Genie GCL-MJ, GCL-MH Owner's Manual

™

GCL-MJ&MH

Medium Duty Operator

JACKSHAFT/HOIST

111852.501539

08-12

TensiBelt

PROPER APPLICATION

Door Type Operator Type HP/Max Door Weight

Sec

tional Jackshaft/Hoist

(Vertical Lift and Lift Clearance Type

Rolling Steel

(Sidemount, Chain Couple)

NOT FOR R E SIDENTIAL U S E

™

(Available in 1/2HP only)

Sectional = 620 lbs. Rolling Steel = 580 lbs.

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

maintain a GCL-MJ&MH

™

Commercial / Industrial 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........................3.1-3.2

Section 4 Installation.................................................................4.1-4.7

Rolling Steel-Front of Hood.................................4.1-4.2

Wall Mount ...............................................................4.3

Sectional Side Mount Chain Couple ................4.4-4.6

Clutch and Brake Adjustment ............................4.6

Hand Chain Installation ........................................4.7

Section 5 Wiring..........................................................................5.1-5.7

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

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

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

Control ..............................................................5.4

Wall

terlock Switches ..................................................5.5

Radio Control & Photocell Wiring .................... 5.6

Sensing Edge Wiring .............................................5.7

Important Safety Instructions............................5.8

Section 6 Operator Setup Procedures ................................6.1-6.8

Control Panel............................................................6.1

Setting Constant Contact ....................................6.2

Setting Limit Travel ................................................6.3

Setting Limit Overrun ...........................................6.4

Monitored Reversing Devices.............................6.5

Max Run Timer.........................................................6.6

Setting the Mid-Stop .............................................6.7

Changing Open & Close Modes ........................6.8

Section 7 Special Operator Features ..........................................7.1-7.2

Operator Cycle Count & Firmware Version...........7.1

Operator Type..................................................................7 2

Section 8 Troubleshooting.............................................................8.1-8.4

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

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

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

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

STB Indicators..................................................................8.5

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

Section 10 Appendix A.............................................................. 10.1-10.9

Basic Operator Parts...........................................10.1-10.2

Basic Shaft Assembly Parts..............................10.3-10.4

Basic Electric Box Parts......................................... 10.5

Appendix B, Screw Terminal Assignme

Appendix C, LCD Display Readouts...................10.7-10.9

Run Codes.................................................................10.7

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

nts.........10.6

9.01-8.01................................................................sedoC rorrE

GCL-MJ&MH

Medium Duty Operator

TOC

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Section 1: How to use this manual

The 11 sections of this Installation Manual provide the information required to install, troubleshoot and maintain an GCL-MJ&MH™ 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

esolved prior to beginning any commercial door operator installation.

WARNING

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

Sections 4-6

Provide step by step installation and set-up instructions for the GCL-MJ&MH™ commercial door operator. Each section is written such that it must be followed in a step by step order installation.

Sections 7-8

Detail important features and troubleshooting information for typical installation and normal operations

t may occur.

tha

Sections 9-11

ovide related information on service and maintenance items, operator drawings for use in

Pr troubleshooting and service activities, along with important warranty and returned goods policy information.

FOR ASSISTANCE CALL 1-800-843-4084

to complete a successful

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Medium Duty Operator

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1.1

Section 2: Safety Information & Instructions

Commercial/Industrial Sectional and Rolling Steel Doors are large, heavy objects that move with the help of springs under high tension

and electric motors. Since moving objects, springs under tension, and electric motors can cause injuries, your safety and the safety

of others depend on you reading the information in this manual. If you have any questions or do not understand the information presented, call your nearest service representative. For the number of your local Genie® Dealer, call 800-OK-GENIE, and for Genie® Factory Technical Advice, call 800-843-4084.

In this Manual, the words Danger, Warning, and Caution are used to stress important safety information. The word: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. 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

WARNING

Could result in

Serious Injury

MOVING DOOR

ELECTRICAL SHOCK

HIGH SPRING TENSION

or Death

WARNING

Could result in

Serious Injury

or Death

WARNING

Could result in

Serious Injury

or Death

WARNING

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 representative using proper tools and instructions.

IMPORTANT

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. 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 causi 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 pu cable to disconnect the operator drive system

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

lling the release

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Medium Duty 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

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

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 are:

MillerEdge ME, MT and CPT series monitored edge sensors used in combination with Timer-Close Module P/N OPABTCX.S, 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®, NEMA4 Monitored Photocells P/N OPAKPEN4GX.S.

operator torque and door travel speed selection.

gde gnisrever era selpmaxE .tnempiuqe yrosseccA-8

doors .cte ,sthgil gninraw ,syaler lortnoc yrailixua,),tcatnoc yratnemom sa etarepo ot tes

rof deriuqer( smaeb llecotohp ro/dna se

and corrosiveness of the location.

ssenitsud ,ssenpmad dna noitacol rotarepo edulcni redisnoc ot smetI .tnemnorivne gnitnuom rotarepO-5

.5.5 egap eeS .skcol rood dna srood ssap htiw srood

room below door shaft, available mounting

cords, loop detectors, photoelectric controls,

WARNING:

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.

GCL-MJ&MH

DO NOT apply line voltage until instructed to do so.

Medium Duty Operator

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3.1

Section 3: Critical Installation Information

ENTRAPMENT PROTECTION

The GCL-MJ&MH™ can be used with the following UL Approved 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.

LISTED DEVICES ALLOWABLE DOOR WIDTH

MillerEdge ME, MT and CPT series monitored edge sensors used in combination with Timer-Close Module or OPAKMEIGX.S Interface Module.

Residential Safe-T-Beam® Monitored Photocells model OSTB-BX P/N 38176R.

Commercial Photoeye Kit P/N OPAKPE.S NEMA4 Monitored Photocells P/N OPAKPEN4GX.S.

ANY WIDTH

30 FEET

35 FEET

Rolling Steel Door Chart (sq. ft.)

Mode l H P

GCL-MJ&MH 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.

Lis ted

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

197 246 246 338 394 394 148 148 197

STEEL, NON-INSULATED STEEL, INSULATED

ALUM. STL/SST

126 126

ALUM. STL/SST 20GA. 22GA.

300 200 N/A

FIRESTAR 2” SLATGRILLESCOUNTER DOOR

Sectional Door Chart (sq. ft.)

Door S er ies ->

UL L is tedHPMod el

GCL-MJ

1/2

GCL-MH

S=Jackshaft,SideMount

T=Trolley

Note: Total door weight, and not the square footage, is the critical factor in selecting the proper operator.

Square footage measurements are based on "square doors." (Example=16' x 16')

NOTE: Doors that require special windloading and wide doors, normally require increased strutting (reinforcement). Strutting doors can significantly increase door

weight beyond weight shown. Consult Customer Service for the impact of wind load andstrutting on square foot limits.

NOTE: "PU-FIP" stands for "polyurethane, foamed-in-place." If no notation is present, insulation is "polystyrene, layed-iin-place."

Ye s TS 620 170 120 230 160 270 200 300 256 256 256 240 160 256 256 210 144

Mounting

Type

C=Jackshaft,CenterMount

216 216 ins. 220 220 ins. 2415 2415 ins. 2411 2411 ins. 125 150 200 200-20 5150 5200 451 452

Max.

16GA.

Door

Flush

Weight

Steel

(Lbs)

CommercialSteelInsulated&Non-Insulated Thermospan Thermomark

16GA.

Flush Steel

Insulated

20GA.

Ribbed

Steel

20GA.

Ribbed

Steel

Insulated

24GA.

Ribbed

Steel

24GA.

Ribbed

Steel

Insulated

Nominal

24GA.

Ribbed

Steel

Nominal

24GA.

Ribbed Steel

Insulated

PU/FIP

Insulated

FIRESTAR 3” SLAT

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

N/A N/A

N/A N/A N/A

PU/FIP

Insulated

PU/FIP

Insulated

1.38"

Insulated

20GA.

Exterior

Raised Panel

1.38"

PU/FIP

Insulated 1/4" or 1/2"

Raised Panel

FIRESTAR 3” SLAT INSULATED

20GA. 22GA.

N/A N/A 256

Aluminum

1/8" Glass

1.38"

Glass

1.38"

SHEET DOOR

26GA

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Medium Duty Operator

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3.2

Section 3: Critical Installation Information

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 connec before installing the operator.

4) Install the door operator at least 8 feet above the floor if the operator has exposed 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.

ted to the door

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Medium Duty Operator

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3.3

Section 4: Installation

Rolling Steel/Grill Doors

Front of Hood

The Rolling Steel Door Operator can be assembled for right-hand or left-

mounting .dooH fo tnorF

hand

Each model can also be wall mounted (next pages).

1) Mounting hardware and instruction will be supplied based on door specifications. (Typical mounting arrangements shown in figures 1 and 2.)

13-7/8"

(OUTPUT SHAFT LENGTH)

(WIDTH OF OPERATOR)

Figure 1

GCL-MJ&MH

Medium Duty Operator

3-7/16"

(OPERATOR

SIDE ROOM REQ'D.))

12"

11"

5-1/8"

Figure 2

17"

3-1/2"

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8-3/4"

4.1

Front of Hood (continued)

5) Attach operator assembly to end plate as shown using hardware provided. Fig 3.

NOTE: At this time, hand tighten only, the mounting bracket nuts

where it attaches to the head plate. This allows for adjustment in order to tension the drive chain.

Attach Operator to Door: Front of Hood.

1) Attach 12 tooth sprocket to operator output shaft.

2) Align keyways and insert key into sprocket and output shaft

keyway.Do not tighten set screw at this time.

3) Attach door sprocket to door shaft. Do not tighten

at this time.

4) Assemble chain using chain master link.

5) Place assembled chain over door shaft sprocket and around the

6) Adjust operator position

12 tooth sprocket.

to remove slack from

the chain.

7) Tighten operator mounting bracket nuts.

8) Tighten sprocket set screws.

Figure 3

GCL-MJ&MH

Medium Duty Operator

SOCKET BUTTON HEAD CAP SCREW IS FACTORY WELDED TO THE HEAD PLATE

112146.0001

(GMX Mounting Bracket)

111983.0001

(GMX Mounting Bracket)

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24121C

(Hex nut w/lkwshr, 5/16-18)

086420.0506

(Bolt, 5/16-18 x 3/4)

086420.0510

(Bolt, 5/16-18 x 1-1/4)

24121C

(Hex nut w/lkwshr, 5/16-18)

080352.0714

(Hex nut, 7/16-14)

FLAT WASHER

4.2

Wall Mount

™

The GCL-MJ&MH by using an

Attach wall mount brackets to operator using the 4 mounting

1) bolts and nuts supplied(Hand-tighten until later). Position the

Attach 12 tooth sprocket to operator output shaft.

Align keyways and insert key into sprocket and

output

Attach door sprocket to door shaft. Do not tighten yet.

Assemble chain using chain master link.

Place assembled chain over door shaft sprocket and operator sprocket.

Raise

Ensure

Tighten operator mounting bracket nuts.

Align chain and secure operator to wall.

10)

Tighten operator chain sprocket set screws.

11)

Slide operator in the wall bracket mounting holes if necessary for fine adjust of chain tension.

JACKSHAFT VERSION

Rolling Steel unit can be wall mounted

optional “Wall Mount Kit.” (P/N 111011.0001.S).

operator in the brackets as shown.

shaft keyway. Do not tighten set screw yet.

or lower operator to remove

slack from the chain.

operator output shaft is parallel with door shaft.

The release cable must be attached before mounting the unit.

RELEASE CORD

where necessary

Fig.4.

15"

(TYPICAL SIDE ROOM)

13-7/8"

(OUTPUT SHAFT LENGTH)

(WIDTH OF OPERATOR)

VERTICALLY ALIGN SPROCKETS/CHAIN

LOCK DOWN HOLES MUST BE USED TO ENSURE MAINTAINING OPERATOR POSITION

Figure 4.

12-1/4" TO 11"

5" TO 3-3/4"

19-5/8"

(HEIGHT OF OPERATOR

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Medium Duty Operator

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4.3

Sectional Doors—Chain Couple

The Wall Mount Operator can be assembled for right hand mounting above or below the door shaft. Fig.5A.

NOTE:The operator output shaft extends 3-7/8" on each side of the

operator frame.

1) Attach 12 tooth sprocket to operator output shaft.

2) Align keyways and insert key into sprocket and output shaft keyway. Do not tighten set screw at this time.

at this time.

4) Assemble chain using chain connecting link.

5) Place assembled chain over door shaft sprocket and operator sprocket.

6) Raise or lower operator to remove slack from the chain.

7) Be certain operator output shaft is parallel with door shaft.

8) Align chain and secu

9) Tighten operator sprocket set screws.

INSTALLATION TIP: While sprocket set screws are loose, help align chain. A properly tensioned drive chain should deflect no more than 1/2" when thumb pressure is applied mid-way between the 2 sprockets.While there is no hard and fast rule governing chain tension, it must be tight enough to prevent clicking, popping and jumping the

teeth of the sprocket. The 1/2" guideline will insure sufficient tension. NOTE: If using slotted mounting holes to mount unit

least 2 lockdown holes in opposite corners to firmly mount unit to wall.

operator to wall or mounting pad.

if possible, manually operate door to

nethgit ton oD.tfahs rood ot tekcorps rood hcattA)3

Fig.5

, you must use at

Fig. 5B

Figure 5A

Figure 5B

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Medium Duty Operator

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4.4

Chain Couple

For Hollow Counterbalance Door Shaft:

1) Use non-threaded hole in door shaft sprocket as a guide and drill a 3/8" diameter hole through one side of the door shaft. Fig. 6A. Insert clevis pin through sprocket and shaft to hold sprocket

2) in position.

3) Drill through opposite side of shaft to obtain proper hole alignment. Fig. 6B. Insert clevis pin through both holes and secure with cotter pin.

Fig. 6C.

For Solid Counterbalance Door Shaft:

1) Insert k

ey into door shaft keyway.

2) Slide sprocket into place and secure with set screws.

To Complete the Installation:

If needed, realign operator spr

ocket with door sprocket. If you have excessive door shaft movement, an optional chain tension plate is available.Fig. 7A

& 7B, pg 4.6.

Figure 6A

Figure 6B

Figure 6C

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Medium Duty Operator

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4.5

Chain Couple

Spreader Bracket

Bracket is available as an optional kit, P/N 111005.0001.S

Installation of optional chain spreader bracket: Fig 7A & 7B.

1) Place sprocket, upper plate and bearing assembly on door shaft as shown.

2) Place lower plate, bearing assembly and sprocket on operator shaft as shown.

3) Install door and operator sprockets and chain assembly as described on page 4.4.

4) Install bolts and nuts through plates.

5) Tighten and align chain and plate and secure operator to wall.

6) Tighten spreader bracket bolts.

SPROCKET GOES ON FIRST

GCL-MJ&MH

DOOR SHAFT

Figure 7A

Medium Duty Operator

OPERATOR SHAFT

SPROCKET GOES ON LAST

Figure 7B

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4.6

Clutch Adjustment Fig. 8

.detsujda eb nac taht hctulc elyts noitcirf a evah srotarepo ehT

NOTE:The clutch is intended to provide protection for the door, the operator and associated equipment. It is not intended for entrapment protection.

To Adjust the Clutch

1) Decrease the tension on the clutch until the operator will not lift

2) Gradually increase tension until the operator will perform a

3) Insert a cotter pin through the adjustment castle nut and bend a

NOTE: Periodically check the system for proper clutch action. If clutch

ts to slip after working properly for some time , check manual

star operation of door BEFORE adjusting clutch. The door may not be operating freely or the counterbalance spring may need adjusting. Repairs and adjustments must be performed by a trained service representative using proper tools and instructions.

or.

the do

Turning the adjustment castle nut counter-clockwise will

decrease tension and clockwise will increase tension.

complete open and close cycle without clutch slippage.

leg of the cotter pin to hold it in place.

Brake Adjustment Fig. 9

1) Loosen the Adjustment Bracket Lock Nut/Bolt.

2) Slide the Adjustment Bracket as needed to reach the desired spring tension.

When properly adjusted, the pivot arm should move with very little effort.

3) Re-tighten the Adjustment Bracket Lock Nut/Bolt.

Figure 8

Figure 9

BRAKE ADJUSTMENT LOCK NUT AND BOLT

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Medium Duty Operator

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4.7

Hand Chain & Keeper

1) Route the hand chain through the chain guide, around the pocket wheel and back through the chain guide. Fig.10.

2) Connect the hand chain ends together as shown in Fig 11 by twisting open the last link on one end of the chain, and slipping the last link on the opposite end onto the open link.

3) Twist open link closed again.

4) Mount chain keeper to wall in line with chain approximately 4 feet from floor.

5) Loop chain around keeper as shown. Fig. 12.Optional Padlock not provided

6) Install release cable. Fig. 13.

NOTE:T hand chain before connecting the link ends together.

o insure smooth operation, make sure there are no twist in the

Figure 10

RELEASE CORD

Figure 11

GCL-MJ&MH

Medium Duty Operator

Figure 12

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Figure 13

4.8

Section 5: Wiring

Line Voltage Wiring

Fig.1

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 lo

educe the risk of electric shock, make sure the chassis

• To r 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. Fig. 2.

Keep low voltage and line voltage wires separate.

•

• Route all line voltage wires as shown.

• Plug all unused conduit holes.

cated on the nameplate.

Figure 1

ROUTE LINE VOLTAGE WIRING IN SHADED AREA AS SHOWN

LINE INPUT TERMINALS

LINE GROUND

HIGH VOLTAGE INPUT PLUGS

Figure 2

LINE IN

POWER CONNECTIONS

L1/ 1

LINE

120V

(HOT)

240V

LINE 1

N/ L2

NEUTRAL

LINE 2

GND

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Medium Duty Operator

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5.1

+ 36 hidden pages