GCL-T ™ Standard Duty Operator TROLLEY 111848.501539 PROPER APPLICATION Operator Type Trolley (Standard, Sidemount or Dual) Door Type Sectional (Standard or Low Headroom Track only) Max Door Weight/HP 1/2HP = 1120 lbs. 3/4HP = 1370 lbs. 1HP = 1620 lbs. EZ Limit™ Multivolt™ TensiBelt™ NOT FOR RESIDENTIAL USE This Installation Manual provides the information required to install, troubleshoot and maintain a GCL-T ™ 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 ........................................
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-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 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.
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-T™ 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.
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 (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. NOTE: Space chain guides evenly between operator and header. Add a chain guide for every 4 feet of door height per chart. UNDER 12’ 12’ to 16’ 2 CAUTION Verify that screws are properly seated in track.
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 insert the track bolts and lock nuts at this time. The spreader bracket will be held in place (temporarily) by the clevis pin which holds the pulley.
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.
Drawbar Installation NOTE: On torsion spring doors with an uneven number of panels, the operator may be attached to the stile nearest to the center. 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.
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 5" ABOVE HIGHEST POINT OF TRAVEL 2" X 6" LEVEL HEADER HIGHEST POINT OF TRAVEL Figure 9 Figure 8 GCL-T Standard Duty Operator www.
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 two (2) 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.
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.
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 associated equipment It is not intended for entrapment protection. Trolley 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.
Line Voltage Wiring Fig. 1 • • • • • • • 1) 2) 3) Section 5: Wiring LINE INPUT TERMINALS LINE GROUND 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.
Low Voltage Control Wiring (general) Fig. 2 1) Connect all LOW VOLTAGE control circuit wires to this end of the 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 10 in this section. • Plug all unused conduit holes.
External Wire Diagram See Appendix B for detailed description of terminals.
Wall Control Figure 3 CONTROL SIGNAL TERMINAL STRIP OPEN CLOSE STOP 3-BUTTON STAT ON GND WARNING: • • OPEN Wall Control(s) must be located so that the door is within sight of the user and is far enough from the door, or positioned such that the user is prevented from coming in contact with the door while operating the controls . Attach the Warning placard adjacent to the Wall Control. Fig. 3A.
Interlock Switches (Wall Mount) 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 (A) must be installed to prevent electric operation when the lock is engaged.
Photocell Wiring CONNECT WIRES TO EITHER TERMINAL (NOT POLARITY SENSITIVE) ODC STB Figure 7 CONTROL SIGNAL TERMINAL STRIP SERIES II (STB) RESIDENTIAL SAFE-T-BEAM™ WARNING: Actuating operator using constant contact on the CLOSE button will override external reversing devices, including photocells. PWR 20 40 VDC @ 250mA MAX CURRENT 2) To Mount Photocells: (Kit includes detailed Instructions). Determine location for mounting.
Sensing Edge Switch Installation Figure 10A Figure 11 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.
External Radio Installation Although the GCL-T™ Operators are equipped with an internal radio, they also provide a universal connection for an external radio. To Add the External Radio 1) Plug the 3-wire pigtail (provided) onto the plug connector marked “EXT RAD.” Fig. 12. 2) Make wiring connections to the pigtail. EXTERNAL RADIO CONNECTOR Optional Accessory Modules PWR 20-40 VDC @ 250 mA MAX. CURRENT EXT RADIO CONNECTOR Yellow Figure 12 Orange Blue F1 (.
WARNING: Verify Line Voltage before making any connections to assure that motor harness is connected to proper motor connector on circuit board. 1) Plug motor harness into proper motor connector on circuit board in electric box. Fig. 13. 2) Apply primary power. Figure 13 208/ 240V 120V SINGLE PHASE Motor Connectors 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.
Section 6: Operator Setup Procedure Control Panel 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. 10.9-10.10) for full display descriptions.
Setting Close Direction The direction of motor rotation depends on mounting position and/or how the main input power phases are wired. This setting is used to insure the door is closing and opening according to the input commands. OPEN Figure 2 SET CLOSE DIR CLOSE STOP 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. SET 2) Press SET/CLEAR CLEAR to begin the calibration procedure and advance to the next screen. Figure 3.
Setting Braking Rate (optional) 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press Scroll until display reads “BRAKING RATE >#.” where # is the deceleration rate, ranging from 0 to 9. 0=max. braking. 9=Min. Figure 6. SET 3) Press SET/CLEAR CLEAR key to toggle between 0 and 9—one digit at a time. 4) Pick a value and operate the door. Adjust as necessary. 5) Press a SCROLL SCROLL key to shift to a new function and lock in the setting.
Setting Travel Limits UP and/or DOWN CAL 1) If operator is in RUN mode, press CAL/RUN RUN to enter calibration mode. SCROLL 2) Press SCROLL until display reads “UP LIMIT>CLR ” or “DOWN LIMIT>CLR ” Figure 7. 3) Jog the door using the OPEN OPEN or CLOSE CLOSE key until you reach the desired height. SET 4) Press SET/CLEAR CLEAR key to switch display to “UP LIMIT>SET “ or “DOWN LIMIT>SET .“ Figure 8. 5) Press a SCROLL SCROLL key to shift to a new function and lock in the limit setting.
Setting Limit Overrun AL U This Setting is a matter of trial and Error 1) If operator is in RUN mode, press CAL/RUN to enter calibration mode. CLOSE CAL 2) Press SCROLL SCROLL until display reads “LIMIT OVERRUN>#” where # is the R increment of travel beyond the CLOSE Limit ranging from 0 to 9. Zero TOP CLEAR turns off the Overrun and the door stops at the DOWN Limit. EN S ROLL function Nine is the maximum distance the door will travel passed the limit.
Monitored Reversing Devices ODC Safe-T-Beams® (OPTIONAL) CAL 1) If operator is in RUN mode, press CAL/RUN RUN to enter calibration mode. SCROLL 2) Press SCROLL (up or down) until display reads “ODC STB>ON” or OPEN “ODC STB>OFF” Figure 16. LEA SET C LL E CLEAR key to toggle between ON 3) Press SET/CLEAR and LOFF. SCROLL 4) Press SCROLL (up or down) to shift to a new function and lock setting. ST CAL 5) Press CAL/RUN RUN to return to run mode.
Setting Open and Close Modes (Constant vs Momentary Contact) OPEN 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL SCROLL until display reads “OPEN MODE>MOM” or “OPEN MODE>C-STP.”Figure 10. OL MOM=momentary contact, meaning youS press and CLOSE release the OPEN OPEN keSEy and the door will continue to move until it reaches C EA its travel limit.
(Optional) Transmitter Programming LEARN NEW XMTR? Adding a Transmitter CLOSE CAL 1) If operator is in RUN mode, press CAL/RUN RUN to enter calibration mode. 2) Press SCROLL SCROL (up or down) until display reads “LEARN NEW XMTR? ” Figure 11. This question along with the instruction “HIT SET FOR YES” will continuously pan across the display window. (Pressing SCROLL or CAL/RUN will cancel the operation.) SET 3) Press SET/CLEAR CLEAR . Display will read “PUSH XMTR BUTTON TWO TIMES TO LEARN XMTR.
Setting Mid-Stop Limit 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 only open to their full height occasionally. The Mid-Stop does not effect the operator when closing. To operate door to full open position from mid-stop, press open button again. NOTE: Setting of the MID-STOP should only be performed AFTER Travel Limit and Max Run Timer settings have been made.
Section 7: Special Operator Features (No user input) Operator Cycle Count 1) Press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL SCROLL until display reads “CYCLES>1,2,3 etc. where the number is the number of open/close cycles the operator has performed. Figure A 3) Press CAL/RUN RUNCAL to return to run mode. OPEN CYCLES 1 CLOSE Figure A STOP GDO V# ######### CLOSE GDO and Display Firmware 1) Press CAL/RUN RUNCAL to enter calibration mode.
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 These operators display their status on the integrated 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 (continued) To view the error code memory OPEN CAL 1) Press CAL/RUN RUN to enter calibration mode. 2) Press SCROLL SCROLL 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. SET 3) Press SET/CLEAR CLEAR . The display will now read “ERROR CODE 2 (This is the error code which was generated before error code 1.
Run Codes (continued) To view the run code memory: CAL 1) Press CAL/RUN RUN to enter calibration mode. 2) Press SCROLL SCROLL 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. SET 3) Press SET/CLEAR 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 Operators include a self-diagnostic circuit board using troubleshooting LED indicators to signal the technician of a problem. Figure 6 +24 VDC STB ENAB TROUBLESHOOTING LED’s STB ENABLE NORMALLY ON - STB ENABLED + 24 VOLTS NORMALLY ON - POWER AVAILABLE DC GCL-T Standard Duty Operator www.geniecompany.com OFF - STB DISABLED OFF - CHECK AC POWER SUPPLY CHECK FUSES 06-12 8.
Safe-T-Beam® 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 1. CHECK WIRING 2.
Section 9: Service and Maintenance Maintenance Schedule 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 MONTHLY SERVICE INTERVAL (FREQUENCY) EVERY 6 MO. EVERY 12 MO. OR OR 5,000 CYCLES 10,000 CYCLES EVERY 36 MO.
Section 10: Appendix A Operator Parts Breakdown 1 2 10 9 6 ITEM NO. 1 2 3 4 7 5 6 7 8 5 3 8 4 9 10 11 12 13 3 14 13 12 GCL-T Standard Duty Operator www.geniecompany.com 14 PARTS LIST PART NUMBER 111010.0001 111391.0001 110877.0060 111394.0001 111394.0002 111421.0001 111404.0001 111396.0001 111396.0002 110635.0001 110635.0002 110635.0003 110635.0004 110635.0005 110635.0006 110635.0007 110635.0008 110635.0009 111429.0009 110636.0001 110627.0001 110625.0002 110625.0001 110607.0001 110607.
Appendix A (continued) Basic Shafts Parts PARTS LIST 114 100 30 150 7 27 30 116 178 96 A 97 115 ITEM NO. PART NUMBER DESCRIPTION 7 27 30 96 97 100 114 115 116 150 178 111027.0001 111073.0001 110695.0001 110313.0010 110881.0001 110819.0003 080415.0022 110313.0004 110818.0004 110739.0001 110738.0001 OUTPUT SHAFT LIIMIT GEAR OUTPUT SHAFT BEARING SPRING PIN DOWEL PIN SQUARE KEY STOCK, 1/4" E-RING SPRING PIN WAVE WASHER DRIVE SPROCKET LIMIT SHAFT SPROCKET PARTS LIST ITEM NO.
Appendix A (continued) Rail Parts Breakdown PARTS LIST 4 6 7 8 9 10 ITEM NO. PART NUMBER 1 2 3 4 5 080105.0708 080352.0714 080322.0446 111390.0001 110732.1125 110732.1149 110732.1173 110732.1197 110732.1221 110732.1245 110732.1269 110732.1317 110744.0001 110768.0001 111078.0001 080019.0001 086480.1620 080401.0616 080302.3240 111178.0001 11 6 7 8 9 10 11 12 13 1 GCL-T 2 3 Standard Duty Operator 5 13 www.geniecompany.
Appendix A (continued) Carriage/Door Arms Parts Breakdown 1 2 3 4 5 6 7 PARTS LIST ITEM NO. 2 PART NUMBER 1 080839.4951 080839.5911 080839.6871 080839.7831 080839.8791 080839.9751 8 12 14 GCL-T Standard Duty Operator 9 10 11 13 www.geniecompany.com 2 3 4 5 6 7 8 9 10 11 12 13 14 111342.0495 111342.0591 111342.0687 111342.0783 111342.0879 111342.0975 111342.1071 111342.1263 080884.0003 110784.0001 075064.0000 080302.2626 086480.2416 110616.0001 110844.0001 606-E04 110842.0001 086621.
Appendix A (cont’) Electric Box Parts Breakdown 6 15 7 8 9 PARTS LIST ITEM NO. PART NUMBER 1 2 10 11 3 4 12 5 6 7 8 9 10 11 12 13 14 15 1 GCL-T 2 Standard Duty Operator 14 13 3 4 5 www.geniecompany.com NS NS 112363.0001.S 112363.0001.S 112363.0001.S 112357.0001.S 112357.0001.S 112357.0001.S 112357.0001.S 111401.0001 111087.0001 111087.0002 111087.0003 8706.E29 8706.F29 22634A 110950.0001 110630.0001 111397.0001 111398.0001 111352.0001 34004DR250 34004C02R5 111451.0001 111439.
Appendix A (cont’) Electric Box Layout Single Phase External Radio Connector Expansion Board Port Limit Sensor Connector Hoist Interlock Connector Motor Connectors Three Phase 208/ 230V 115V 1 PH 1 PH Fuse Radio Antenna Input (Coax) Internal Radio Board Fuse Brake Connector Transformer Connectors Input Power Connectors GCL-T Standard Duty Operator www.geniecompany.com 208/ 230V 460V 3 PH 3 PH Motor Connectors Transformer Connectors Input Power Connectors 06-12 10.
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 Section 10: Appendix B 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.
Run Code Displays 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-T 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.
Error Code Displays 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-T 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.
Section 10: Appendix C Error Codes Displays (continued) 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-T 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-T Standard Duty Operator www.geniecompany.com 06-12 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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1 Door Drive Mt.
