Genie GCL-MT Owner's Manual
™
GCL-MT
Medium Duty Operator
TROLLEY
111850.501539
08-12
TensiBelt
PROPER APPLICATION
Door Type Operator Type HP/Max Door Weight
Sectional Trolley
(Standard Lift
Low Headroom)
NOT FOR R E S I DENTIAL U S E
This Installation Manual provides the information required to install, troubleshoot and
maintain a GCL-MT
™
Commercial / Industrial Door Operator.
™
1/2HP = 620 lbs
(Available in 1/2HP only)
THIS PAGE LEFT BLANK
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Medium Duty Operator
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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...............................................................4.1-4.9
Drawbar Assembly................................................4.1-4.6
Attach Operator ....................................................4 7
Connection to the Door .....................................4.8
Clutch and Brake Adjustment ..........................4.9
Section 5 Power and Control Wiring .................................5.1-5.7
Line Voltage Wiring..............................................5.1
Low Voltage Control Wirin
External Wire Diagram ........................................5 3
Wall Control.............................................................5.4
Interlock Switches & Radio Control................5 5
Radio Control & Photocell Wiring ...................5.6
Sensing Edge Wiring............................................5 7
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.....................
Max Run Timer .......................................................6.6
Setting the Mid-Stop ...........................................6 7
Changing Open & Close Modes ......................6.8
g ..............................5.2
......6.5
Section 7 Special Operator Features .................................7.1-7.2
Operator Cycle Count..........................................7.1
Circuit Board Firmware version .......................7.1
Operator Type ........................................................7.2
Section 8 Troubleshooting....................................................8.1-8.4
Section 9 Service & Maintenance .......................................9.1
Section 10 Appendix A .............................................................10.1-10.9
Section 11 Warranty...................................................................11.1
Display Operation.................................................8.1
Error Codes..............................................................8.1-8.2
Run Codes................................................................8.2-8.3
LED Indicators ........................................................8.4
Safe-T-Beam® Monitored Photocell
Troubleshooting Chart .......................................8.5
Basic Operator Parts........................................10.1
Basic Shaft Assembly Parts............................10.2
Basic Rail/Trolley Pa r ts.................................10.3
Basic Electric Box
Appendix B..............................................................10.5
Screw Terminal Assignments.......................10.5
Appendix C..............................................................10.6-10.8
Display Run Codes...........................................10.6
Display Er
Parts...................................10.4
ror Codes .........................................10.7-10.8
GCL-MT
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-MT™ 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-MT™ 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
tha
Sections 9-11
Pr
troubleshooting and service activities, along with important warranty and returned goods policy
information.
FOR ASSISTANCE CALL 1-800-843-4084
occur.
t may
ovide related information on service and maintenance items, operator drawings for use in
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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
.snoitcurtsni dna sloot reporp gnisu evitatneserper
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 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
operated manually by pulling the release
cable to disconnect the operator drive system.
7. Keep instructions in a prominent location
near the pushbutton.
the condition causing
, the door can be
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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 doors with pass doors and door locks. See page 5.5.
8-Accessory equipment. Examples are reversing edges and/or photocell beams (required 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 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).
2) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPE.S.
3) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPEN4GX.S.
operator torque and door travel speed selection.
and corrosiveness of the location.
dustiness 5-Operator mounting environment. Items to consider include operator location and dampness,
doors set to operate as momentary contact,), auxiliary control relays, warning lights, etc.
room below door shaft, available mounting
cords, loop detectors, photoelectric controls,
GCL-MT
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.
Medium Duty Operator
DO NOT apply line voltage until instructed to do so.
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3.1
Section 3: Critical Installation Information
ENTRAPMENT PROTECTION
The GCL-MT™ 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
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 Monitored Photoeye Kit P/N OPAKPE.S
Commercial NEMA4 Monitored Photocells P/N OPAKPEN4GX.S.
Sectional Door Chart (sq. ft.)
Door S er ies ->
UL L is tedHPMod el
GCL-MT 1/2
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
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
Insulated
Steel
OPERATOR
24GA.
Ribbed
Steel
WILL NOT ALLOW MOMENTARY CONTACT OPERATION IN THE CLOSE DIRECTION.
HTDIW ROOD ELBAWOLLA SECIVED DETSIL
ANY WIDTH
30 FEET
30 FEET
35 FEET
Aluminum
PU/FIP
PU/FIP
24GA.
Ribbed
Steel
Insulated
Nominal
24GA.
Ribbed
Steel
Nominal
24GA.
Ribbed Steel
Insulated
PU/FIP
Insulated
PU/FIP
Insulated
1.38"
PU/FIP
Insulated
2"
PU/FIP
Insulated
2"
20GA.
Exterior
Insulated 1/4" or 1/2"
Insulated
Raised
Raised
Panel
Panel
2"
1.38"
1/8" Glass
1.38"
Glass
1.38"
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Medium Duty Operator
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3.2
Section 4: Installation
IMPORTANT
INSTALLATION INSTRUCTIONS
To reduce the risk of severe injury or death:
WARNING
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 t
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 c
of the door.
7) Install the Entrapment Warning Placard next to the control station
prominent location.
8) For products having a manual release, instruct the end user on the operation of the
manual release.
-
Figure 1
he power unit) that are connected to t
annot reach it, and (c) away from all moving parts
he door
and in a
Drawbar Assembly
The Model GCL-MT™ Drawbar Operator consists of the Power Unit (A),
Drawbar Track (B), Chain Guides (C), Drawbar Arm (E), Front Spreader (G),
Front Idler Pulley (H), Drive Chain (J), Drive Sprocket (K) and Drawbar
Track Spacer (L). The Drawbar track length, chain length and quantity of
chain guides will vary by door heights. Fig.1.
1) The Drawbar Track Spacers are attached to the Power
Unit at the factory. Fig. 1.
– Attach Track to Power Unit at the Spacers using eight
(8) 1/4"-20 x 1-1/2" track bolts and 1/4"-20 keps nuts (provided).
Fig. 2. The curved part of the Track MUST be toward the
electrical panel.
NOTE: Drawbar tracks must be thirty (30) inches longer than the door’s
height. Tracks have been pre-punched at the door plant for the chain
guide assemblies.
Figure 2
1/4"-20
KEPS NUTS
Track Spacers are factory installed.
1/4"-20
KEPS NUTS
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Medium Duty Operator
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4.1
Drawbar Assembly (cont’)
3) Insert the carriage into the tracks as shown in Fig. 3.
NOTE: One end of the carriage has a notch (Detail A) which will be
used to locate the chain pin (Detail B). This end of the carriage faces
the front spreader bracket and away from the power unit.
4) Attach the front spreader bracket to the front of the operator
tracks with two (2) track bolts and two (2) locknuts (check hole
alignment before installing).
5) Position the idler pulley inside the track and insert the
3/8" x 4-1/2" clevis pin. Secure the clevis pin using the
hitch pin. Fig. 4.
NOTE:Track bolts MUST be installed
from inside the track.
CARRIAGE
DETAIL A
NOTCH
Figure 3
CHAIN
PIN
TRACK
CHAIN
DETAIL B
GCL-MT
Medium Duty Operator
FRONT
SPREADER
BRACKET
LOCK NUT
CLEVIS PIN
IDLER PULLEY
TRACK
BOLTS
EXPLODED VIEW ASSEMBLED VIEW
HITCH PIN
LOCK
NUT
TRACK
Figure 4
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2
4.
Drawbar Assembly (cont’)
6) Attach the chain guide assemblies to the drawbar tracks
using track bolts and locknuts. Fig. 5.
NOTE: Space chain guides evenly between operator and header. Doors
12 foot tall and under will use 2 chain guides. Doors over 12 feet will
require 3 chain guides.
CHAIN GUIDE
BRACKET
PLASTIC SLIDE
GUIDE
NOTE:Verify that track bolts are properly seated in track. Failure to seat
bolts can cause carriage to bind in door track.
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Medium Duty Operator
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TRACK
Figure 5
SLOTS ARE PROVIDED
TO ATTACH BRACKET
USING TRACK BOLT
WITH LOCK NUT
(BOTH SIDES)
ALTERNATELY: A 9/32 HOLE
CAN BE DRILLED IN
THE TRACK. THE HOLES
WILL NEED TO BE
DEBURRED BEFORE
INSERTING TRACK BOLTS
4.3
Drawbar Assembly (cont’)
7) Uncoil the drawbar chain and install by routing the chain over
the chain guides and around the drive sprocket on the output
shaft as shown in Fig. 6
.
8) Pass the chain through the rectangular slot in the carriage and
insert the chain pin through the end link of the chain.
9) Pass the other end of the chain between the front spreader
bracket and the idler pulley. Make certain the chain is
not twisted.
10) Move chain toward the carriage.
11) Attach the eye bolt to the chain using the #41 master chain link.
12) Attach the chain to the carriage.
13) Insert the eye bolt through the hole in the carriage.
14) Place the spring and flat washer
over the eyebolt.
15) Thread a single nut onto the eyebolt as shown in Detail A, Fig 6
16) Tighten Chain with no more than 2" of sag and add second
locknut. Detail A, Fig 6.
Check to ensure the following:
The chain is properly engaging the output sprocket.
The chain pin is properly seated in the indentations on the
front of the carriage.
The chain is properly seated on the rib of the idler pulley.
The chain is not twisted.
WARNING
DO NOT apply line voltage until instructed to do so.
Repairs and adjustments, including particularly to cables and
spring assemblies under high tension, must be made by a trained
service representative using proper tools and instructions.
.
MASTER LINK
EYEBOLT
CHAIN PIN
CARRIAGE
CHAIN
SPRING
WASHER
Figure 6
TROLLEY
SPROCKET
& SHAFT
DETAIL A
LOCK
NUT
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Medium Duty Operator
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4.4
Drawbar Installation
CAUTION
Check the working condition of the door before installing the
operator.Door must be free from sticking and binding.
If the door is equipped with a latching device, secure the locking
bar in the open (unlocked) position. This style operator will act as a
latching device when the door is down and therefor the door’s
lock is no longer needed.
If the door lock is to remain functional, an interlock switch MUST
be installed which will prevent operation of the door whenever
the door lock is engaged. Refer to the Wiring Instructions, section
5.5, of this manual for proper connection of the interlock switch.
1) Measure the
vertical line as shown in Fig. 7.(If the vertical line is not in line
with a door stile, a means of attaching the door bracket to the
door must be provided. This can be accomplished by spanning
the center of the door’s top section (between the top and
bottom rail) with a suitable material such as wood or steel.
NOTE: On torsion spring doors with an uneven number of panels, the
operator may be attached to the stile nearest to the center.
2) Prepare for attaching drawbar to header. If suitable woodwork is
not already in place, securely affix a 2" x 6" block of wood as
shown in Fig. 7.
3) Center the block on the header.
4) Mark the center ve
5)
Use a level, as shown in Fig
of travel for the door.
6) Mark a horizontal line across the vertical line you made on
the header at 2-1/2" above the highest point of door travel.
width of the door to determine the center. Make a
rtical line on this block.
. 8 (pg 4.6) to find the highest point
HEADER
VERTICAL LINE
(SEE STEP 1)
CENTERLINE
OF DOOR
Figure 7
2" X 6" (SEE STEP 2)
HORIZONTAL LINE
(SEE STEP 6)
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Medium Duty Operator
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4.5
Drawbar Installation (cont’)
1) Raise the operator into a position approximately 4" above the
horizontal door tracks.
2) Temporarily suspend the operator from the ceiling
superstructure with rope or by some other safe and
suitable means.
3) Position the bottom edge of the front spreader bracket on
your horizontal mark on the header. Fig. 8.
2" X 6"
HEADER
MAKE MARK 2-1/2"
ABOVE HIGH ARC OF
DOOR FOR HORIZONTAL
LINE
HIGH ARC
OF DOOR
Figure 8
LEVEL
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Medium Duty Operator
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4.6
Attach Operator.
4) Center spreader bracket on the vertical line. Use two (2)
1/4" x 1-3/4" lag bolts to attach the bracket to the header. Fig. 9.
5) Raise the door and position the operator so that the
drawbar tracks are level and the operator chain is in line
with the center of the door (or the stile where the door bracket
will be attached). Fig. 9.
6) Secure the operator in this position by installing steel angles
(not furnished) between the ceiling superstructure and the
operator power unit. Fig. 10.
1/4" X 1-3/4" LAG BOLTS
STEEL
ANGLES
(NOT INCLUDED)
07-11
Figure 10
Figure 9
ROPE OR CABLE
STEEL ANGLES
(NOT INCLUDED)
DRILL HOLE IN ANGLE
AND MOUNT USING
REAR SUPPORT
CARRIAGE BOLT
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Medium Duty Operator
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4.7
Connection to the Door
1) Pull down on the drawbar arm locking sleeve and attach to
carriage.
2) Position the door bracket on the door as shown in Fig. 11,
with mounting holes on the door centerline. (Even with or
above top door roller).
3) Fasten the door bracket to the door using two
1/4" -20 X 2-1/4" carriage bolts and nuts for wood doors.
Use 1/4"- 20 self tapping sheet metal screws for metal doors.
Or as recommended by the door manufacturer.
4) Use two (2) 3/8" -16 X 7/8" bolts and nuts to attach the
door curved door arm to the straight drawbar arm.
NOTE: Use the set of holes that align the drawbar in a near vertical
position for operators without a brake
rearward angle for operators with a brake.
For units without a brake, set arms as close to 0 degrees as possible.
Fig.12.
NOTE: If the door strut interferes with the mounting of the door
bracket, position the door bracket below the strut. DO NOT,in any way,
cut or modify the strut.
GCL-MT
Medium Duty Operator
. Set arms at a 20-30 degree
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Figure 11
CLEVIS/COTTER
PIN
Figure 12
Top Door Roller
Door Center Line
DOOR
BRACKET
FRONT SPREADER
BRACKET
STRUT
1 -5/8" (REF.)
ATTACH TO DOOR WITH
1/4" -20 X 2 -1/4"
CARRIAGE BOLTS
W/NUTS
(OR AS RECOMMENDED
BY DOOR
MANUFACTURER)
DRAWBAR ARM (STRAIGHT)
RELEASE CORD
3/8"-16 X 7/8" HEX HEAD BOLTS
WITH 3/8" - 16 FLANGE NUTS
DRAWBAR ARM (CURVED)
DOOR BRACKET
TRACK
CARRIAGE
4.8
Clutch Adjustment
These operators have a friction style clutch that can be adjusted.
NOTE:The clutch is intended to provide protection for the door, the operator and
associated equipment. It is not intended for entrapment protection. They
have a motor reversing feature that is integrated with the clutch assembly. If an
obstruction is placed in the pathway of the door during operation the motor will
stop and reverse when the clutch begins to slip. Therefore, the adjustment of the clutch
should be such that the door and operator function in this manner. The clutch should be
such that the door and operator function in this steps for clutch adjustment follow:
To Adjust the Clutch
1) Decrease the tension on the clutch until the operator will not lift the door.
Turn the adjusting castle nut counter-clockwise to decrease clutch tension and
clockwise to increase clutch tension.
2) After completing step 1, begin to increase tension on the clutch until the operator
is capable of lifting the door through the complete cycle without clutch slippage.
3) Test the reversing feature of the operator by placing an obstruction under the
door during a close cycle. The door should reverse on the obstruction and return
to the open position. If the door does not close but comes down part way and
reverses without any obstructions in its path, then increase the clutch tension
until the door will close fully.
4) Finally, insert the cotter pin through the castle nut and shaft and bend the
outer leg of the cotter pin.
NOTE: Periodically check the system for proper clutch a
starts to slip after w
operation of door BEFORE adjusting clutch. The door ma
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.
orking properly for some time, check manual
ction. If clutch
y not be
To Adjust the Brake
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.
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Medium Duty Operator
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Figure 13
41 erugiF
LOCK NUT & BOLT for
BRAKE ADJUSTMENT
4.9
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