11852.501539 GCL-MJ&MH ™ Medium Duty Operator JACKSHAFT/HOIST TensiBelt™ PROPER APPLICATION Door Type Operator Type HP/Max Door Weight Sectional Jackshaft/Hoist (Available in 1/2HP only) (Vertical Lift and Lift Clearance Type Rolling Steel (Sidemount, Chain Couple) Sectional = 620 lbs. Rolling Steel = 580 lbs. NOT FOR RESIDENTIAL USE 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 Section 2 Section 3 Section 4 Section 5 Section 6 How to use this manual .......................................1.1 Safety Information & Instructions.....................2.1 Critical Installation Information........................3.1-3.2 Installation.................................................................4.1-4.7 Rolling Steel-Front of Hood.................................4.1-4.2 Wall Mount ...............................................................4.
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 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 understand the information presented, call your nearest service representative.
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, room below door shaft, available mounting surface integrity, power supply location, and convenient chain hoist and release cable positioning.
ENTRAPMENT PROTECTION Section 3: Critical Installation Information 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.
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.
Section 4: Installation Rolling Steel/Grill Doors Front of Hood The Rolling Steel Door Operator can be assembled for right-hand or lefthand mounting Front of Hood. 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) 12" Figure 1 5-1/8" 11" Figure 2 8-3/4" 17" 3-1/2" 3-7/16" (OPERATOR SIDE ROOM REQ'D.
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.
Wall Mount The GCL-MJ&MH™ Rolling Steel unit can be wall mounted where necessary by using an optional “Wall Mount Kit.” (P/N 111011.0001.S). Fig.4. 1) Attach wall mount brackets to operator using the 4 mounting bolts and nuts supplied(Hand-tighten until later). Position the operator in the brackets as shown. 2) Attach 12 tooth sprocket to operator output shaft. 3) Align keyways and insert key into sprocket and output shaft keyway. Do not tighten set screw yet. 4) Attach door sprocket to door shaft.
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. 3) Attach door sprocket to door shaft. Do not tighten at this time. 4) Assemble chain using chain connecting link.
Chain Couple I 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. 2) Insert clevis pin through sprocket and shaft to hold sprocket in position. 3) Drill through opposite side of shaft to obtain proper hole alignment. Fig. 6B. 4) Insert clevis pin through both holes and secure with cotter pin. Fig. 6C.
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.
Clutch Adjustment Fig. 8 The o perators 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. To Adjust the Clutch 1) Decrease the tension on the clutch until the operator will not lift the door. Turning the adjustment castle nut counter-clockwise will decrease tension and clockwise will increase tension.
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.
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.
Low Voltage Control Wiring (general) Fig. 3 1) Connect all LOW VOLTAGE control circuit wires to this side of unit using 1/2" conduit or flexible convoluted tubing. Keep low voltage and line voltage wires separate. Route all low voltage control wiring as shown. This includes all control circuit wires such as wall controls, timers and single button input devices as well as radio control and safety circuit wiring. See Figs 2 through 13 in this section.
External Wire Diagram PWR 20-40 VDC @ 315mA MAX CURRENT See Appendix B for detailed description of terminals.
Wall Control 1) For one 3 - button installation, make connections as shown in Fig. 4. 2) For a multiple 3 - button installations, make connections as shown in Fig. 5. 3) For single button accessory controls, make connections as shown in Fig. 6. NOTE: If an External STOP button is NOT being installed, a jumper wire must be installed between the "STOP" AND "GND" terminals as shown in Fig. 6.
Interlock Switches CONTROL SIGNAL TERMINAL STRIP 1) Optional external interlock switches are required with some Sectional or Rolling Steel Doors to prevent the door from operating under certain conditions including the following: If the door is equipped with a functioning door lock, an interlock switch must be installed to prevent electric operation when the lock is engaged.
Radio Control Installation Figure 8 1) For a 3-wire radio control installation, make connections as shown in Fig. 8. NOTE: PWR terminal supplies 20 – 40VDC. Radios used must be compatible with this voltage range. NOTE: If no voltage is present at PWR terminal, check fuse on circuit board. Series II Safe-T-Beam® Monitored Photocells 1) Monitored SERIES II (STB) photocells can be installed as shown in Fig. 9. Wiring to these photocells can be connected to either terminal (they are not polarity sensitive).
Sensing Edge Switch Installation Figure 12 shows an example of a typical sensing edge installation. Left hand side is shown but right hand is a mirror image of this. 1A) If wiring from sensing edge switch to operator is coiled cord or 2 wire jacketed cord: • Install junction box 12” above the center of the door opening on same side as sensing switch. • Secure one end of cord to junction box using a cable clamp.
IMPORTANT SAFETY INSTRUCTIONS WARNING To reduce the risk of severe injury or death: 1) READ AND FOLLOW ALL INSTRUCTIONS. 2) Never let children operate or play with door controls. Keep the remote control (where provided) away from children. 3) Personnel should keep away from a door in motion and keep the moving door in sight until it is completely closed or opened. NO ONE SHOULD CROSS THE PATH OF A MOVING DOOR. 4) Test the door’s safety features at least once a month.
Section 6: Operator Setup Procedure Control Panel These operators include a full function control panel including a liquid crystal display (LCD), calibration keys and Open, Close and Stop keys for on board operator control.See Fig.1. The open, close and stop keys function as a 3-button wall control. The Display will show current operator conditions and calibration information. Due to limited character space,some displays will be abbreviated. See Appendix C (pgs.10.7-10.9) for full display descriptions.
Setting Constant Contact These operators are shipped from the factory with both open and close operating modes set to constant contact – stop (C – STP) If your unit is set to Momentary Contact (MOM) Open and/or CLOSE, reset the operating modes by taking the following steps: 1) Press CAL/RUN to enter calibration mode. Fig. 2. 2) Press SET/CLEAR until display reads “OPEN MODE > C-STP.” Fig. 3. 3) Press SCROLL (DN) until display reads “CLOSE MODE.” Fig. 4.
Setting Limit Travel UP LIMIT TRAVEL NUT 1) Engage door to Operator. NOTE: Verify open and close operating modes are set to constant contact – Stop (C-STP). See page 6.2 for details. 2) Press CAL/RUN until operator is in run mode. 3) Press and hold OPEN Key on Control Panel. Run door to desired open position, release OPEN Key. 4) Push LIMIT LOCKING BAR away from Limit Sensors and turn Open Limit Travel Nut until travel nut arrow and open limit sensor arrow are aligned and the display reads “IDLE>UP LIMIT.
Setting Limit Overrun WARNING: The Limit Overrun function will override external reversing devices, including photocells and sensing edges or reversing edges. Therefore,any externally connected devices will be disabled during that portion of the door travel controlled by the Limit Overrun function. The Down Limit Overrun function should be used to close the door no more than the final 2". A) The Limit Overrun setting is a matter of trial and error.
Monitored Reversing Devices ODC Safe-T-Beams® (OPTIONAL) 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL SCROLL (up or down) until display reads “ODC STB>ON” or “ODC STB>OFF” Figure 9. SET 3) Press SET/CLEAR CLEAR key to toggle between ON and OFF. 4) Press SCROLL SCROLL (up or down) to shift to a new function and lock setting. 5) Press CAL/RUN RUNCAL to return to run mode.
Max Run Timer This operator will automatically set its maximum run timers (MRT) when the unit is run two full cycles from limit to limit, without stopping, in the run mode. The Max Run Timer is a feature that prevents the unit from running continuously in the event of a slipping clutch, etc. NOTE: The MRT’s are set to the time required to run from one limit to the other, plus 5 seconds (nominal). When the MRT is exceeded, the operator stops and may reverse.
Setting the Mid-Stop This operator includes a programmable Mid-Stop. This feature allows the operator to stop at a user selectable point when opening. It is used when operating very tall doors that seldom open to their full height. The Mid-Stop does not affect the operator when closing. 1) To operate door to full open position from mid-stop, press open button again. MID-STOP CLR NOTE: Setting of the MID-STOP should only be performed AFTER Travel Limit and Max Run Timer settings have been made.
Changing Open and Close Modes NOTE: Once the travel limit and safety modes have been set, the OPEN and CLOSE modes may be set for Momentary Contact if desired. OPEN MODE MOM WARNING If momentary contact control is to be used, a monitored external reversing device such as a photocell system or sensing edge switch must be used. NOTE: The radio control input will not operate when the open or close mode is set in the Constant Contact mode. Operating modes affect all control inputs and keys. .
Section 7: Special Operator Features Operator Cycle Count Fig. 1 These operators include a built-in cycle counter that store the count with or without power to the operator. CYCLES 1 To view the Cycle Count: 1) Press CAL/RUN to enter calibration mode. 2) Press SCROLL ( ) or ( ) until display reads “CYCLES > .” This will display current cycle count. 3) Press CAL/RUN to return to run mode. Figure 1 Circuit Board Firmware Version Fig.
Operator Type Fig. 3 These operators are available for use in jackshaft or trolley configurations. The same control board is used for either configuration, however the control board must be set for the appropriate GDO configuration. A board set for trolley mode will not work in a jackshaft operator and vice-versa. NOTE: The GDO type is factory set. The installer should not have to set this feature.
Section 8: Troubleshooting Display Operation in Run Mode The operators display their status on the LCD display. Each time the operator runs, stops, reverses or refuses to run, the display will indicate why the action did, or did not, take place. Once an error code has been generated, the operator will continue to display the error code while the operator is not running. This error code can be cleared by pressing the STOP button or STOP key on the keypad.
Error Codes (cont’) To view the error code memory: (Fig. 1 & 2) 1) Press CAL/RUN to enter calibration mode. 2) Press SCROLL ( ) or ( ) until display reads “ERROR CODE 1 >.” The display will begin flashing the error code number and 2-digit error code followed by its description. Reminder: Error code number 1 is the latest code generated. 3) Press SET/CLEAR. The display will now read “ERROR CODE 2 >.” (This is the error code which was generated before error code 1.
Run Codes (cont’) To view the run code memory: (Fig. 3 & 4) 1) Press CAL/RUN to enter calibration mode. 2) Press SCROLL ( ) or ( ) until display reads “RUN CODE 1 > .” The display will begin flashing the run code number and code followed by its description. Remember: run code number 1 is the latest code generated. 3) Press SET/CLEAR. The display will now read “RUN CODE 2 > .” (This is the run code which was generated before run code 1.
LED Indicators Fig. 6 These operators include a self-diagnostic circuit board using troubleshooting LED indicators to signal the technician of a problem.
Monitored Photocell Self-diagnostic Troubleshooting Chart SOURCE (RED LED) SENSOR (GREEN LED) INDICATED CONDITION ON ON NORMAL OPERATION 1. POWER HEAD NOT POWERED OFF OFF 2. WIRING FROM POWER HEAD BAD ON 1. WIRING TO SOURCE MISSING OR BAD 2. POWER HAS BEEN INTERRUPTED 2 BLINKS, PAUSE (REPEAT) ON 1. BEAM NOT ALIGNED 2. BEAM OBSTRUCTED 3. SENSOR DEFECTIVE 2 BLINKS, PAUSE (REPEAT) OFF 3 BLINKS, PAUSE (REPEAT) ON 4 BLINKS, PAUSE (REPEAT) ON OFF REQUIRED ACTION NONE REQUIRED 1.
Maintenance Schedule Section 9: Service and Maintenance The following table provides a schedule of recommended Service and Maintenance items to be completed by a trained service representative. CAUTION: Failure to perform the recommended Service & Maintenance may result in premature failure of the operator. SERVICE ITEM SERVICE INTERVAL (FREQUENCY) EVERY 6 MO. EVERY 12 MO. EVERY 36 MO.
Section 10: Appendix A PARTS LIST Basic Hoist Operator Parts 23 138 22 ITEM NO. PART NUMBER 1 167 159 164 161 160 21 135 137 21 168 37 165 127 133 22 23 37 39 125 127 128 129 130 131 132 133 134 135 136 137 138 159 160 161 164 165 167 168 110380.0001 110380.0002 110847.0001 110847.0002 110450.0001 110449.0001 108190.0001 110443.0001 110503.0001 110807.0001 111007.0001 8115B17 110809.0001 110807.0001 107978.0001 110502.0001 110522.0001 110521.0001 110808.0001 110549.0001 110824.0001 111051.
Section 10: Appendix A Basic Jackshaft Operator Parts 23 138 22 PARTS LIST ITEM NO. PART NUMBER 1 SEE SEPARATE ILLUSTRATED PARTS BREAKDOWN FOR OUTPUT SHAFT ASSY 167 159 164 161 160 21 135 137 21 SEE SEPARATE ILLUSTRATED PARTS BREAKDOWN FOR INTERMEDIATE SHAFT ASSY 168 37 133 39 134 136 1 GCL-MJ&MH Medium Duty Operator 161 132 130 131 176 www.geniecompany.com 22 23 37 39 128 130 131 132 133 134 135 136 137 138 159 160 161 164 166 167 168 176 110380.0001 110380.0002 110847.0001 110847.
Appendix A (cont’) Basic Shaft Assembly Parts PARTS LIST 40 42 41 44 38 45 46 47 48 CLUTCH KIT 99 94 29 150 104 29 119 153 116 115 106 153 INTERMEDIATE SHAFT ASSEMBLY (HOIST) GCL-MJ&MH Medium Duty Operator ITEM NO. PART NO. 7 29 32 34 38 40 41 42 44 45 46 47 48 91 92 94 96 99 102 104 105 106 115 116 119 150 151 152 153 110478.0003 110813.0001 106064.0001 110872.0001 111125.0001 080401.0624 075197.0000 110472.0001 086649.0029 108015.0001 075193.0000 111037.0001 110881.0001 107967.0001 110876.
Appendix A (cont’) Basic Shaft Assembly Parts 3 4 5 6 7 8 9 10 11 12 PARTS LIST 13 INTERMEDIATE SHAFT ASSEMBLY (JACKSHAFT) ITEM NO. PART NO. 2 1 9 OUTPUT SHAFT ASSEMBLY (INDIRECT) 19 20 21 24 25 GCL-MJ&MH Medium Duty Operator 15 16 13 14 22 23 22 17 18 20 8 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 110472.0001 080401.0624 075197.0000 111324.0001.S 110881.0001.S 075193.0000 111037.0001 110819.0001 086649.0029 110392.0001 110387.0001 110817.0001 110813.
Appendix A (cont’) Basic Electric Box Parts 21 22 23 24 25 26 35 20 26 25 24 23 21 27 139 PARTS LIST 140 ITEM NO. PART NO. WIRING LAYOUT - HOIST 2 139 JACKSHAFT DIFFERENCE OR 13 2 17 12 GCL-MJ&MH 19 Medium Duty Operator www.geniecompany.com 110405.0001 110405.0002 12 112365.0001.S 13 110846.0001 110846.0002 17 110957.0001 19 110830.0001 110830.0002 20 111048.0001 21 109876.0003 22 110818.0003 23 077538.0000 24 110823.0001 25 110550.0001 26 110459.0001 27 601332.0001 35 111851.
Section 10: Appendix B Screw Terminal Assignments FUNCTION INPUT 11-POSITION TERMINAL BLOCK INSIDE ELECTRIC BOX OPEN CLOSE STOP GND 1-BTN ODC STB ODC STB N-O REVERSE N-O REVERSE EXT INTLK EXT INTLK 2-POSITION TERMINAL BLOCK (INSIDE ELECTRIC BOX) L1 / L1 N / L2 CONNECTION TYPE Causes door to open if not at Up Limit. Causes a closing door to reverse. Causes door to close if not at Down Limit. Causes a moving door to stop. Prevents the operator from running.
Section 10: Appendix C Display Run Codes Condition Code 0C 0D 0E 0F 10 11 12 13 14 20 21 22 24 2A 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F DISPLAY IDLE > DOWN LIMIT IDLE > UP LIMIT IDLE > MID STOP IDLE > NO LIMIT OPENING > OPEN BTN OPENING > ONE BTN OPENING > RADIO OPENING > AUX OPEN OPENING > OPEN KEY CLOSING > CLOSE PB CLOSING > ONE BTN CLOSING > RADIO CLOSING > CLOSE KP CLOSING > TCM CLS HALT > WALL BUTTON HALT > ONE BUTTON HALT > RADIO HALT > AUX.
Display Condition Error Codes Code 40 41 42 43 44 45 46 47 48 49 4A 4B 4F 50 51 52 57 58 59 5A 5C 5D 60 61 62 63 64 65 66 67 68 69 6C 6D 6E 6F DISPLAY REV > REV > REV > REV > REV > REV > REV > REV > REV > REV > REV > REV > OPEN BUTTON ONE BUTTON RADIO AUX OPEN OPEN KEY N-O SAFETY ODC STB N-C SAFETY MON.
Display Error Codes (cont’) Condition Code 70 71 74 75 76 77 80 81 82 83 84 85 86 88 8A 8E 8F 90 A0 A1 A2 A3 A4 A5 A6 A7 AA DISPLAY BOARD FAILURE 70 BOARD FAILURE 71 BOARD FAILURE 74 BOARD FAILURE 75 BOARD FAILURE 76 BOARD FAILURE 77 BOARD FAILURE 80 BOARD FAILURE 81 BOARD FAILURE 82 BOARD FAILURE 83 BOARD FAILURE 84 EXP PORT PROBLEM BOARD FAILURE 86 TCM FAILURE AOM FAILURE REV INTERRUPTED LIMIT MOD.
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GCL-MJ&MH Medium Duty Operator www.geniecompany.com 08-12 11.1 SIGNATURE OF SELLER: DATE OF INSTALLATION: FACTORY ORDER #: SELLER S ADDRESS: SELLER: INSTALLATION ADDRESS ORIGINAL PURCHASER Claims under this warranty must be made promptly after discovery within the applicable warranty period and in writing to the Seller or to the authorized distributor or installer whose name and address appear below.
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One Door Dr. Mt.
