
bracing procedure or the availability or a
Reinforcement Kit. See Page 9.
• Model AUD-S is a Commercial Vehicular
Door Operator and as such IS NOT recommended
for pedestrian traffic. In installations where it is
known that pedestrians will be nearby ensure a
pedestrian door is available for entrance and exit
to the building. In addition YOU MUST install an
auxiliary entrapment protection device (reversing
door edge or photoelectric beam device).
• Connect an auxiliary entrapment protection
device (reversing edge or photoelectric device
across the door opening). a device of this type is
•

STRONGLY ADVISED FOR ALL commercial
operator installations. An auxiliary entrapment
protection device is REQUIRED when the three
button control station is out of sight of the door
or any other automatic or manual control is
used.
• Install the opener at least 8 feet or more
above the floor.
• Do not connect the opener to the source of
power until instructed to do so.
•
Locate the control station:
a) within sight of the door and;
b) at a minimum height of five feet above
the floor and;
c) away from all moving parts of the door.
• Do not overtighten the clutch adjustment to
compensate for a poorly working door.
• Securely attach any WARNING signs or
placards to either the door or above the control
station as directed.
• After installing the opener, all safety features
must be tested for proper operation (see page
19).

COMPONENT IDENTIFICATION LISTING
ITEM #
1
2
7
8
9
10
11
12
13
14
15
16
17

PART#

006031
101315
107049
006034
006049
106265
006084
006031
100512

—— AR - As Required

DESCRIPTION
Operator Power Head
Track Rails
3/8-16 Keps Hex Nut
3/8 - 16 X 6-1/2 Hex Head Blot
Track Bracket
1/2 - 15 Hex Nut
1/2 Split Lockwasher
Front Idler Assembly
Chain For Track Rail
3 Piece Chain Connecting Link
Chain Tension Adjustment Bolt
3/8 - 16 Keps Hex Nut
Track Trolley

QUAN. ITEM #
1
2
6
1
AR
2
2
1
1
1
1
2
1

18
19
20
21
22
23
26
16
27
28
29
25
4
5
6

PART#

DESCRIPTION

005031
100513
100236
100235
100108
100469

3 Button Station
Release Door Arm
Extension Door Arm
Curved Door Arm
Door Bracket
Hardware Pkg Com. Door Arm
3/8 - 16 X 2-1/2 Carriage Bolt
3/8 - 16 X 1 Hex Head Bolt
3/8 Nylon Insert Locknut
5/16 - 18 X 1-1/4 Hex Head Bolt
5/16 - 18 Keps Hex Nuts
Hardware Pkg Com. Track Assy
3/8 - 16 Hex Nut
3/8 Split Lockwasher
3/8 - 16 X 1-1/2 Hex Head Bolt

100468

QUAN
1
1
2
1
1
1
2
1
1
4
4
1
AR
AR
AR

6

RAIL/CHAIN ASSEMBLY INSTRUCTIONS

RAIL/CHAIN ASSEMBLY
Refer to Figure 1 parts illustrations. The part names and item numbers are
referenced identically to the part names and numbers in the assembly procedures
that follow. Before starting assembly of the operator track check for the
proper length. The tracks are supplied for 8 Foot, 10/12/14 Foot,
16/18 Foot and 20/22 Foot high doors. The tracks should be
107068
three (3) feet longer than the door height. If the tracks
supplied with the operator are longer than the door
height plus 3 feet, it will be necessary to cut off two
feet (or 4 feet for 10 Foot rail) from the power head
mounting end as shown in Figure 2.
CAUTION: WHEN NECESSARY TO
CUT THE TRACK ENSURE THE
ENDS ARE LINED UP AS IN
FIGURE 2.
1) Assemble the
operator track by
assembling the items
as shown in Figure 2.

48” FOR 10FT RAIL

Figure 2

2) After the track is assembled, position track assembly onto
the operator power head and attach with four 3/8”-16 x 1” bolts,
lock washers and nuts (supplied in a separate hardware package
#100470).

3) Referring to Figure 1 , 2 and 3 (below) , slide the trolley
onto the track with the chain take up bolt lug (C) toward the
power head. Thread one 3/8-16 keps nut (attached star washer)
onto the Chain take up bolt with the keps part (attached star
washer) away from the chain attachment end. Insert the chain
take up bolt threaded end through the lug hole on the trolley (C)
just far enough to start a second 3/8-16 keps nut. Attach one end
of the chain to the opposite end of the threaded stud using a 3piece chain link (provided). See Figure 3.

NOTE: To keep #41 chain (used
on 1/2 and 3/4 H.P. operators) centered
on the threaded stud, place a .065" thick flat
washer (provided) on each side of the flat, as
indicated by the arrows in Figure 4, when installing
the connecting link. One-third horsepower operators use the
narrower #65 chain and the use of the spacers is not required.
Install chain around drive sprocket at operator head then around
idler at front end of rail and thread through opening at front end
of carrier. If the rail is equipped with a chain guide-spacer near
its center (12 foot rail or longer only) pass the chain over it in one
direction and under it in the other direction to separate the two
lengths of chain. Apply initial tension by pushing forward on the
carrier while pulling chain tight through opening in the carrier in
the direction of D. When maximum tension has been applied by
this means, swing chain forward and insert retaining plate, E, in
place. Insert 1/4-20 x 5/8 hex head machine screw through
retaining plate, E, and tighten plate in place. Make final
adjustment of chain tension to remove excess sag by adjusting
nuts on threaded rod at chain lug, C.

100461

Figure 4

Figure 3

7

INSTALLATION INSTRUCTIONS

CAUTION

CAUTION

TO AVOID DAMAGE TO DOOR AND OPERATOR
ENSURE ALL DOOR LOCKS ARE DISABLED.
USE AN INTERLOCK SWITCH IF A LOCK IS
REQUIRED TO RETAIN FUNCTIONALITY.
1) Locate the center of the door and mark a line on the wall
directly above the door. Extend this line approximately 20” up
the wall. See Figure 5.

A MINIMUM OF TWO PERSONS ARE
REQUIRED FOR OPERATOR
INSTALLATION.
ENSURE A SAFE RIGID WORKING
PLATFORM IS AVAILABLE.
3) Using the projected lines for location, mount a suitable
wood block or angle iron, depending on the structure of the
building, to the wall above the door opening as shown in Figure
7. Ensure the block or angle iron used will provide a sound and
secure mounting pad for the operator rail front mounting bracket,
see CAUTION warning below.
107096

107094

Figure 5
2) Slowly raise the garage door and observe the action of the
top section. When the top section reaches the highest point
(high arc), use a level and project a line from this point to the
center of the door. See Figure 6.

Figure 7

CAUTION

107095

Figure 6

THE FRONT MOUNTING SURFACE FOR THE
OPERATOR MUST BE SOUND AND SECURE.
IF NECESSARY PROVIDE REINFORCEMENT
IN THIS AREA BEFORE MOUNTING THE
OPERATOR RAIL FRONT MOUNTING
BRACKET.

8

INSTALLATION INSTRUCTIONS

4) Mount the front mounting bracket (Item 9) to the mounting
pad as shown in Figure 8. The location of the door’s torsion
shaft may prevent you from placing the mounting pad in the
location shown. Mount the pad as close as possible to three (3)
inches above the door’s high arc point.

6) Swing the operator to a horizontal position above the door
guide rails (high enough to raise the door) and temporarily
secure by suspending from the ceiling with a suitable rope or
chain or support from the floor to the operator. Now open the
garage door slowly, being careful not to dislodge the temporary
support. Lower the operator until it is level. Make sure the
operator is aligned with the center of the door and the bottom of
the rail is at least 2” above the high arc of the door. See Figure
10.

WARNING
FAILURE TO SUSPEND THE OPERATOR
SECURELY MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.

107051

107052

Figure 8

Figure 10

5) With the door in the down position, loosely attach the rail
support to the mounting bracket using two (2) bolts, lockwashers
and nuts (Items 4, 5, 6). See Figure 9.

7) Tighten securely the two (2) bolts, nuts and washers that
were loosely attached in Step 5. See Figure 11.

107054

107053

Figure 9

WARNING

Figure 11

SPRINGS, PULLEYS, CABLES AND MOUNTING HARDWARE USED TO
BALANCE YOUR GARAGE DOOR ARE UNDER EXTREME TENSION AT
ALL TIMES AND CAN CAUSE SEVERE INJURY OR DEATH IF DISTURBED.
DO NOT ATTEMPT ADJUSTMENT.

9

INSTALLATION INSTRUCTIONS
8) Figure 12 details a typical method of hanging the operator
from the ceiling. Each installation will vary due to the
difference in building structures; but in all installations side
braces should be used to further strengthen the installation. If
the operator track (rail) is longer than 15 feet a mid support is
recommended.

107142

107141

Figure 12

Figure 13

9) Fully close the door and move the trolley to within 2
inches of the idler sprocket. Using Figure 13 as a guide,
connect the release arm (Item 19) to the trolley. Connect the
two extension arms (Item 20) and the door curved arm (Item 21)
to the door release arm with 5/16 inch bolts and keps nuts
(Items 28 & 29).

107143

10) Refer to Figure 14. Attach the door bracket (Item 22) to
the curved arm using a 3/8 bolt and locknut (Items 16 & 27).
Tighten the bolt until snug then back off 1/4 to 1/2 turns so as to
allow the arm to pivot on the bolt freely. Position the door
bracket to the scribed center line on the door. Use suitable
hardware to attach the door bracket to the door.

IMPORTANT
TO AVOID DAMAGE TO THE DOOR TOP
SECTION REINFORCE THE CENTER STILE
WITH A VERTICAL BRACE. ADDITIONAL
BRACING/REINFORCEMENT MAY BE
REQUIRED WHEN THE DOOR IS
CONTROLLED BY AN AUTOMATIC DOOR
OPERATOR; CONSULT THE DOOR
MANUFACTURER FOR INSTRUCTIONS.

Figure 14
NOTE
BEFORE PROCEEDING RECHECK ALL
BOLTS, NUTS AND LAG SCREWS AND
ENSURE THEY ARE TIGHT.

10

ELECTRICAL WIRING INSTRUCTIONS

WARNING
TO PREVENT THE RISK OF PERSONAL INJURY
OR DEATH :
• DISCONNECT POWER AT THE FUSE BOX
BEFORE PROCEEDING.
• ELECTRICAL CONNECTIONS MUST BE MADE
BY A QUALIFIED INDIVIDUAL.
• OBSERVE LOCAL ELECTRICAL CODES WHEN
WIRING THE OPERATOR.

WARNING: The AUD-S Series operators have been designed
and constructed for use with voltages from 115 Volts AC to
480 Volts AC, in single or three phase. Check the operator
nameplate label on the control box cover for the proper
voltage and phase. The application of an improper input
voltage or phase will result in catastrophic failure to the
internal electrical components.
Observe local electrical codes when wiring the operator.
When hard wiring, observe state and local electrical codes. A
wiring diagram is attached to the inside of the control box cover.
Connect the appropriate voltage and phase power leads to the
appropriate terminals as per the wiring diagram and connect a
ground wire to the grounding screw. On three phase units,
incorrect phasing of the power supply will cause the motor to
rotate in the wrong direction (open when CLOSE button is pushed
and vice versa). To correct this, interchange any two of the
incoming three phase conductors.
The wiring diagram attached inside the cover of the control box
details all of the field wiring terminal connections for the operator.
Always connect the wires to the push-button controls and auxiliary
devices exactly as shown.
Warning: Control voltage of the opener is 5 volts DC, Class 2.
Do not run the power leads and control circuit wiring in the same
electrical conduit.

WARNING
TO PREVENT THE RISK OF PERSONAL
INJURY AND/OR DAMAGE TO DOOR OR
PROPERTY, ONLY OPERATE DOOR
CONTROL WHEN DOOR IS IN CLEAR VIEW.
IF CONTROL STATION CANNOT BE
LOCATED WHERE THE DOOR IS VISIBLE
OR IF ANY OTHER DEVICE IS USED TO
CONTROL THE DOOR AN AUXILIARY
ENTRAPMENT DEVISE (DOOR EDGE OR
PHOTOELECTRIC) MUST BE CONNECTED.

WARNING
RISK OF ENTRAPMENT THAT MAY
RESULT IN SERIOUS PERSONAL INJURY
OR DEATH. DISCONNECT POWER TO
THE OPENER BEFORE AND DURING
INSTALLATION OF AN ACCESSORY
REVERSING DOOR EDGE OR
PHOTOELECTRIC DEVICE. DO NOT
RECONNECT POWER TO OPENER UNTIL
INSTRUCTED TO DO SO. ENSURE
DOORWAY IS CLEAR BEFORE STARTING
TESTING OF UNIT.
Note: AUD-S Series model openers are pre-wired for door
reversing edge components. To comply with code requirements,
the door reversing edge components must be installed and wired
to the opener. Refer to Figure 15 Door Edge component
installation and Figure 16 for Door Edge and photoelectric
device wiring.
If a Safe-Finish™ or Access Alliance Safe-Finish II™ photobeam is connected and the photo-beam detects an obstruction or
becomes inactive, an opening door continues to open and a
closing door stops, pauses and starts open. While in this mode,
if a problem is detected while the opener is stopped, a close
action will require constant activation of the push button. If the
photo-beam is attached and is properly working for 1 second, it
will be auto detected and the monitored function will be
turned on. Once the monitoring function is active, it will remain
active even if the power is removed and the photo-beam is
disconnected and power is restored. While in this mode, if a
problem is detected while the opener is stopped, a close will
require constant activation.
Openers which are equipped with a reversing edge circuit may
have one or more additional means of control which should be
wired in accordance with the diagram supplied in the opener
and also illustrated on Pages 20 & 21. To add a second three
button station, refer to Figure 18.
Number 22 gauge wire or heavier must be used for wiring
the control stations and auxiliary control devices to the
operator. Smaller gauge wire will cause operational
problems, especially when multiple push-button stations are
used or during summer months.

CAUTION
TO AVOID DAMAGE TO DOOR AND OPERATOR
ENSURE ALL DOOR LOCKS ARE DISABLED.
USE AN INTERLOCK SWITCH IF A LOCK IS
REQUIRED TO RETAIN FUNCTIONALITY.

PNEUMATIC DOOR EDGE INSTALLATION - FIELD WIRING

11

CLOSE

STOP

COM

OPEN

NO REV

Figure 15

TB1

OPEN

CLOSE

STOP

NC REV

PHOTO

COM

SINGLE

ILOCK

24 VAC

Figure 16

COM

MOTOR
CONTROL
BOARD

Door Edge and Photoelectric Wiring
See text on page 10 for operation when Safe-Finish™ or Access
Alliance Safe-Finish II™ photo-beams are connected.

SAFE FINISH PHOTOBEAM

3-WIRE PHOTOBEAM

Note: When adding a
photocell device with a
Normally Closed output
remove the factory installed
jumper from the connection
terminals.

12

3/SINGLE BUTTON STATION / INTERLOCK FIELD WIRING

D12

OPEN

CLOSE

C3
C11

C9

D8

R38

STOP

R87

RADIO
24V
COM
RM3
RM2
RM1
VCC
P7
R54

R30

PB3

MOTOR
CONTROL
BOARD
R29

PB2

D2

C24

R26

PB1

C10

R57

R25

U4

C25

U1

R3

C1

R2

R65

PCB 112695 REV B TSLK

R84
U5

R5

D3

MOTOR
CONTROL
BOARD

R55
R56

C8

R94
R95

C1

PB2

PB3

CLOSE

STOP

STOP

CLOSE

COM

NC REV

OPEN

NO REV

OPEN

CLOSE

STOP

D12

COM

NO REV

NC REV

PHOTO

PB1

OPEN

R3
C25

PCB 112695 REV B TSLK

R2

Figure 17

Single 3 Button Station

c.p. ALLSTAR CORP

R93

D1

Figure 18

U5

R4

R8

Figure 19

C21

P5

R24

TB1

EXTERNAL INTERLOCK

PHOTO

COM

SINGLE

ILOCK

24 VAC

Single Button and External Interlock Wiring

COM

MOTOR
CONTROL
BOARD

CDOMCB 2005

Multiple 3 Button Station

Note: When adding an External Interlock
remove the factory installed jumper from
the connection terminals.

TURNING ON THE POWER TO THE OPERATOR
NOTE: It is now necessary to turn on the power in order to change the Operating Mode (if
applicable), program any changes desired to the operator’s other settings, check for proper
performance of all the operator’s features to include the brake (if applicable) and clutch
(adjusting settings if necessary); and to set and finalize any adjustments to the limit settings.
Before doing so, ensure that all mounting hardware are installed and properly tightened, that all
electrical connections are per local code requirements, and that proper wiring practices have been
followed. Also, double-check that all ropes have been removed from the door and that the
doorway is clear.

OPERATION AND ADJUSTMENT INSTRUCTIONS

13

IMPORTANT SAFETY INSTRUCTIONS FOR OWNER

WARNING

TO REDUCE THE RISK OF SEVERE INJURY OR
DEATH: READ AND FOLLOW ALL INSTRUCTIONS!

• Understand all of the operating features of your door control system at the

time of its installation. Your installing dealer will demonstrate them for you.
• NEVER let children operate or play with door controls. Keep the Remote
Control away from children.
• ALWAYS keep a moving door in sight and keep people and objects away from
the door area until the door is completely closed. NO ONE SHOULD CROSS
THE PATH OF A MOVING DOOR.
• TEST THE DOOR OPENER’S REVERSING FEATURE (where applicable)
MONTHLY. The door MUST reverse upon contact with a 4” high object on the
floor. After adjusting the force setting (clutch) or the limit of travel, ALWAYS
RETEST the Opener. Failure to ADJUST THE OPENER PROPERLY may result
in SERIOUS INJURY OR DEATH.
• If possible, USE THE MANUAL RELEASE only when the door is closed. Use
caution when using the Release with the door open. WEAK OR BROKEN
SPRINGS MAY ALLOW THE DOOR TO CLOSE RAPIDLY, CAUSING SEVERE
INJURY OR DEATH.
• KEEP THE GARAGE DOOR PROPERLY BALANCED. See the door owner's
manual. An improperly balanced door MAY CAUSE SEVERE INJURY OR
DEATH. Have a QUALIFIED SERVICE PERSON MAKE REPAIRS TO CABLES,
SPRING ASSEMBLIES AND OTHER HARDWARE. SAVE THIS INSTRUCTION
MANUAL FOR END USER
• Inspect and maintain your door system as described in this manual.

WARNING
AVOID ELECTROCUTION:
DO NOT ROUTE LOW VOLTAGE WIRES IN
SAME CONDUIT AS HIGH VOLTAGE
WIRES. FOLLOW ALL LOCAL
ELECTRICAL CODES OR THE NATIONAL
ELECTRICAL CODE.

WARNING
FAILURE TO TEST REVERSING
SYSTEM COULD RESULT IN DEATH
OR SERIOUS INJURY. TEST THIS
SYSTEM ONCE A MONTH.

14

OPERATION AND ADJUSTMENT INSTRUCTIONS
SETTING THE SWITCH SELECTABLE OPERATING MODES
Settable
Switches
Location

B2 Operation
Open Button: Momentary activation; open override of closing
door.
Close Button: Momentary activation.
Stop Button: Momentary activation; stops open, close or reverse
action.
Single Button: Momentary activation to open; open override of
closing door, closes door from mid-stop or open limit.
Reverse: Momentary activation will reverse a closing door,
reverse to full open (ignores mid-stop) unless stopped by stop
pushbutton input.
Mid-Stop: Activation stops an opening door; momentary contact
of open button at mid stop will restart door to full open position;
if door is moving open, constant pressure on open button will
bypass mid-stop.
Auto Close Timer: N/A.
D1 Operation
Open Button: Constant activation; open override of closing
door.
Close Button: Constant activation, door will stop when button is
released.
Stop Button: Momentary activation; stops open, close or reverse
action (not required).
Single Button: N/A.
Reverse: Momentary activation will stop a closing door.

K5

HIGH VOLTAGE

K3

K4

K2

COM

OLS

TR3

MO4

CLS

K6

COM

P1

STATUS

POWER

SW1

MO3
MO2
R49

R89
TR1

24V
COM

R34 LD3

S4
S3
S2
S1

LD4

R62

R22

R33

R47

C16

R23

R27
R28

OFF
R61

C6

R9

R19

R20

R82

R60

R17

R18

D3

R5

R13

R14

R65

R1

R21

C10

C9

RM2
RM1
VCC

C30

P7
R12

R87

R16

R94

R6

R7

R95

R90

R84

R2

R93

D1

R3

U5

C25

R4

R8

R54
R30

R11
R15

PB1

PB2

C1

C21
R24

PB3

D12

CLOSE

STOP

COM

OPEN

R5

NO REV

P5

R60

C7

R38

R55
R56

C8

C12

C2

R29

R58

P6

R85

R26

S1

24V

U4

COM

Q1

R61

24V

RM3

U1

R83

RADIO
COM

FRA

OFF

R45
R57

C24
D8

R31

R46

R25

EDGE
VCC

R53

R83

R51

D2

R52
TR4

OPEN

CLOSE

STOP

NC REV

COM

Figure 20

PHOTO

COM

TB1

ILOCK

R28

LD2

R10

PCB 112695 REV B TSLK

C14

SINGLE

LD4

S4
S3
S2
S1

R48
TR2

CDOMCB 2005
c.p. ALLSTAR CORP.

3

SW1

C13

P3

RO1

US

P2

C3

ILK

C11

MO1

R27

C2 Operation (Factory default)
Open Button: Momentary activation; open override of closing
door.
Close Button: Constant activation, door will stop when butto full
open (ignores mid-stop) unless stopped by stop pushbutton
input.
Mid-Stop: Activation stops an opening door; momentary contact
of open button at mid stop will restart door to full open position;
if door is moving open, constant pressure on open button will
bypass mid-stop.n is released.
Stop Button: Momentary activation; stops open, close or reverse
action.
Single Button: Momentary activation to open; open override of
closing door.
Reverse: Momentary activation will reverse a closing door,
reverse to
Auto Close Timer: N/A.

P4

24 VAC

Changing the Switch Selectable Operation Modes
The following modes are selected by setting the on-board dip
switches, Figure 20 at right shows where the switches are
located on the operator control board. For each Operational
Mode, the switches are set to either ON or OFF according to the
table at right below. For all the modes, if a reversing device is
attached, it will function as noted. If a monitored reversing
device has been recognized and becomes inactive then the mode
will default to constant pressure activation for close regardless
of the dip switch setting. The switches must be set to one of the
six Operational Mode combinations for the operator to function.

MOTOR CONTROL BOARD

Operating
Mode

Switch Switch Switch Switch
1
2
3
4

C2 Operation

OFF

OFF

OFF

OFF

B2 Operation

ON

OFF

OFF

OFF

D1 Operation

OFF

ON

OFF

OFF

E2 Operation

ON

ON

OFF

OFF

TS Operation

OFF

OFF

ON

OFF

T Operation

ON

OFF

ON

OFF

Mid-Stop: Activation stops an opening door; after the door stops
at the mid stop, constant contact of open button at mid stop will
restart door to full open position.
Auto Close Timer: N/A.
E2 Operation (roll-back)
Open Button: Momentary activation; open override of closing
door.
Close Button: Constant activation, door will reverse to full open
(ignores mid-stop) when button is released.
Stop Button: Momentary activation; stops open, close or reverse
action.
Single Button: N/A.
Reverse: Momentary activation to reverse a closing door,
reverse to full open (ignores mid-stop) unless stopped by stop
pushbutton input.
Mid-Stop: Activation stops an opening door; momentary contact
of open button at mid stop will restart door to full open position;
if door is moving open, constant pressure on open button will
bypass mid-stop.
Auto Close Timer: N/A

15

OPERATION AND ADJUSTMENT INSTRUCTIONS
TS Operation
Open Button: Momentary activation; open override of closing
door.
Close Button: Momentary activation.
Stop Button: Momentary activation; stops open, close or reverse
action.
Single Button: Momentary activation to open; open override of
closing door, closes door from mid-stop or open limit.
Reverse: Momentary activation will reverse a closing door,
reverse to full open (ignores mid-stop) unless stopped by stop
pushbutton input.
Mid-Stop: Activation stops an opening door; momentary contact
of open button at mid stop will restart door to full open position;
if door is moving open, constant pressure on open button will
bypass mid-stop.
Auto Close Timer: Closes door from mid-stop or open limit after
pre-set time. Stop will deactivate the auto close timer. Open will
reactivate the auto close timer or reset the auto close timer when
the door is at the mid-stop or open limit. Single button will reset
the auto close timer from the mid-stop or open limit. Reverse
will reactivate the auto close timer or reset the auto close timer
when the door is at the mid-stop or open limit.

T Operation, Dip-Switch Setting
Open Button: Momentary activation; open override of closing
door.
Close Button: Momentary activation.
Stop Button: Momentary activation; stops open, close or reverse
action.
Single Button: Momentary activation to open; open override of
closing door, closes door from mid-stop or open limit.
Reverse: Momentary activation will reverse a closing door,
reverse to full open (ignores mid-stop) unless stopped by stop
pushbutton input.
Mid-Stop: Activation stops an opening door; momentary contact
of open button at mid stop will restart door to full open position;
if door is moving open, constant pressure on open button will
bypass mid-stop.
Auto Close Timer: Closes door from mid-stop or open limit after
pre-set time. Stop will deactivate the auto close timer. Open will
reactivate the auto close timer or reset the auto close timer when
the door is at the open limit. Single button will reset the auto
close timer from the mid-stop or open limit. Reverse deactivates
the auto close timer if the door is closing. Reverse will reset the
auto close timer at the mid-stop or open limit if the auto close
timer has not been previously deactivated.

SETUP MODES
Setup Modes
Various operating characteristics can be modified via the setup
modes. The operator is moved to the close limit position and
the on-board dip switches (see Figure 20, page 14) are
TEMPORARILY set according to the table at right to enter a
Setup Mode. The on board OPEN and STOP buttons are used
to modify the characteristic. Once set, the values are stored in
non-volatile memory.
These values are set to factory defaults that should be
satisfactory for many applications. All values as described here
can be reset to the factory defaults as follows:
Remove 24 VAC power from the control board.
Press and hold the on-board stop button.
Re-apply 24 VAC while holding the on-board stop button.
After completing the procedure to modify the operating
characteristic the switches must be returned to the originally set
Operating Mode setting (see section previous).
Delay on Reverse Setup
To help prevent stress on the door components, this feature
allows for a delay time between the door stopping and reversing
when a command to reverse is received as the door is closing.
The factory default time is 0.75 seconds; the minimum time is
0.4 seconds; the maximum time is 2 seconds.
After moving the door to the close position and temporarily
setting the switches to the appropriate settings in the table,
pressing STOP will reset the time to the minimum setting.
Every time OPEN is pressed, 200 mS is added to the time (up to
the maximum).
Changing the dip-switch setting to any other setting will save
the new time. Return the dip switches to the originally set

Setup Mode

Switch Switch Switch Switch
1
2
3
4

Delay on Reverse

ON

ON

ON

ON

Close Limit Delay

OFF

ON

ON

ON

Mid-Stop Limit

ON

OFF

ON

ON

Auto Close Timer

OFF

OFF

ON

ON

Maximum Run
Time

OFF

ON

OFF

ON

Operating Mode setting (see section previous).
Close Limit Delay Setup
To provide for irregularities in the floor, this feature allows for
the door to continue to travel down after the Reverse Cutout
Limit is activated. The factory default time is 0.32 seconds; the
minimum time is 0.12 seconds; the maximum time is 0.66
seconds.
After moving the door to the close position and temporarily
setting the switches to the appropriate settings in the table,
pressing STOP will reset the time to the minimum setting.
Every time OPEN is pressed, 0.02 seconds are added to the time
(up to the maximum).
Changing the dip-switch setting to any other setting will save
the new time. Return the dip switches to the originally set
Operating Mode setting (see section previous).

16

OPERATION AND ADJUSTMENT INSTRUCTIONS

Mid-Stop Limit Setup
This features provides a timing function to stop a door as it is
traveling open at a Mid Stop position instead of the full open
position. The door can then be moved to the full open position
if desired by pressing the Open button. A single button input
when the door is at the mid stop position will cause the door to
begin moving in the close direction. The factory default is not
set; the minimum run time to mid-stop limit is 6 seconds.
After moving the door to the close position and temporarily
setting the switches to the appropriate settings in the table,
pressing STOP will remove the mid-stop limit setting.
Pressing OPEN will start the door open. When the door reaches
the desired mid-stop position, press STOP.
Changing the dip-switch setting to any other setting will save
the mid-stop limit position. Return the dip switches to the
originally set Operating Mode setting (see section previous).
Note: The door must move a sufficient distance to fully
disengage the Reverse Cutout Limit nut from the Reverse Cutout
Limit switch to set the mid-stop limit.
Auto Close Timer Setup
This feature allows for a modification of the amount of time
between the door reaching either the Mid Stop or the Full Open
position and automatically starting in the close direction. The
Auto Close feature is only active when the operator is set to the
T or TS Operating Mode (see section previous). The factory
default is 30 seconds; the minimum time is 5 seconds; the
maximum time is 5 minutes.

After moving the door to the close position and temporarily
setting the switches to the appropriate settings in the table,
pressing STOP will clear and turn off the auto close timer.
Every time OPEN is pressed, 5 seconds is added to the time.
Changing the dip-switch settings to any other settings will save
the new time. Return the dip switches to the originally set
Operating Mode setting (see section previous).
Maximum Run Time Setup
This feature provides for a maximum amount of time the motor
will be energized after an input is recognized. The factory
default time is 30 seconds; the maximum time is 60 seconds.
After moving the door to the close position and temporarily
setting the switches to the appropriate settings in the table,
pressing STOP will reset the time to the factory default setting.
Pressing OPEN will start the door open. The run time will be
recorded when the door reaches the open limit. To prevent
nuisance problems, 0.75 seconds are added to this time. Pressing
stop before the door reaches the open limit will stop the door
and reset the time to the factory default.
Changing the dip-switch setting to any other setting will save
the new time. Return the dip switches to the originally set
Operating Mode setting (see section previous).

BRAKE ADJUSTMENT

The solenoid operated brake may require
occasional adjustment. Adjustment is necessary
if door tends to drift downward after reaching the
open limit. Follow the instructions below and
use Figure 21 as a guide.
(1) Loosen shoe adjusting screw and bottom
bracket arm of solenoid.
(2) Move tab until drum has a slight drag.
(3) Reverse drag slightly from tab and tighten
shoe adjustment screw.

107103

Figure 21

17

OPERATION AND ADJUSTMENT INSTRUCTIONS

remember to use the STOP button to stop the door at the Fully
Open Position.

WARNING
TO AVOID RISK OF ENTRAPMENT AND
POSSIBLE DAMAGE TO THE DOOR AND
OPERATOR THE CLUTCH MUST BE
ADJUSTED AND ANY ENTRAPMENT
PRTOTECTION DEVICES CONNECTED
BEFORE APPLYING POWER TO THE
OPERATOR TO SET THE LIMITS.
SETTING THE LIMIT SWITCHES
1) With the cover open on the electrical enclosure, reference
Figure 23 below. There are two (2) switches (A and B) mounted
to the ‘V’ bracket (F). The switches are activated by the two limit
nuts (C and E) on the threaded shaft which move laterally along
the shaft as the operator opens and closes the door. When a limit
nut nears the end of the shaft it activates a switch, that send a
message back to the motor control board to stop the door. Follow
either 2 or 2A below depending on how the door and trolley are
orientated.
2) For original installation setting, the door (connected as
normal to the operator trolley) should be positioned approximately
4 inches shy of the fully closed position. If this is the case, depress
the Limit Nut Retention Plate (D) so it disengages from the slots
in the limit nuts and move the Close Limit Nut (C) on the shaft
until it engages the Close limit
Limit Switch (B) (see Step 5 for an
explanation of the Close limit
function). You will need to listen
A
for an audible click. Move the
Open Limit Nut (E) to the center of
the threaded shaft. Release the
retaining bracket and be sure that it
engages in slots of both limit nuts.

4) Depress the limit nut retaining plate (D) so it disengages
from the slots in the limit nuts. Turn the OPEN limit nut (E) on
the shaft until it engages the Open Limit Switch (A). You will
need to listen for an audible click. Release the retaining bracket
and be sure that it engages in slots of both limit nuts.
5) With all due care use the built-in three button station on
the motor control board or the wall mounted three button station
to lower the door to approximately 4 inches shy of the fully
closed position and repeat Step #4 with the Close Limit nut (C)
and the Close Limit switch (B). The actual Close Limit position
is a timed function whereas the door continues to run for a
certain period of time after the Close Limit switch is activated.
This amount of time (Close Limit Delay) is factory set to 0.32
seconds and will provide reversing cutout of approximately 4
inches from the floor for a door traveling at 12 inches per
seconds. If the door fails to reverse when an object at least four
inches high is placed in its path (see Testing, page 19) it may be
necessary to adjust the Close Limit Delay time, see procedure
on page 15.
6) Move the door to the fully open position then the fully
closed position and observe the stopping position. Reset the
Limit Nut(s) per above instructions if desired.
7) A fine adjustment can be done (if necessary) by loosening
the screws holding the Limit Switches to the V bracket and
moving the switch within the slots on the bracket.

E

D

C

113116

B

2A) If the door and operator
trolley are at some other position
other than fully closed, depress the
Limit Nut Retention Plate (D) so it
disengages from the slots in the
limit nuts and move the BOTH the
Limit nuts to the center of the
threaded shaft. Release the
retaining bracket and be sure that it
engages in slots of both limit nuts.
3) With all due care use the
built-in three button station on the
motor control board or the wall
mounted three button station to
raise the door to the fully open
position. You will need to
ABCDEF-

OPEN LIMIT SWITCH
CLOSE LIMIT SWITCH
CLOSE LIMIT NUT
LIMIT NUT RETAINING PLATE
OPEN LIMIT NUT
“V” BRACKET

Figure 22
Limit Assembly

F

18

OPERATION AND ADJUSTMENT INSTRUCTIONS
CLUTCH ADJUSTMENT

WARNING
RISK OF ENTRAPMENT THAT MAY
RESULT IN SERIOUS PERSONAL
INJURY OR DEATH. DISCONNECT
POWER TO THE OPENER BEFORE
SERVICING OR MAKING
ADJUSTMENTS. ENSURE DOORWAY
IS CLEAR BEFORE STARTING TESTING
OF OPERATOR.
The clutch serves to protect the door, the electric operator and
other equipment from undue stress or damage caused by starting
forces and/or an obstruction to the door. It should be set no
tighter than is necessary to smoothly and consistently move the
door throughout its full range of travel. When properly set, it will
slip freely if the door should encounter an obstruction, and it
should be possible to stop the travel of the door by hand.

The fiber disk will wear during normal operation and should be
replaced when it becomes difficult or impossible to sufficiently
tighten the clutch to obtain smooth operation of the door when it
is in good working condition. To replace the fiber disk, first
loosen the motor mounting bolts and remove the V-belt then the
clutch adjusting nuts, spring and clutch pulley. Check condition
of V-belt before reassembly and replace if required. After
reassembly, adjust clutch as described above.

107101

WARNING: Before adjustment remove power to the
operator.
To adjust the clutch, loosen the jamb nut, , and turn the adjusting
nut, as shown at right Make adjustments in 1/4 turn increments.
Always re-tighten the jamb nut before running the operator to
prevent clutch from changing its setting.

CAUTION
NEVER COMPRESS CLUTCH SPRING BEYOND
POINT LIMITED BY THE DESIGN OF THE
OPERATOR OR REPLACE IT WITH A
HEAVIER SPRING
Due to changing conditions of the door and normal wear, it may
be necessary to occasionally readjust the clutch to obtain
dependable operation.
WARNING: BEFORE DOING SO BE CERTAIN THAT
THE DOOR IS IN GOOD WORKING CONDITION,
PROPERLY COUNTERBALANCED AND THAT THE
CLUTCH IS NOT SLIPPING BECAUSE OF LOOSE OR
MISSING HARDWARE, BINDING IN THE TRACK,
RUBBING AGAINST THE DOOR STOPS OR DEFECTIVE
OR MISADJUSTED SPRINGS. ANY SERVICE
REQUIRED TO THE DOOR, DOOR SPRINGS OR DOOR
OPERATOR MUST BE PREFORMED BY A QUALIFIED
PROFESSIONAL DOOR INSTALLER.

Figure 23

WARNING
IMPROPER ADJUSTMENT OF CLUTCH
SETTING COULD CAUSE ENTRAPMENT,
INJURY OR DEATH.
SET CLUTCH ADJUSTMENT FOR JUST
ENOUGH FORCE TO OPERATE THE DOOR
RELIABLY, BUT NO STRONGER. Contact a
service professional to correct any binding,
sticking or other door problems. DO NOT
OVER-ADJUST CLUTCH SETTING TO
COMPENSATE FOR A POORLY WORKING
DOOR.

OPERATION AND ADJUSTMENT INSTRUCTIONS

19

TESTING
Following installation, the operator MUST be tested and
respond correctly to all controls as specified on the wiring
diagram. Keep personnel and equipment clear of the area
beneath the door when performing the tests. When testing the
3-button wall station, first observe that each button operates the
door in the direction indicated and that the STOP button
performs that function. With the door stopped at its full open
position, the OPEN button should be inoperative. This should
be verified and, likewise, the CLOSE button should be
inoperative with the door fully closed.
Certain operator control circuits use only a single button or a
two button control station and may be designed to function
differently than the more common three-button circuit
described above. Test the controls in accordance with the
description of operation as indicated on the wiring diagram and
as selected on pages 14, 15, and 16, Operating & Set-Up
Modes.
Observe the door when traveling in each direction for
smoothness of operation. Test the setting of the clutch by
restraining the door by hand. The clutch should slip. Re-check
the limit settings. The door should close tightly at the floor
without excessive impact. Likewise, it should fully clear the
door opening without the carrier striking the stops on the rail.
The AU-S series operators are equipped with a reversing edge
circuit and to conform with code, need to be connected to a
pneumatic or foam door edge or photoelectric device. To test an
edge for proper reversal, place an object beneath the leading
edge of the door. To test a photoelectric device for proper
reversal, start the door down and obstruct the beam. The door

CAUTION
DO NOT STAND UNDER DOOR
TO TEST REVERSING EDGE
USE A CORRUGATED BOX
OR OTHER SIMILAR OBJECT
should instantly reverse when it comes into contact with the
object provided the height of the object exceeds the cut out point
built into the close limit switch (approx. four (4) inches).
If the operator is equipped with other means of control, such as
additional 3 button stations or radio controls, each of these should
be tested separately for proper operation.
Test the manual disconnect with the door in the fully closed
position. The door arm should freely fall away from the carrier
when the release chain is pulled. If it is difficult to release and the
door arm appears to be under compression, reset the CLOSE limit
slightly to reduce the travel of the carrier in the close direction.

WARNING
ALWAYS DISCONNECT POWER TO
THE OPERATOR BEFORE SERVICING,
CONNECTING ACCESSORY DEVICES
OR MAKING ADJUSTMENTS.

MAINTENANCE
Normally, very little maintenance is required. A monthly visual
inspection must be made for loose or missing hardware and for
excessive slack in the V-Belt and drawbar chain. The clutch
must be tested periodically and adjustments made if necessary
(see page 18). The brake (where applicable) is adjusted at the
factory and will need periodic adjustment for wear. When
adjustment becomes necessary see Figure 21 on page 16 for
the adjustment procedure.
Test the reversing edge circuit at least once a month by
permitting the door to contact an obstruction while closing. To
test a pneumatic or foam door edge for proper reversal, place an
object beneath the leading edge of the door. To test a
photoelectric device for proper reversal, start the door down
and obstruct the beam. The door should instantly reverse when
it comes into contact with the object provided the height of the
object exceeds the cut out point built into the close limit switch
(approx. four (4) inches).

CAUTION
DO NOT STAND UNDER DOOR
TO TEST REVERSING EDGE
USE A CORRUGATED BOX
OR OTHER SIMILAR OBJECT
Lubrication of the operator is not required. It is important, for
trouble free service from the operator, that the door be kept free
from binding, properly counter balanced and periodically
lubricated. An annual inspection of the door by a qualified
overhead door professional is recommended.
Warning: Repairs and adjustments to the door and operator
should be performed only by someone qualified to service
commercial overhead doors and operators.

20

WIRING DIAGRAM/SCHEMATIC - SINGLE PHASE
CLOSE LIMIT

WHITE
GREY
GREY

RUN

START

BRAKE

RED

COM
NO

ORANGE
ORANGE

BLUE

COM
NO

YELLOW
OPEN LIMIT
WHITE
OVERLOAD
DEVICE

P4

BLACK

L1

WHITE

N
K5

HIGH VOLTAGE

K3

K4

K6

GROUND
COM

CLS

TR3

OLS

COM

SW1
P1

S4
S3
S2
S1

POWE

MO4
MO3
MO2

ILK

P2

COM

C13

R48
TR2

LINE

R10

R62

R22

R47

C16
C6

R19

R20

R82

R45

R17

R18

D3

R57

R13

R14

R65

R1

R21

C10
D2

R52
TR4

OFF

R51

24V

D8

COM

C9

R31

U1

RM3
RM2

EDGE

RM1

FRA

VCC
P7
R38

R58

R11

R12

R87

R15

R16

R6

R7

24V
C12

CDOMCB 2005

R56

C25

R93

D1

R55

R3

R90

C7

R4

R8

C21

R24

PB1

PB2

PB3

ON BOARD OPEN/CLOSE/
STOP CONTROL BUTTONS

P5

LOAD

c.p. ALLSTAR CORP.

Q1

R54

C1

P6

R30

C2

R29

R85

C8

S1

R26

24 VAC
TRANSFORMER

C30

COM

U4

VCC

R46

RADIO

C24

RO1

C14

P3

R49

R89
TR1

24V

C11

MO1

OPERATING MODES
SWITCH SETTINGS
MODE S1 S2 S3 S4
C2
OFF OFF OFF OFF
B2
ON OFF OFF OFF
D1
OFF ON OFF OFF
E2
ON ON OFF OFF
OFF OFF ON OFF
TS
T
ON OFF ON OFF

OPEN

CLOSE

STOP

TB1

OPEN

CLOSE

COM

STOP

CLOSE

NO REV

PHOTO

NC REV

COM

ILOCK

SINGLE

COM

24 VAC

OPEN

STOP

YELLOW
YELLOW
SINGLE BUTTON

*

EXTERNAL INTERLOCK

2-WIRE EDGE

*

SAFE FINISH
PHOTOBEAM

SINGLE PHASE
CAPACITOR START
MOTOR - 120 VAC

3-WIRE
PHOTOBEAM

MOTOR WIRING CHART

REMOVE FACTORY JUMPER
IF USING NC REV INPUT

CDO OPERATORS WITH CDO-MCB MOTOR CONTROL SYSTEM

A.O. SMITH

BALDOR

SINGLE VOLTAGE - 115 VAC, 1P MOTOR

YELLOW

BL/BLK

208/230 VOLTS, 3 PHASE
DUAL VOLTAGE MOTOR
BL/BLK

RED (AU)
BLUE (T,J,H)

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

WHITE
L2

BL/BLK

BLACK
3

YELLOW

YELLOW

4

WHITE
YELLOW

BL/BLK

L2

575 VOLTS, 3 PHASE
SINGLE VOLTAGE MOTOR

BLUE (AU)
RED (T,J,H)
RED (AU)
BLUE (T,J,H)

YELLOW

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

3

BL/BLK

4

BL/BLK

5
8
2

BALDOR
DUAL VOLTAGE MOTOR - 230V 1P
YELLOW

BL/BLK

1

TO REVERSE MOTOR DIRECTION, SWITCH
INCOMING LEADS TO TERMINALS 5 AND 8.

BL/BLK

BLUE (AU)
RED (T,J,H)
RED (AU)
BLUE (T,J,H)

RED (AU)
BLUE (T,J,H)
WHITE

DUAL VOLTAGE MOTOR
BL/BLK

BLUE (AU)
RED (T,J,H)

BRAKE

BLACK
2 1

460 VOLTS, 3 PHASE
YELLOW

BRAKE

BLUE (AU)
RED (T,J,H)

WHITE

YELLOW

ORANGE

Wire Nut Connection
Wire Nut Connection
TO REVERSE MOTOR, SWITCH LEADS 3/4 & 2/1 TO REVERSE MOTOR, SWITCH LEADS L1 & L2

TO REVERSE MOTOR, SWITCH LEADS 1 & 3

YELLOW

BLUE (AU)
RED (T,J,H)

L1

1
5

RED (AU)
BLUE (T,J,H)
WHITE

BL/BLK

2

3

BRAKE

BLACK
4

ORANGE

RED
BLUE

WHITE

BRAKE

1

YELLOW

BL/BLK

RED (AU)
BLUE (T,J,H)

RED
BLUE

BRAKE

WHITE

BLUE

BL/BLK

L1
3 4

BRAKE

BLUE (AU)
RED (T,J,H)

2

RED (AU)
BLUE (T,J,H)

BL/BLK
RED

BRAKE

YELLOW

3

BRAKE

RED (AU)
BLUE (T,J,H)

DUAL VOLTAGE MOTOR - 115V 1P

8
4

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
INCOMING LEADS TO TERMINALS 5 AND 8.

21

WIRING DIAGRAM/SCHEMATIC - THREE PHASE
CLOSE LIMIT

WHITE
GREY
GREY

BRAKE +

RED

COM
NO

ORANGE
ORANGE

BLUE

COM
NO

+CONNECTION SHOWN FOR 208 &
230V - FOR 460V SEE MOTOR DIAG.
ON INSIDE OF CONT. BOX COVER

OPEN LIMIT

OVERLOAD
DEVICE
L3

P4

ORANGE
BLACK

L1

WHITE

L2
K5

HIGH VOLTAGE

K3

K4

K6

GROUND
OLS

COM

TR3

MO4

CLS

COM

SW1
P1

S4
S3
S2
S1

POWE

MO3
MO2
MO1
ILK

P2

P3
R10

R49

R89
TR1

24V

R62

R22

R47

C16

COM

R48
TR2

LINE

R20

R82

R17

R18

D3

R13

R14

R65

R1

R21

C10

R57

RADIO

C24

24V

D8

COM

C9

R31

U1

RM3
RM2

EDGE

RM1

FRA

VCC
P7
R38

R58

R11

R12

R87

R15

R16

R6

R7

24V
C12

CDOMCB 2005
c.p. ALLSTAR CORP.

Q1

R93

D1

R55
R56

C25

R4

R8

C21

R24

PB1

PB2

PB3

ON BOARD OPEN/CLOSE/
STOP CONTROL BUTTONS

P5

LOAD

R90

C7

R54

R3

C1

P6

R30

C2

R29

R85

C8

S1

R26

24 VAC
TRANSFORMER

C30

COM

U4

VCC

R46
R45

D2

R52
TR4

OFF

RO1

C14

C6

R19

C11

C13

R51

OPERATING MODES
SWITCH SETTINGS
MODE S1 S2 S3 S4
C2
OFF OFF OFF OFF
B2
ON OFF OFF OFF
OFF ON OFF OFF
D1
E2
ON ON OFF OFF
OFF OFF ON OFF
TS
T
ON OFF ON OFF

OPEN

OVERLOAD
DEVICE

CLOSE

STOP

TB1

OPEN

STOP

CLOSE

CLOSE
COM

NO REV

NC REV

PHOTO

COM

ILOCK

SINGLE

24 VAC

COM

OPEN

STOP

YELLOW
YELLOW
SINGLE BUTTON

*

EXTERNAL INTERLOCK

2-WIRE EDGE

*

SAFE FINISH
PHOTOBEAM

THREE PHASE
MOTOR
208/230/460 VAC

3-WIRE
PHOTOBEAM

MOTOR WIRING CHART

REMOVE FACTORY JUMPER
IF USING NC REV INPUT

CDO OPERATORS WITH CDO-MCB MOTOR CONTROL SYSTEM

A.O. SMITH

BALDOR

SINGLE VOLTAGE - 115 VAC, 1P MOTOR

YELLOW

BL/BLK

208/230 VOLTS, 3 PHASE
DUAL VOLTAGE MOTOR
BL/BLK

RED (AU)
BLUE (T,J,H)

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

ORANGE
BLACK
2 1

WHITE
L2

BL/BLK

BLACK
3

YELLOW

YELLOW

4

WHITE
YELLOW

BLUE (AU)
RED (T,J,H)
RED (AU)
BLUE (T,J,H)

BL/BLK

L2

WHITE

1

3

BL/BLK

4

BL/BLK

5
8
2

TO REVERSE MOTOR DIRECTION, SWITCH
INCOMING LEADS TO TERMINALS 5 AND 8.

460 VOLTS, 3 PHASE

575 VOLTS, 3 PHASE

BALDOR

DUAL VOLTAGE MOTOR

SINGLE VOLTAGE MOTOR

DUAL VOLTAGE MOTOR - 230V 1P

YELLOW
BRAKE

BLUE (AU)
RED (T,J,H)

WHITE

YELLOW

ORANGE

Wire Nut Connection
Wire Nut Connection
TO REVERSE MOTOR, SWITCH LEADS 3/4 & 2/1 TO REVERSE MOTOR, SWITCH LEADS L1 & L2

TO REVERSE MOTOR, SWITCH LEADS 1 & 3

YELLOW

BLUE (AU)
RED (T,J,H)

L1

BRAKE

BLACK

WHITE

BRAKE

BLUE

RED
BLUE

BL/BLK

BLUE (AU)
RED (T,J,H)
RED (AU)
BLUE (T,J,H)

YELLOW

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

BL/BLK

BLUE (AU)
RED (T,J,H)
RED (AU)
BLUE (T,J,H)

YELLOW

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
ANY TWO INCOMING LEADS.

1
5

RED (AU)
BLUE (T,J,H)
WHITE

BL/BLK

2

3

BRAKE

4

BL/BLK

RED (AU)
BLUE (T,J,H)

RED
BLUE

BRAKE

WHITE

1

YELLOW

BL/BLK

L1
3 4

BRAKE

BLUE (AU)
RED (T,J,H)

2

RED (AU)
BLUE (T,J,H)

BL/BLK
RED

BRAKE

YELLOW

3

BRAKE

RED (AU)
BLUE (T,J,H)

DUAL VOLTAGE MOTOR - 115V 1P

8
4

BL/BLK

TO REVERSE MOTOR DIRECTION, SWITCH
INCOMING LEADS TO TERMINALS 5 AND 8.

22

OPERATOR DIMENSIONS / NOTES
FIGURE 24 - OPERATOR DIMENSIONS

107093

NOTES

23

PARTS IDENTIFICATION

Ref

Part #

Description

Ref

Part #

Description

Assemblies
A

Parts

106798 Frame Assembly w/Shafts, AUD (1/3 HP)

1

100513 Straight Arm with Disconnect

107412 Frame Assembly w/Shafts, AUD (1/2 & 3/4 HP)

2

108877 Curved Arm

C

110075 Clutch Shaft Assembly, AUD

3

100236 Arm Extension (2 Required)

D

109848 Drive Shaft Assembly, AUD (1/3 HP)

4

008071 Flange Bearing, 3/4” ID

110078 Drive Shaft Assembly, AUD (1/2 & 3/4 HP)

5

105549 Snap Ring, 3/4”

F

106265 Front Idler Assembly

G

100174 Door Arm Assembly

7

009044 Motor Pulley, 4L

H

100512 Trolley Assembly

8

106814 Sprocket, 65B10, 3/4” Bore

9

106815 Sprocket, 65B27, 3/4” Bore

10

100314 Sprocket, 41B10, 3/4” Bore

109273 Brake Assembly, AUD, 115 VAC

12

009244 Limit Chain, #65, 18” with Master Link

109274 Brake Assembly, AUD, 230 VAC (also used on 460 VAC)

13

107144 Primary Chain, #65, 17” with Master Link

15

105385 Brake Solenoid, 115 VAC

Brake standard on 1/2 & 3/4 HP, optional on 1/3 HP
K

N

Call

Control Box Assembly

O

Call

Track and Chain Packages

105386 Brake Solenoid, 230 VAC (also used on 460 VAC)
Motors
P

17

110042 Brake Shoe

100465 Motor, 1/3 HP, 48 Frame, ODP, 115 VAC, 1 Phase

18

106806 Brake Drum with 4L Pulley, 5/8” Bore

100466 Motor, 1/2 HP, 48 Frame, ODP, 115 VAC, 1 Phase

19

009087 V Belt, 4L350

005156 Motor, 1/3 HP, 56 Frame, ODP, 115/230 VAC, 1 Phase

20

009155 Clutch Pulley with Bushing, 4L

005026 Motor, 1/2 HP, 56 Frame, ODP, 115/230 VAC, 1 Phase

21

009028 Clutch Fiber Disk

005027 Motor, 3/4 HP, 56 Frame, ODP, 115/230 VAC, 1 Phase

22

100133 Clutch Plate

005183 Motor, 1/3 HP, 56 Frame, ODP, 230/460 VAC, 3 Phase

23

105308 Clutch Spring

005184 Motor, 1/2 HP, 56 Frame, ODP, 230/460 VAC, 3 Phase

24

100636 Clutch Lock Nut

005038 Motor, 3/4 HP, 56 Frame, ODP, 230/460 VAC, 3 Phase

25

107517 Clutch Adjusting Nut

SPECIFICATIONS
MODEL : AUD_ _ _ _S
VOLTS : _____

24

HP:_____

PHASE : _____

* UL AND CANADIAN UL LISTED
* HIGH STARTING TORQUE, CONTINUOUS DUTY MOTOR
* MOTOR OVERLOAD PROTECTION
* CLASS 2 (24 VOLT) CONTROL CIRCUIT
* SOLENOID BRAKE (STANDARD ON 3/4 HP, OPTIONAL
ON 1/3 HP AND 1/2 HP)
* SOLID STATE MOTOR CONTROL CIRCUITRY WITH
ADVANCED OPERATIONAL FEATURES STANDARD
* THREE BUTTON CONTROL: OPEN, CLOSE, STOP
* WIRED TO ACCEPT REVERSING EDGE INPUT
* HEAVY GAUGE, POWDER-COATED STEEL FRAME
RAILS AND CONTROL BOX
* ALL SPROCKETS AND PULLEYS PINNED OR KEYED,
SOLID STEEL DRIVE SHAFTS
* FULLY ADJUSTABLE FRICTION CLUTCH
* MANUAL DOOR DISCONNECT
* FULLY ADJUSTABLE, INTERNAL, SHAFT DRIVEN LIMITS

Manufacturer’s Limited Warranty
Linear LLC warrants its Allstar brand commercial door operators to be free from defect in material and workmanship for a period of two (2)
years from the date of purchase. To obtain service contact your dealer.
To obtain service under this warranty the buyer must obtain authorization instructions for the return of any goods from Linear before
returning the goods. The goods must be returned with complete identification, with copy of proof-of-purchase, freight prepaid and in
accordance with Linear’s instructions or they will not be accepted. In no event will Linear be responsible for goods returned without proper
authorization or identification.
Goods returned to Linear for warranty repair within the warranty period, which upon receipt by Linear are confirmed to be defective and
covered by this limited warranty, will be repaired or replaced at Linear’s sole option, at no cost and returned pre-paid. Defective parts will
be repaired or replaced with new or factory rebuilt parts at Linear’s sole option.
This limited warranty does not cover non-defect damage, damage caused by unreasonable use, damage caused by improper installation or
care, vandalism or lightning, fire or excessive heat, flood or other acts of God (including, but not limited to misuse, abuse or alterations,
failure to provide reasonable and necessary maintenance), labor charges for dismantling or reinstalling a repaired or replaced unit, or
replacement batteries.
These warranties are in lieu of all other warranties, either expressed or implied. All implied warranties of merchantability and/or fitness for a
particular purpose are hereby disclaimed and excluded. Under no circumstances shall Linear be liable for consequential, incidental or special
damages arising in connection with the use or inability to use this product. In no event shall Linear’s liability for breach of warranty, breach
of contract, negligence or strict liability exceed the cost of the product covered hereby. No person is authorized to assume for Linear any
other liability in connection with the sale of this product.
This warranty gives you specific legal rights. You may also have other rights which vary from state to state. Warranty effective after
October 1st 2007.
For Information:
877-441-9300 800-421-1587 www.allstarcorp.com

This Door Operator is built in the USA and
complies with all requirements of
ANSI/UL Standard 325.
Copyright © 2007 Linear LLC

P/N 190-113269

Rev. B

August 2007



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