Genie GCL-GCX Owner's Manual

CO M M ERC I A L L I NE

COUNTER DOOR OPERATOR

GCL-GCX

PROPER APPLICATION

Door Type Operator Type Max Door Weight/HP

Rolling Steel Counter Door 1/2HP = 500 lbs. Counter Door

™

112070.501539

08-12

NOT F OR R E S I D E N T I A L USE

This Installation Manual provides the information required to install, troubleshoot and

maintain a GCL-GCX

™

Counter Door Operator.

Table of Contents

Section 1 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Section 2 Safety Information & Instructions . . . . . . . . . . . . . . . . . . . . 2.1

Section 3 Critical Installation Information . . . . . . . . . . . . . . . . . . .3.1-3.3

Section 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-4.3

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-4.2

Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

Optional Timer-Close or Aux. Output Modules . . . . . . . . . 4.4

Section 5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-5.8

Line Voltage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1

Low Voltage Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

External Wire Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

Wall Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4

Montored/Non-monitored Photocells . . . . . . . . . . . . . . . . . 5.5

Section 6 Operator Setup Procedures . . . . . . . . . . . . . . . . . . . . . . .6.1-6.7

Setting Close Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.3

Montored/Non-monitored Sensing Edge . . . . . . . . . . . . . . 5.6

Locking Bottom Bar / Interlock Switch. . . . . . . . . . . . . . . . . . 5.7

External Radio/Safety Instructions . . . . . . . . . . . . . . . . . . . . . 5.8

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Limit Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Open & Close Modes . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Mid-Stop Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting the MRT, Monitored Reversing Devices . . . . .

6.1

6.4

6.5

6.6

6.7

Section 7 Special Operational Features. . . . . . . . . . . . . . . . . . . . . 7.1-7.4

Operator Cycle Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

GDO & Display Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1

Operator Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2

Optional Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-7.4

Section 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1-8.5

Display Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1-8.2

Run Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2-8.3

LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4

Safe-T-Beam® Self-Diagnostic Troubleshooting Chart . .8.5

Section 9 Service & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1

Section 10 Appendixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1-10.7

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1-10.2

Operator Parts Breakdown (Exploded View) . . . . . . 10.1

Operator Parts Breakdown (Parts List) . . . . . . . . . . . . 10.2

Base Electric Box Parts Breakdown . . . . . . . . . . . . . . . 10.3

Appendix B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

Screw Terminal Assignments. . . . . . . . . . . . . . . . . . . . . 10.4

Appendix C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5-10.7

Run Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Error Codes. .

Section 11 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6-10.7

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TOC

Section 1: How to use this manual

The 11 sections of this Installation Manual provide the information required to install, troubleshoot and maintain an GCX commercial/industrial door operator.

Section 2

Provides important defining information related to safety terminology used throughout this manual, as well as safety related instructions which must be followed at all times while doing any steps/tasks/instructions detailed in this manual.

Section 3

Details pre-installation concerns/issues/decisions that are recommended to be considered and/or resolved prior to beginning any commercial door operator installation.

WARNING

Sections 4-6

Provide step by step installation and set-up instructions for the GCX commercial door operator. Each section is written such that it must be followed in a step by step order to complete a successful installation.

Sections 7-8 Detail important features and troubleshooting information for typical installation and normal operations that may occur.

Sections 9-11 Provide related information on service and maintenance items, operator drawings for use in troubleshooting and service activities, along with important warranty and returned goods policy information.

Failure to correctly perform all steps in sections 4-6 can result in serious injury or death.

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Counter Door Operator

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1.1

Section 2: Safety Information & Instructions

Overhead Doors are large, heavy objects that move with the help of springs under high tension and electric motors. Since moving

representative. For the number of your local Genie® Dealer, call 800-OK-GENIE, and for Genie® Factory Technical

call 800-843-4084.

In this Manual, the words Danger, Warning, and Caution are used to stress important safety information. The word: DANGER WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in injury or property damage.

The word NOTE is used to indicate important steps to be followed or important considerations.

POTENTIAL HAZARD EFFECT PREVENTION

ELECTRICAL SHOCK

HIGH SPRING TENSION

indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Could result in

Serious Injury

MOVING DOOR

or Death

WARNING

Could result in

Serious Injury

or Death

WARNING

Could result in

Serious Injury

or Death

WARNING

Advice,

Do Not operate unless the doorway is in sight and free of

obstructions. Keep people clear of opening while door is moving.

Do Not allow children to play with the door operator. Do Not change operator control to momentary contact unless an

external reversing means is installed. Do Not operate a door that jams or one that has a broken spring

Turn off electrical power before removing operator cover. When replacing the cover, make sure wires are not pinched or near

moving parts. Operator must be electrically grounded.

Do Not try to remove, repair or adjust springs or anything to which door spring parts are fastened, such as, wood block, steel bracket, cable or any other structure or like item.

Repairs and adjustments must be made by a trained service

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IMPORTANT

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READ PRIOR TO ANY DOOR OPERATION

1. Read manual and warnings carefully.

2. Keep the door in good working condition. Periodically lubricate all moving parts of door.

3. If door has a sensing edge, check operations monthly. Make any necessary repairs to keep it functional.

4. AT LEAST twice a year, manually operate door by disconnecting it from the operator. The Door should open and close freely. If it does not, the door must be taken out of service and a trained service representative must correct the condition causing the malfunction.

5. The Operator Motor is protected against overheating by an internal thermal protector. If the operator ceases to function because motor protector has tripped, a trained service technician may need to correct the condition which caused the overheating. When motor has cooled, thermal protector will automatically reset and normal operation can be resumed.

6. In case of power failure, the door can be operated manually by pulling the release cable to disconnect the operator drive syste

7. Keep instructions in a prominent location near the pushbutton.

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Counter Door Operator

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2.1

Section 3: Critical Installation Information

Job Site Issues to Consider/Concerns

The following list of items should be considered prior to selecting an operator for a given job site.

1-Available power supply. 2-Type of door.

3-Potential operator mounting obstructions. Items to consider include, but are not limited to: side room, room above door shaft,

surface integrity, power supply location, and convenient chain hoist and release cable positioning. 4-Size of door for appropriate 5-Operator mounting environment. Items to consider include operator location, dampness of location, dustiness of the 6-Door activation needs/requirements. Examples include 3 button control stations, 1 button control stations, radio controls, pull

key switches, etc. See “Entrapment Protection” section below.

7-Interlock switches are required under certain conditions for

8-Accessory equipment. Examples include reversing edges and/or photocell beams, which are required for

warning lights, etc.

ENTRAPMENT PROTECTION

The installation of a fail safe external reversing device (such as a monitored reversing edge or photocell system, etc.) is required on all momentary contact electronically operated commercial doors. If such a reversing device is not installed, the operator will revert to a constant contact control switch for operation (Closing only).

The Reversing Devices currently UL Approved with this model are:

MillerEdge ME, MT and CPT series monitored edge sensors used in combination with Timer-Close Module P/N OPABTCX.S, and/or OPAKMEIGX.S INTERFACE MODULE.

2) Residential Safe-T-Beam® Monitored Photocells from The Genie® Company, model OSTB-BX (P/N 38176R).

3) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPE.S.

4) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPEN4GX.S.

WARNING: DO NOT apply line voltage until instructed to do so.

operator torque and door travel speed selection.

doors with pass doors and door locks. See Section 5.5 below.

See “Entrapment Protection” section below.

doors set to operate as momentary contact, auxiliary control relays,

room below door shaft, available mounting

location and corrosiveness of the location.

cords, loop detectors, photoelectric controls,

CAUTION:

Check working condition of door before installing the operator. Door must be free from sticking and binding. If equipped, deactivate

any door locking device(s). Door repairs and adjustments, including cables and spring assemblies MUST be made by a trained service representative using proper tools and instructions.

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Counter Door Operator

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3.1

ENTRAPMENT PROTECTION

The GCX can be used with the following UL Listed entrapment devices in compliance with UL325 requirements active starting August 29, 2010.

UNTIL ONE OF THESE MONITORED EXTERNAL ENTRAPMENT DEVICES IS INSTALLED, THE OPERATOR WILL NOT ALLOW MOMENTARY CONTACT OPERATION IN THE CLOSE DIRECTION.

APPROVED DEVICES Miller Edge ME, MT & CPT series monitored edge sensors used in combination with either the Genie®

Timer-Close Module or Direct connect through STB inputs using the OPAKMEIGX.S Interface Module.

Safe-T-Beam® from Genie®—P/N 38176R.

Commercial Photoeye Kit—P/N OPAKPE.S. Monitored Photocells—P/N OPAKPEN4GX.S.

Rolling Steel Door Chart (sq. ft.)

Model H P

GCL-GCX 1/2 YES

Note: Total door weight and not square footage is the critical factor in selecting the proper operator. These Sq.Ft. measurements are based on square doors, e.g. 16' x 16'.

Unbalanced Fire Shutters have a maximum square footage of 52 for 22GA. steel and 42 for 20GA. steel.

L is ted

16GA. 18GA. 20GA. 22GA. 24GA. 26GA. 18GA. 20GA. 22GA.

GCL-GCX

STEEL, NON-INSULATED STEEL, INSULATED

ALUM. STL/SST

N/A N/A 144 144 144 144 N/A N/A N/A

Counter Door Operator

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126 126

ALUM. STL/SST 20GA. 22GA.

142 108 82

FIRESTAR 2” SLATGRILLESCOUNTER DOOR

ALLOWABLE DOOR WIDTH

ANY WIDTH

30 FEET

FIRESTAR 3” SLAT

16GA. 18GA. 20GA. 22GA.

94 N/A

N/A N/A N/A

FIRESTAR 3” SLAT INSULATED

20GA. 22GA.

N/A N/A

SHEET DOOR

26GA

N/A

3.2

IMPORTANT

INSTALLATION INSTRUCTIONS

WARNING

To reduce the risk of severe injury or death:

1) READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2) Install only on a properly operating and balanced door. A door that is operating

improperly could cause severe injury. Have qualified service personnel make repairs to cables, spring assemblies and other hardware before installing the operator.

3) Remove all pull ropes and remove, or make inoperative, all locks (unless mechanically and/or electronically interlocked to the power unit) that are connected to the door before installing the operator.

4) Install the door operator at least 8 feet above the floor if the oper moving parts.

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

6) Locate the control station: (a) within sight of the door, (b) a minimum of 5 feet above

the floor so that small children cannot reach it, and (c) away from all moving parts of the door.

7) Install the Entrapment Warning Placard next to the control station and in a prominent location.

8) For products having a manual release, instruct the end user on the operation of the manual release.

ator has exposed

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Counter Door Operator

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3.3

Section 4: Installation

Mounting

Unless otherwise stated, these instructions will show right side mount installations. Left side mount is opposite.

1) Insert four(4) 3/8"-16 x 1" carriage bolts into headplate. FIG. 1.

• Threads to outside of plate.

• Retain by pushing 4 speed nuts onto bolts.

2) Complete installation of door as instructed in door installation manual up to "mounting of hood."

3) Make certain both headplates are at 90° to wall.

• If not at 90°, use temporary external brace to hold in place.

4) Install hood and secure with hood mounting screws.

• When hood is secure, remove temporary brace if used (in step3).

• Leave door in FULL OPEN position.

5) Place 3/8" flat washers and 3/8"-16 keps nuts on 3/8" carriage bolts closest to wall. FIG. 2.

• Leave nuts flush with ends of bolts. .rotarepo XCG morf draug niahc evomeR )6

Figure 1 Figure 2

SPEED NUT

CARRIAGE BOLT

FLAT WASHERS & KEPS NUTS

nuts flush with end of bolts

WALL

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4.1

Mounting (continued)

7) Slide open ended slots of frame under flat washers installed in step 5. FIG. 3.

• Locate other frame slots over remaining two(2) carriage bolts and bring frame

against headplate.

• Put 3/8" washers and keps nuts on remaining bolts.

• DO NOT fully tighten nuts.

• Slide operator toward wall as far as slots allow. FIG. 4.

8) Place driven sprocket and key on door shaft and align with output sprocket

on operator. FIG. 4A.

• Secure sprocket and key in place with set screws.

9) Wrap #25 roller chain around both sprockets and join with connecting link. FIG. 5 & 6.

• Chain length is correct for 9-1/2" headplate.

• For 11-1/2" headplate, add short #25 chain (provided) to long chain using extra

connecting link.

• Slide operator away from hood until drive chain is tensioned but not tight. FIG. 7.

• Tighten mounting nuts.

Figure 4A

Figure 3

Figure 6

TOWARD WALL AS FAR AS SLOTS WILL ALLOW

GCL-GCXGCL-GCX

Figure 4

Counter Door Operator

Figure 5

Figure 7

90°

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4.2

Manual Release

NOTE: In case of power failure, door can be operated manually.

The operator can be disconnected from door by pulling red pull rope attached to Drop Release Lever to allow opening door. FIG. 8.

• When door is in manual operation, limit switch setting is not affected.

• Releasing pull rope will re-engage operator.

1) Install Release Cord.

2) Locate and install the wall control.

3) Locate and install Warning Placard. FIG. 9.

4) Remove four (4) self-tapping screws from front panel of the enclosure and remove front panel to expose control circuits and allow for installation of any optional accessory board.

FIG. 8.

Figure 8

DROP RELEASE LEVER

(install release cord here)

Warning

MUST

Figure

Placard

BE ATTACHED

ADJACENT

to push button.

11173500 1

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Counter Door Operator

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4.3

Optional Timer-Close Module or Auxiliary Output Module

These instructions apply to either board. Although they perform different functions, they mount in the same way.

2) Orient the module so mounting bracket tabs are to the left and wire terminals are facing up.

3) Make desired wiring connections, in accordance with instruction manual accompanying the module.

4) Insert module into the area indicated and slide front mounting tab into slot on side panel of the enclosure. FIG. 10 & 11.

5) Adjust module so that it is level with GCX enclosure.

• There is a mounting hole on side panel of enclosure which will line up with hole in module mounting bracket.

• Attach module by inserting self-tapping screw (provided in kit) through module bracket and into hole in side panel. Do not overtighten.

6) Replace front panel.

Figure 10

Figure 11

GCL-GCX

Counter Door Operator

MOUNTING BRACKET TAB

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Self tapping screw

4.4

Line Voltage Wiring Fig. 1

Section 5: Wiring

WARNING

• DO NOT apply power to operator until instructed to do so.

• The Genie® Company recommends that line voltage wiring be performed by a qualified electrician.

• Be sure that electrical power has been disconnected from the input power wires being connected to the operator prior to handling these wires. An appropriate lock-out /tag-out procedure is recommended.

• Line voltage wiring must meet all local building codes.

• Make sure operator voltage, phase and frequency nameplate ratings are identical to the job site line voltage ratings.

• Input power wiring must be properly sized for the operators amperage rating located on the nameplate.

• To reduce the risk of electric shock, make sure the chassis of this unit is properly grounded.

1) Remove LINE VOLTAGE INPUT PLUG and install proper fittings and 1/2”conduit.

2) Route proper LINE VOLTAGE wires into operator.

3) Locate LINE INPUT terminals on circuit board. Using correct connectors, attach wires to LINE INPUTS, and GROUND terminal.

• Keep low voltage and line voltage wires separate.

• Route all line voltage wires as shown.

• Plug all unused conduit holes.

Figure 1

S B

CAL RUN

SET

SCROLL

CLR

SCROLL

STB ENAB + 4

S Y

S YSB SB

VAC EXT IN LK HOIST IN LK

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5.1

Low Voltage Control Wiring

Fig. 2

1) Connect all LOW VOLTAGE control circuit wires to this side

of unit using 1/2” conduit or flexible convoluted

tubing.

• Keep low voltage and line voltage wires separate.

• Route all low voltage control wiring as shown. This includes

all control circuit wires such as wall controls,

button input devices as well as

radio control and safety

circuit wiring.

timers and single

• Plug all unused conduit holes.

Figure 2

CAL RUN

S B

SCROLL

SET

CLR

STB ENAB + 24

S Y

SS B S B

VAC EXT NTLK HOST NTLK

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5.2

3-BUTTON

STATION

OPEN

STOP

REMOVE JUMPER IF STOP BUTTON IS USED

See Appendix B for detailed description of terminals.

External Wire Diagram

EXT

N-O

ODC

1-BTNGNDSTOPCLOSEOPEN

STB

1-BTN STATION

N/O

KEY SWITCH STATION

N/O

CARD READER

N/O

O/C PULL SWITCH

N/O

REVERSE

STB

INTLK

REMOVE JUMPER WHEN INSTALLING EXTERNAL INTERLOCK

SENSING EDGE SWITCH

(DO NOT CONNECT 2-WIRE MONITORED SENSING EDGE SWITCH TO THESE INPUTS)

PWR 20 40 VDC @ 315mA MAX CURRENT

EXT RAD O CONNECTOR

ORANGE

BLUE

NOM + 24VDC

YELLOW

RELAY

GND

RADIO

Located inside

Electrical Box

GCL-GCX

MULT PLE 3 BUTTON STAT ON

NSTALLAT ONS REQU RE THE STOP BUTTON TO BE W RED

N SER ES See Fig 5 pg 5 4

Counter Door Operator

SERIES II SAFE-T-BEAM® (STB)

(*CONNECT STB WIRES TO EITHER TERMINAL)

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MONITORED EDGE INTERFACE MODULE (OPAKMEIGX.S)

THRU-BEAM PHOTOCELLS

2-WIRE MONITORED SENSING EDGE SWITCH

5.3

+ 30 hidden pages