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
In
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.
r
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.
ng
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:
1)
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
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.
UL
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
PU/FIP
Insulated
Insulated
PU/FIP
PU/FIP
Insulated
1.38"
Insulated
2"
2"
20GA.
Exterior
Raised Panel
1.38"
PU/FIP
Insulated 1/4" or 1/2"
Raised Panel
2"
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
2)
Attach 12 tooth sprocket to operator output shaft.
3)
Align keyways and insert key into sprocket and
output
4)
Attach door sprocket to door shaft. Do not tighten yet.
5)
Assemble chain using chain master link.
6)
Place assembled chain over door shaft sprocket and operator sprocket.
7)
Raise
Ensure
8)
Tighten operator mounting bracket nuts.
9)
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
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.
re
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
B.
Fig. 5B
Figure 5A
Figure 5B
GCL-MJ&MH
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.
4)
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.
I
Figure 6A
L
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.
PL
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
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