The 11 sections of this Installation Manual provide the information required to install, troubleshoot and maintain an GCL-T™ 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 GCL-T™ 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.
GCL-T
Standard Duty Operator
www.geniecompany.com 06-12
1.1
Section 2: Safety Information & Instructions
WARNING
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 under stand 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:
ER
DANGWARNING CAUTION
The word NOTE is used to indicate important steps to be followed or important considerations.
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR
ELECTRICAL SHOCK
HIGH SPRING TENSION
indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in injury or property damage.
Do Not operate unless the doorway is in sight and free of
WARNING
Could result in
Serious Injury
or Death
WARNING
Could result in
Serious Injury
or Death
WARNING
Could result in
Serious Injury
or Death
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 causing
the malfunction.
5. The Operator Motor is protected against
overheating by an internal t
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 system.
7. Keep instructions in a prominent location
near the pushbutton.
hermal protector.
GCL-T
Standard 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
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) 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®, Monitored Photocells for NEMA4, P/N OPAKPEN4GX.S.
operator torque and door travel speed selection.
button control stations, 1 button control stations, radio controls, pull
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,
.cte ,sthgil gninraw ,syaler lortnoc yrailixua,),tcatnoc yratnemom sa etarepo ot tes srood
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-T
Standard Duty Operator
DO NOT apply line voltage until instructed to do so.
www.geniecompany.com 06-12
3.1
Section 3: Critical Installation Information
ENTRAPMENT PROTECTION
UNTIL ONE OF THESE MONITORED EXTERNAL ENTRAPMENT DEVICES IS INSTALLED, TH.NOITCERID ESOLC EHT NI NOITAREPO TCATNOC YRATNEMOM WOLLA TON LLIW
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.
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."
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 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.
Drawbar Assembly
The Drawbar Operator consists of the Power Unit (A), Drawbar Rail
(B), Chain Guides (C), Front Spreader (D), Front Idler Pulley (E), Drive Chain (F), Drive
Sprocket (G) and Drawbar Arm (H). The Drawbar rail length, chain length and
quantity of chain guides will vary by door heights. Fig. 1.
NOTE: Drawbar rail must be (29) inches longer than the door’s height. Rails
have been sized properly and pre-punched for the chain guide assemblies from
the factory.
Figure 1
D
E
C
B
F
G
A
GCL-T
Standard Duty Operator
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4.1
Drawbar Assembly (continued)
1) Attach Rails to Power Unit using four (4) 7/16”-14 x 1” bolts, 7/16”-14 keps nuts and 7/16” lock washers (provided). Fig. 2.
2) Attach the chain guide assemblies to the drawbar rails using
Track Bolts and locknuts (provided). Fig. 3.
CAUTION
Verify that screws are properly seated in track. Failure to seat screws can
cause carriage to bind in door track.
Figure 2
7/16"
BOLTS
NOTE: Space chain guides evenly between operator and header. Add a chain
guide for every 4 feet of door height per chart.
UNDER 12’
2345
NOTE: Chain Guide mounting holes have been pre-drilled at standard locations along the track. If different locations are needed, hole size should be
1/4" dia. Be sure to de-burr the holes.
Figure 3
12’ to 16’16’ to 20’20’ to 24’
PLASTIC CHAIN GUIDE
CHAIN GUIDE BRACKET
GCL-T
Standard Duty Operator
TRACK BOLTS/
LOCKNUTS
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4.2
Drawbar Assembly (continued)
3) Insert the carriage into the rails as shown in Fig. 4.
NOTE: The end of the carriage with the chain tension adjustment bolt should be
toward the operator.
4) Place the spreader bracket in position around the drawbar rail. Do not
will be held in place (temporarily) by the clevis pin which holds
the pulley.
5) Install the idler pulley inside the rails by inserting the 3/8” x 4-1/2” clevis
pin through one of the rails and as you feed it through an idler sleeve and the idler pulley followed by the second sleeve . Place fender
washer (7/16” x 1-1/4”) over end of clevis pin. Secure clevis pin using
cotter pin. Fig. 5.
redaerps ehT .emit siht ta stun kcol dna stlob kcart eht tresni
bracket
NOTE: For building of the spreader bracket assembly on a Dual Trolley unit see
the separate Drawbar instruction sheet for Sidemount and Dual Trolley models.
OPERATOR
GCL-T
Standard Duty Operator
RAIL
CARRIAGE
Figure 4
IDLER PULLEY
FRONT
SPREADER
BRACKET
DOOR
SLEEVE
WASHER
CLEVIS PIN
Figure 5
www.geniecompany.com 06-12
LOCKNUTS
DO NOT INSTALL YET!
COTTER PIN
/STLOB KCART
4.3
Drawbar Assembly (continued)
6) Uncoil the drawbar chain and install by routing the chain over the chain
guides (A) and around the drive sprocket (B) on the output shaft as shown
in Fig. 6.
7) Attach to Chain Tension Adjusting Bolt (C) using a master link (provided).
8) Pass the other end of the chain between the front spreader bracket and
the idler pulley (D). Make certain the chain is not twisted.
9) Attach the chain to the carriage (E) using a master link.
10) Insert the Adjusting Bolt through the hole in the Carriage and place the
tensioning spring, flat washer and adjusting nut onto the bolt. Detail A,
Fig 6.
11) Tighten Chain so that it will not jump a sprockets or pulley. Add locknut.
Check to ensure the following:
• The chain is properly engaging the output sprocket.
• The chain is not twisted.
D
Figure 6
A
A
B
E
C
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.
GCL-T
Standard Duty Operator
www.geniecompany.com 06-12
Detail A
MASTER
LINK
FLAT WASHER
LOCKNUT
ADJUSTING NUT
TENSIONING
SPRING
MASTER
LINK
CHAIN
TENSION
ADJUSTMENT
SCREW
4.4
Drawbar Installation
CAUTION
Check the working condition of the door before installing the operator. The
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 width of the door to determine the center. Make a vertical
line above the door, 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).
2) Prepare for attaching drawbar to header. If woodwork, or other suitable
material is not already in place, securely affix a 2” x 6” block of wood or
metal plate as shown in Fig. 7.
3) Center the block/plate on the header.
4) Mark the door’s vertical center line on this block/plate.
5) Use a level, as shown in Fig. 8 (pg 4.6) to find the highest point of travel for
the door.
6) Mark a horizontal line across the vertical line you made on the header
at 5” above the highest point of door travel.
NOTE: On torsion spring doors with an uneven number of panels, the operator
may be attached to the stile nearest to the center.
VERT CAL L NE
(SEE STEP 1)
HEADER
CENTERLINE
OF DOOR
ATTACHMENT MATER AL
(SEE STEP 2)
HOR ZONTAL L NE
(SEE STEP 6)
Figure 7
GCL-T
Standard Duty Operator
www.geniecompany.com 06-12
4.5
Drawbar Installation (continued)
7) Raise the door end (idler pulley) of the drawbar while resting the operator
on the floor or other desired material.
8) Position the spreader bracket on your centerline with its bottom edge on
your horizontal mark. Fig. 9.
• Fasten spreader bracket to header using fasteners appropriate for the
header material.
MARK A HORIZONTAL LINE
ABOVE HIGHEST POINT OF TRAVEL
2" X 6"
HEADER
5"
LEVEL
HIGHEST POINT
OF TRAVEL
GCL-T
Standard Duty Operator
Figure 8
Figure 9
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4.6
Attach Operator
1) Raise the operator and position it so that the drawbar rails are
level and perpendicular to the face of the door (or the stile where
the door bracket will be attached). Fig. 10.
2) Lock the drawbar rails into the spreader bracket using the
track bolts (1/4”-20 X 9/16”) and two(2) locknuts.
3) Secure the operator in position by installing steel angles (not
provided) between the ceiling superstructure and the operator
power unit. Fig. 11.
two (2)
Figure 10
TRACK BOLTS
& LOCK NUTS
LEVEL
WALLWALL
ROPE, CABLE,
CHAIN, ETC.
DOOR FROM ABOVE
RAILS
90°
NOTE: Track bolts MUST be installed from inside the rails.
Figure 11
DRILL HOLE IN ANGLE
AND MOUNT USING
REAR SUPPORT
CARRIAGE BOLT
STEEL
ANGLES
(NOT INCLUDED)
GCL-T
Standard 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. (See NOTE 2.)
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) For wood doors fasten the door bracket to the door using two 1/4” -20 X 2-1/4”
carriage bolts and nuts. For metal doors use two 1/4”- 20 self tapping sheet metal screws, or as recommended by the door manufacturer.
4) Use two (2) 3/8” -16 X 7/8” bolts and nuts to attach the door arms together.
NOTE: Use the set of holes that align the drawbar in a near vertical position for operators
without a brake. Set arms at a 20-30 degree rearward angle for operators with a brake.
Fig. 12.
For units without a brake, set arms as close to 0 degrees (vertical) as possible.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.
Figure 11
NOTE 2: In case of emergency, pulling the Emergency
Release Knob (Fig. 12) disengages the door from operator
allowing for the door to be shut manually.
Figure 12
When installing non-brake units
with drawbar near vertical, it is
important to make sure there
is adequate room between the
door bracket and drawbar rail
for the door arms to go vertical.
Without sufficient clearance
and by running the dood arms
vertical, a significant amount of
force could be applied possibly
leading to damage.
There is an optional drawbar
kit with a cusion springbox
available: P/N OPAKDBT.S
GCL-T
Standard Duty Operator
WITH BRAKEWITHOUT BRAKE
AVOID THIS SETUP
20°-30°
with Brake
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WITHOUT BRAKE
CORRECT
4.8
Clutch Adjustment Fig. 13
The Operators have a friction style clutch that can be adjusted.
NOTE: The clutch is intended to provide protection for the door, the operator and
yellorT .noitcetorp tnempartne rof dednetni ton si tI tnempiuqe detaicossa
operators 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.
The adjustment of the clutch should be such that the door and operator function in
this manner. The steps for clutch adjustment follow:
CLUTCH PULLEY
WASHER
To Adjust the Clutch
1) Decrease the compression on the clutch until the operator will not lift
the door.
•Turn the adjusting castle nut counter-clockwise to decrease clutch
compression and clockwise to increase clutch compression.
2) After completing step 1, begin to increase compression on the clutch until the operator is capable of lifting the door through the
complete cycle
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 compression 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 action. If clutch starts to slip after
working properly for some time, check manual 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.
GCL-T
Standard Duty Operator
without clutch slippage.
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COTTER PIN
ADJUSTING NUT
Figure 13
SPRING
CLUTCH
PAD
CLUTCH
PLATE
4.9
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 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
• Route all line voltage wires as shown.
• Plug all unused conduit holes.
voltage and line voltage wires separate.
Figure 1
HIGH
VOLTAGE
INPUT PLUGS
(Right & Left)
HIGH
VOLTAGE
INPUT PLUGS
(Right & Left)
LINE INPUT
TERMINALS
LINE INPUT
TERMINALS
P
LINE
GROUND
ROUTE HIGH VOLTAGE WIRING
IN THE SHADED AREA AS SHOWN
LINE
GROUND
Three Phase
LINE IN
POWER CONNECTIONS
1
2
LINE 1
LINE 2 L NE 3
GND
LINE IN
Single Phase
POWER CONNECTIONS
N/ 2
LINE
NEU RAL
5V
(HO
LINE
LINE 2
208V
230V
GND
GCL-T
Standard Duty Operator
ROUTE HIGH VOLTAGE WIRING
IN THE SHADED AREA AS SHOWN
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5.1
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