Garage Construction Project

2026-01-22 - Site Visit - Garage Door Seal Installation

11 min read

Garage Door Seal Installation - Final Completion

Garage door installers returned to complete the installation by adding exterior weatherstripping seals around all three garage doors.

Weather

Weather: Cloudy, 19°F (feels like 5°F with wind chill). Very cold winter evening.

Summary

The installers arrived to finish the garage door installation that was started on January 5 and completed on January 21. Today’s work consisted of installing the exterior weatherstripping seals (rubber gaskets) that attach tightly around the exterior perimeter of each garage door opening, creating a weather seal when the doors are closed.

Work Completed

  • Installed exterior weatherstripping/gaskets around all three 8’×9’ garage door openings
  • Seals create tight perimeter seal when doors are closed
  • Garage door installation now fully complete

Door Operation Issue — Shuddering on Close (Bays 1 & 2)

When greeting the installers and demonstrating the temporary power setup, owner observed that Bay 1 and Bay 2 doors exhibit a “shuddering” motion during the first few feet of travel when closing from fully open position. Bay 3 (nearest the entry door) does not have this issue.

Temporary Power Configuration

House outlet
    │
    └──[ 30' 12/3 cord ]──[ ~70' 16/3 cord(s) ]──┬──[ 1-to-3 outdoor splitter ]
                                                  │
                                                  ├── Bay 3 (direct) ← NO shuddering
                                                  │
                                                  ├──[ 25' 16/3 ]── Bay 2 ← shuddering
                                                  │
                                                  └──[ 25' 16/3 ]── Bay 1 ← shuddering

Cord specifications:

SegmentLengthGaugeNotes
House to junction30’12/3Only 12-gauge cord available
Junction to garage~70’16/3Multiple 16/3 cords daisy-chained
Splitter to Bay 3Direct—Plugs directly into splitter
Splitter to Bay 225’16/3Additional 16-gauge extension
Splitter to Bay 125’16/3Additional 16-gauge extension

Total cord length:

  • Bay 3: ~100 feet (30’ of 12/3 + ~70’ of 16/3)
  • Bay 2: ~125 feet (30’ of 12/3 + ~70’ of 16/3 + 25’ of 16/3)
  • Bay 1: ~125 feet (30’ of 12/3 + ~70’ of 16/3 + 25’ of 16/3)

Battery charge differential:

  • Bay 3 was the only opener plugged in on January 21 (previous day) for approximately 5 hours
  • Bays 1 & 2 had zero charging time before today’s power connection
  • Bay 3’s partially charged battery can supplement voltage during high-torque moments, masking some voltage drop effects
  • This differential likely contributes to Bay 3 operating smoothly despite still having ~100’ of undersized wire

Wire Gauge Analysis — Root Cause Identified

Online wire size calculator results:

  • Input: 120V, single phase, 100’, 3% allowable voltage drop, 5A load
  • Result: Minimum 14 AWG copper or 12 AWG aluminum required

Current setup problem:

  • Only the first 30’ is 12-gauge (adequate)
  • Remaining ~70-95’ uses 16-gauge wire (severely undersized)
  • 16-gauge wire has ~2.5× the resistance of 12-gauge per foot

Voltage drop calculation context:

  • At 5A load over 100’ of 16-gauge: ~8-10% voltage drop (vs 3% acceptable)
  • Garage door openers draw more than 5A at startup — actual drop likely worse
  • Bays 1 & 2 have additional 25’ of 16-gauge, compounding the problem

Conclusion: The 16-gauge extension cords are almost certainly the root cause of the shuddering issue. The voltage drop under motor load is too severe for reliable operation.

Manual Warning — “NEVER USE AN EXTENSION CORD!”

The Genie 6170H-B manual explicitly states “NEVER USE AN EXTENSION CORD!” (pages 3 and 16, appearing twice for emphasis). This warning exists precisely because of the issue we’re experiencing:

  • Most homeowners would reach for a 16/3 cord (or worse, a lightweight indoor lamp cord)
  • Wall-mount jackshaft openers have significant startup inrush current
  • Undersized wire causes voltage sag → erratic motor behavior
  • The observed shuddering is the predictable result of ignoring this warning

Manual does NOT specify amperage: The Genie manual does not publish peak or continuous amperage ratings. The rating label on the powerhead may contain this information. Typical wall-mount openers draw:

ConditionTypical Range
Startup/Peak (inrush)6-10A+
Running (continuous)2-4A

The 5A estimate used in our wire calculator was likely conservative — actual startup draw is probably higher, making the voltage drop even worse than calculated.

Possible Causes Discussed

TheoryStatusNotes
Voltage drop from undersized wire⚠️ ROOT CAUSE IDENTIFIEDWire gauge analysis confirms 16-gauge cords are severely undersized for 100’+ motor loads. Calculator shows 14 AWG minimum required; actual setup uses 16 AWG for ~70-95’ of the run.
MisalignmentUnlikelyWould not correlate with cord length/gauge pattern
Cold weatherContributing factor19°F conditions may worsen the issue but not the primary cause

Installer Response

The installers stated:

  • This issue has occurred before with wall-mounted (jackshaft) opener systems
  • They will research the issue further
  • If the problem persists after batteries are fully charged and weather warms, they can return to make adjustments

Additional Factors to Consider

Power-Related (Beyond Cord Length):

FactorStatusNotes
Extension cord gauge (AWG)⚠️ CONFIRMED ISSUE16-gauge used for ~70-95’ of run; 12-gauge minimum required. This is the root cause.
Splitter qualityUnknownMay add minor resistance but not primary issue
Battery capacityMonitoringDeeply discharged SLA batteries may have reduced capacity even after recharging

Mechanical Causes:

CauseNotes
Torsion spring tensionIf springs aren’t perfectly tuned to door weight, opener works harder
Track alignmentSlight binding at certain points in travel
Roller break-inNew rollers sometimes need a few dozen cycles to seat properly
Cable drum wrapCables seating on drums during initial travel could cause momentary resistance
Opener mounting rigidityIf wall mount bracket isn’t perfectly solid, motor torque could cause vibration
Door balanceUnbalanced door forces opener to work harder

Cold Weather Specific:

CauseNotes
Lubricant viscosityGrease on tracks/rollers/hinges thickens significantly at 19°F
Metal contractionTracks, rollers, hinges contract slightly — tighter tolerances
Stiff weather sealsNew seals stiffer in cold (affects bottom of travel, not top)

Why “First Few Feet From Fully Open”?

When closing from fully open, the door is horizontal in the ceiling track area with torsion springs at maximum wind. This is a high-torque demand moment — exactly when voltage drop hurts most.

Diagnostic Plan (When Weather Permits)

  1. Check main extension cord gauge ✅ DONE — Confirmed: 30’ of 12/3, remainder is 16/3 (undersized)
  2. Upgrade test: Replace 16/3 cords with 12/3 cords for entire run
    • If shuddering stops → confirms voltage drop from undersized wire (expected)
    • Requires acquiring additional 12/3 extension cords (~70-100’ total)
  3. Bypass test (alternative): Run single 12/3 cord directly to Bay 1 or Bay 2
    • Tests if 12-gauge alone resolves the issue
    • Only practical if existing 30’ 12/3 can reach one opener directly
  4. Definitive test: Observe after permanent 200A service connected — will confirm power was the cause

Monitoring Plan

  1. Observe door behavior after batteries have charged for 24-48 hours on temporary power
    • Note: Bay 3 had ~5 hrs head start on charging — once all batteries equalize, Bay 3 may also start shuddering (confirming voltage drop as cause)
    • Alternatively, Bays 1 & 2 may improve as their batteries charge and can supplement voltage
  2. Observe door behavior when temperatures rise above freezing
  3. Key test: Observe door behavior after permanent 200A electrical service is connected — if shuddering resolves, voltage drop was the cause
  4. If shuddering persists under normal conditions with permanent power, contact installer for adjustment visit

Temporary Power Setup

Prior to the installers’ arrival, owner ran an extension cord to the garage and connected all three Genie 6170H-B openers to provide temporary power. This allows the doors to operate normally while awaiting permanent 200A electrical service (ground thawing in progress, see Timeline).

Battery Backup Observations

Issue Discovered

When inspecting the openers before plugging in the extension cord, owner observed that 2 of 3 openers had completely drained backup batteries:

  • No indicator lights on the opener powerheads
  • No Safe-T-Beam LEDs illuminated (normally red/green when powered)
  • Third opener still had some battery charge remaining

The openers had been sitting without power since installation on January 21 (approximately 1 day).

Battery Concerns Discussed

Owner mentioned to the installers that research indicated SLA (Sealed Lead Acid) batteries used in the Genie openers can suffer reduced lifespan and capacity when deeply discharged. Deep discharge is generally harmful to lead-acid battery chemistry.

Possible Built-in Protection

After the installers left, owner speculated that the Genie 6170H-B openers may include low-voltage cutoff protection — internal electronics that detect critically low battery voltage and power down non-essential systems before the battery reaches a harmful discharge level.

Evidence from manual review:

  • Manual (page 36) shows distinct LED states for battery status:
    • Green steady = Charged, normal
    • Green flashing = Discharging, battery in use
    • Yellow flashing = Charging
    • Red-to-yellow flashing = Dead battery (with “Replace Battery” instruction)
  • The “Dead Battery” detection suggests the opener monitors battery voltage
  • However, manual does not explicitly confirm a low-voltage cutoff feature

Battery specifications from manual (page 30):

  • Type: 12V, 5AH, SLA (Sealed Lead Acid)
  • Replacement part: P/N 111658.0002.S
  • Recommended 24-48 hour initial charge before testing

Conclusion

It remains unclear whether the openers have true low-voltage cutoff protection or simply continue drawing power until the battery is fully depleted. The presence of battery state monitoring suggests some protection may exist, but installers should still connect temporary power promptly after installation to avoid potential battery damage.

Recommendations for Future Installations

  1. If garage will lack permanent power for an extended period after opener installation, arrange temporary power immediately
  2. Monitor battery backup LEDs — if showing “Dead Battery” (red-to-yellow flashing), batteries may need replacement
  3. Consider contacting Genie customer support (1-800-35-GENIE) for definitive information on low-voltage cutoff behavior

Aladdin Connect Smart Home Integration

The Genie 6170H-B openers include integrated Aladdin Connect WiFi capability for smartphone control and monitoring. Before setting up the app, WiFi signal strength at the garage needs to be verified.

WiFi Setup Prerequisites

  1. Test WiFi signal strength at each opener location

    • House has Ubiquiti PoE WiFi AP — typically good coverage in garage area
    • Use smartphone WiFi meter to verify signal at each bay
    • Aladdin Connect requires 2.4GHz WiFi network

  2. If signal is weak:

    • Relocate AP if possible
    • Install WiFi range extender
    • Consider future ethernet run to garage for dedicated AP (see Network Planning)

Aladdin Connect Setup Steps (per manual pages 25-26)

  1. Download Aladdin Connect app (iOS/Android)
  2. Create account
  3. Scan QR code on opener or manual
  4. Connect opener to WiFi network
  5. Add users and configure rules (auto-close, notifications, etc.)

Features:

  • Remote open/close from anywhere
  • Door status notifications
  • Activity history/reports
  • Auto-close rules at scheduled times
  • Up to 20 users per account
  • Up to 20 openers per account

Note: Light fixture must be installed and operational for Aladdin Connect to function.

Integration Possibilities

Action Items

  • Monitor Bay 1 & 2 shuddering after batteries fully charged (24-48 hrs) — stage:: 6
  • Monitor Bay 1 & 2 shuddering when temperatures rise above freezing — stage:: 6
  • Check main extension cord gauge (should be 12-gauge for 100’ run) — stage:: 6 ✅ DONE: 30’ of 12/3, then 16/3 (undersized)
  • (Optional) Acquire additional 12/3 extension cords (~70-100’) to replace undersized 16/3 cords — stage:: 6
  • Bypass test: Run 12/3 cord direct to Bay 1 or Bay 2 to confirm voltage drop is the cause — stage:: 6
  • Contact installer for adjustment visit only if shuddering persists with proper power (permanent service or 12-gauge cords) — stage:: 6
  • Test WiFi signal strength at each opener location — stage:: 6
  • Set up Aladdin Connect app for all three openers — stage:: 6
  • Monitor battery backup status after extended temporary power use — stage:: 6
  • Consider contacting Genie support to confirm low-voltage cutoff behavior — stage:: 6
  • Plan permanent power connection (electrical trench thawing in progress) — stage:: 6

Key Lessons Learned

This troubleshooting session provided valuable insights into electrical fundamentals and garage door opener operation:

1. Manufacturer Warnings Exist for a Reason

The Genie manual’s “NEVER USE AN EXTENSION CORD!” warning (appearing twice) isn’t just liability protection — it reflects real-world failure modes the manufacturer has encountered. Most homeowners reach for whatever cord is handy, typically 16/3 or lighter, which cannot handle motor inrush current over any significant distance.

2. Wire Gauge Matters Exponentially with Distance

AWGResistance/ft100’ Round-Trip Resistance
121.59 mΩ0.318Ω
142.53 mΩ0.506Ω
164.02 mΩ0.804Ω

At 16-gauge, voltage drop is ~2.5× worse than 12-gauge for the same length. For 100’+ runs with motor loads, 12-gauge is the minimum — not just a recommendation.

3. Motor Startup (Inrush) Current is the Critical Factor

Motors draw significantly more current at startup than during continuous operation:

  • Startup: 6-10A+ (high torque demand)
  • Running: 2-4A (steady state)

Voltage drop that’s “acceptable” at running current becomes severe during startup, exactly when the motor needs full voltage to overcome static friction and accelerate the load.

4. Symptom Location = Diagnostic Clue

The fact that shuddering occurred on Bays 1 & 2 (longer cord runs) but NOT Bay 3 (shorter run) was the key diagnostic pattern. Always look for correlations between symptoms and physical configuration.

5. Multiple Contributing Factors Can Mask Root Cause

Bay 3’s smooth operation despite still having undersized wire was initially puzzling. The explanation: its battery had 5 hours of charging head-start, allowing it to supplement voltage during high-demand moments. Real-world troubleshooting often involves multiple interacting variables.

6. Temporary Solutions Have Temporary Problems

The shuddering issue will resolve itself once permanent 200A service is connected. Sometimes the best “fix” is patience — especially when the underlying infrastructure (proper electrical service) is already in progress.

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