GCL-MT ™ Medium Duty Operator 111850.501539 08-12 TROLLEY TensiBelt™ PROPER APPLICATION Door Type Sectional (Standard Lift Low Headroom) Operator Type Trolley HP/Max Door Weight 1/2HP = 620 lbs (Available in 1/2HP only) NOT FOR RESIDENTIAL USE This Installation Manual provides the information required to install, troubleshoot and maintain a GCL-MT™ Commercial / Industrial Door 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 ......................
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 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.
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 OPERATOR WILL NOT ALLOW MOMENTARY CONTACT OPERATION IN THE CLOSE DIRECTION. LISTED DEVICES MillerEdge ME, MT and CPT series monitored edge sensors used in combination with Timer-Close Module or OPAKMEIGX.S Interface Module.
Section 4: Installation Drawbar Assembly 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.
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).
Drawbar Assembly (cont’) 6) Attach the chain guide assemblies to the drawbar tracks using track bolts and locknuts. Fig. 5. PLASTIC SLIDE GUIDE CHAIN GUIDE BRACKET 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. NOTE: Verify that track bolts are properly seated in track. Failure to seat bolts can cause carriage to bind in door track.
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.
Drawbar Installation VERTICAL LINE (SEE STEP 1) 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.
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" MAKE MARK 2-1/2" ABOVE HIGH ARC OF DOOR FOR HORIZONTAL LINE LEVEL HEADER HIGH ARC OF DOOR Figure 8 GCL-MT Medium Duty Operator www.geniecompany.
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.
Connection to the Door Door Center Line Top Door Roller 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.
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.
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 4 through 13 in this section.
External Wire Diagram See Appendix B for detailed description of terminals. POWER CONNECTIONS L1/ L1 N/ L2 120V LINE (HOT) NEUTRAL 240V LINE 1 LINE 2 CLASS 2 SUPPLY 0-40 VDC OPEN CLOSE STOP GND 1-BTN ODC STB ODC STB N-O SAFETY N-O SAFETY EXT INTLK EXTERNAL RADIO TERMINAL STRIP CLASS 2 SUPPLY 0-40 VDC EXT INTLK MULT PLE 3-BUTTON STATION INSTALLATIONS REQUIRE THE STOP BUTTON TO BE WIRED IN SER ES. See Fig. 5, pg 5.
Wall Control CONTROL SIGNAL TERMINAL STRIP 1) For a single 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 OPEN 1) Optional external interlock switches are required on some Sectional or Rolling Steel Doors to prevent 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 and Photocell Wiring Figure 8 Series II Safe-T-Beam® Monitored Photocells 1) Monitored SERIES II (STB) photocells (P/N OPAKPE.S or OPAKPEN4GX.S) and Safe-T-Beam® Monitored Photocells from Genie® (P/N 38176R). Fig. 9. Wiring to these photocells can be connected to either terminal (they are not polarity sensitive). ( Troubleshooting in Section 8). NOTE: Monitored Sensing device must be installed or unit will be Constant Contact Close. WARNING CONNECT WIRES TO EITHER TERMINAL.
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.
Control Panel Section 6: Operator Setup Procedure The 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.10.11-10.13) for full display descriptions.
Setting Constant Contact The 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 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 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 15. SET LEA 3) Press SET/CLEAR and OFF. ROL CLEAR key to toggle between ON SE SCROLL 4) Press 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 The operator includes a programmable Mid-Stop. This feature allows the operator stop at a user selectable point when opening. It is used when operating very tall doors that only open to their full height occasionally. The Mid-Stop does not effect 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 The 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 > .
LED Indicators Fig. 6 These operators include a self-diagnostic circuit board using troubleshooting LED indicators to signal the technician of a problem. TROUBLESHOOTING LED’s HOIST EXTERNAL + 24 VOLTS STB INTERLOCK INTERLOCK DC ENABLE OFF ON TROUBLESHOOTING LED S STB ENAB + 24 VAC TB N B + 4 AC XT N LK O ST N LK EXT INTLK FUSE F2 HOIST INTLK DETAIL ON ON ON OFF ON ON OFF OFF ON OFF OFF OFF Figure 7 GCL-MT Medium Duty Operator www.geniecompany.
Safe-T-Beam® Monitored Photocell Self-diagnostic Troubleshooting Chart SOURCE (RED LED) SENSOR (GREEN LED) INDICATED CONDITION REQUIRED ACTION NORMAL OPERATION 1. POWER HEAD NOT POWERED 2. WIRING FROM POWER HEAD BAD NONE REQUIRED 1. CHECK BREAKERS, FUSES, PLUGS 2. CHECK WIRING FOR OBVIOUS SHORTS ON ON OFF OFF OFF ON 1. WIRING TO SOURCE MISSING OR BAD 2. POWER HAS BEEN INTERRUPTED 1. CHECK WIRING 2. REMOVE POWER AND REAPPLY 2 BLINKS, PAUSE (REPEAT) ON 1. BEAM NOT ALIGNED 2. BEAM OBSTRUCTED 3.
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 Basic Operator Parts 137 21 23 138 22 134 160 39 161 136 164 1 161 159 PARTS LIST ITEM NO. 1 21 22 23 39 134 135 136 137 138 159 160 161 164 135 SEE SEPARATE ILLUSTRATED PARTS LIST FOR INTERMEDIATE SHAFT ASSY SEE SEPARATE ILLUSTRATED PARTS LIST FOR ELECTRIC BOX & LIMIT SHAFT PART NUMBER 110380** 110847** 110450.0001 110449.0001 110443** 110522.0001 110521.0001 110808.0001.S 110549.0001 110824.0001.S 111051.0002 111051.0001 110803.0001.S 111804.0001.
Appendix A (cont’) Basic Shaft Assembly Parts 3 8 6 7 4 6 3 2 1 PARTS LIST 20 19 4 5 OUTPUT SHAFT ASSEMBLY 18 17 21 22 23 24 25 26 27 14 15 GCL-MT Medium Duty Operator 17 14 13 ITEM NO. PART NUMBER DESCRIPTION 1 2 3 4 5 6 7 8 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 086563.0001 110526.0001 080415.0021 110819.0001 110818.0001 106062.0003 110520.0001 107894.0001 110465.0001 080415.0021 110819.0001 110818.0001 110813.0001 110464.0001 110881.0001 080401.0624 110472.0001 075197.
Appendix A (cont’) Basic Rail/Trolley Parts 54 53 60 ** CONTACT DEALER FOR PROPER PART 77 175 77 64 PARTS LIST 58 174 GCL-MT Medium Duty Operator 173 172 www.geniecompany.com 61 ITEM NO. PART NUMBER 53 54 58 60 61 64 77 172 173 174 175 176 108380.0001 086621.0672 076169.0000 110999.0001 110997.0001 110972.0001* 407743** 110843.0001 26013D 110842.0001 110920.0001 100132.
Appendix A (cont’) Basic Electric Box Parts 35 20 PARTS LIST 139 14 140 ITEM NO. PART NUMBER 2 110405.0001.S 110405.0002.S 112365.0001.S 110846.0001 110846.0002 36424R 110957.0001.S 110966.0001.S 110830.0001 110830.0002 110851.0001 110423.0001 110870.
Section 10: Appendix B Screw Terminal Assignments 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 FUNCTION 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. Common ground connection for Open, Close, Stop & 1-Btn Inputs.
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 GCL-MT 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 Error Codes Condition 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 GCL-MT DISPLAY REV > OPEN BUTTON REV > ONE BUTTON REV > RADIO REV > AUX OPEN REV > OPEN KEY REV > N-O SAFETY REV > ODC STB REV > N-C SAFETY REV > 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 GCL-MT 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.
GCL-MT 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.
