GCL-GCX ™ 112070.501539 CO M M E RC I A L L I N E COUNTER DOOR OPERATOR PROPER APPLICATION Door Type Rolling Steel Counter Door Operator Type Counter Door Max Door Weight/HP 1/2HP = 500 lbs. NOT FOR RESIDENTIAL USE This Installation Manual provides the information required to install, troubleshoot and maintain a GCL-GCX™ Counter 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 . . . . . . . . . . . . . . . . . . .3.1-3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-4.3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1: How to use this manual The 11 sections of this Installation Manual provide the information required to install, troubleshoot and maintain an GCX 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 Overhead 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 The GCX 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. 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 using the OPAKMEIGX.
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 Mounting Unless otherwise stated, these instructions will show right side mount installations. Left side mount is opposite. 1) Insert four(4) 3/8"-16 x 1" carriage bolts into headplate. FIG. 1. • Threads to outside of plate. • Retain by pushing 4 speed nuts onto bolts. 2) Complete installation of door as instructed in door installation manual up to "mounting of hood." 3) Make certain both headplates are at 90° to wall. • If not at 90°, use temporary external brace to hold in place.
Figure 3 Mounting (continued) 7) Slide open ended slots of frame under flat washers installed in step 5. FIG. 3. • Locate other frame slots over remaining two(2) carriage bolts and bring frame against headplate. • Put 3/8" washers and keps nuts on remaining bolts. • DO NOT fully tighten nuts. • Slide operator toward wall as far as slots allow. FIG. 4. 8) Place driven sprocket and key on door shaft and align with output sprocket on operator. FIG. 4A. • Secure sprocket and key in place with set screws.
Manual Release NOTE: In case of power failure, door can be operated manually. Figure 8 The operator can be disconnected from door by pulling red pull rope attached to Drop Release Lever to allow opening door. FIG. 8. • When door is in manual operation, limit switch setting is not affected. DROP RELEASE LEVER • Releasing pull rope will re-engage operator. (install release cord here) 1) Install Release Cord. 2) Locate and install the wall control. 3) Locate and install Warning Placard. FIG. 9.
Optional Timer-Close Module or Auxiliary Output Module These instructions apply to either board. Although they perform different functions, they mount in the same way. Figure 10 2) Orient the module so mounting bracket tabs are to the left and wire terminals are facing up. 3) Make desired wiring connections, in accordance with instruction manual accompanying the module. 4) Insert module into the area indicated and slide front mounting tab into slot on side panel of the enclosure. FIG. 10 & 11.
Line Voltage Wiring Fig. 1 • • • • • • • Section 5: Wiring 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 Fig. 2 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. 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 WARNING: • • • Wall Control(s) must be located so that the door is within sight of the user. Attach the Warning placard adjacent to the Wall Control. Fig. 3A. Attach the Caution Label adjacent to the Wall Control. Fig. 3B. CLOSE Entrapment Warning Placard P/N 111980.
Series II Safe-T-Beam® Monitored Photocells Photocell Wiring 1) Monitored SERIES II (STB) photocells (P/N 38176R.S or OPAKPE.S) can be installed as shown in Fig. 6. Wiring to these photocells can be connected to either terminal (they are not polarity sensitive). ( Troubleshooting in Section 8). Figure 6 NOTE: Installer must enable ODC STB in calibration mode. See page 6.7. CONNECT WIRES TO EITHER TERMINAL.
Sensing Edge Switch Installation Figure 10 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. 1B) If connection is to be made through a take up reel cord: NON-MONITORED EDGE ONLY.
Locking Bottom Bar / Interlock Figure 11 shows an example of a typical locking bottom bar. Left hand side Interlock Switch is shown. Right hand mount is mirror image. NOTE: Interlock Switch is mandatory on doors equipped with an electronically controlled commercial operator.
External Radio Installation IMPORTANT SAFETY INSTRUCTIONS WARNING - To reduce the risk of severe injury or death: To Add the External Radio 1) Plug the pigtail with the 3-terminal strip attached (provided) onto the plug connector marked “EXT RAD.” Fig. 12. 2) Make wiring connections to the terminal strip per the diagram below.
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. 10.5-10.7) for full display descriptions.
Setting Close Direction The direction of motor rotation depends on mounting position. This setting is used to insure the door is closing and opening according to the input commands. OPEN SET CLOSE DIR Figure 2 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL SCROLL until “SET CLOSE DIR” is displayed. Figure 2. SET 2) Press SET/CLEAR CLEAR to begin the calibration procedure and advance to the next screen. Figure 3. 3 ) Briefly press the CLOSE CLOSE key.
Setting Travel Limits CAL UP and/or DOWN CAL 1) If operator is in RUN mode, press CAL/RUN RUN to enter calibration mode. 2) Press SCROLL CROL 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 CROLL key to shift to a new function and lock in the limit setting.
Setting Limit Overrun CAL RU This Setting is a matter of trial and Error 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL CROLL until display reads “LIMIT OVERRUN>#” where # is the EN increment of travel beyond the CLOSE LimitS ROLL ranging from 0 to 9. Zero turns off the Overrun function and the door stops at the DOWN Limit. R Nine is the maximum distance the door will travel passed the limit.
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” “OPEN MODE>C-STP.”Figure 10. • MOM=momentary contact, meaning you press and release the OPEN OPEN or CLOSE CLOSE key and the door will continue to move until it reaches its travel limit.
Setting Mid-Stop Limit The 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.
Resetting the MRT (The Max Run Timer is set automatically once the unit is OPEN cycled between Limits. The Max Run Timer prevents the unit from running continuously in the event of a problem. 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 will not respond to any command until it is reset by pressing one of the calibration keys AL UN unit.
Section 7: Special Operator Features (No user input) Operator Cycle Count RN 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 and Display Firmware C N P 1) Press CAL/RUN to enter calibration mode. 2) Press SCROLL SCROLL until display reads “GDO V# > ######.
Operator Type Fig. 3 Operator circuit boards 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: 1) Press CAL/RUN RUNCALRC 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: L 1) Press CAL/RUN RUNCAL 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 The operators include a self-diagnostic circuit board using troubleshooting LED indicators to signal the technician of a problem. LED STB ENABLE ON STB ENABLED + 24 VOLTS POWER AVAILABLE DC INTLK ENABLED EXT INTLK HOIST INTLK INTLK ENABLED OFF STB DISABLED 1. CHECK AC POWER SUPPLY 2. CHECK FUSES 1. INTLK SWITCH OPEN 2. CHECK POWER SUPPLY 3. CHECK MAIN POWER FUSE 4. CHECK SECONDARY FUSE (2A) Figure 6 1. INTLK SWITCH OPEN 2. HOIST RELEASE NEEDS RESET 3.
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 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.
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 156 142 143 144 23 145 Operator Parts Breakdown (Exploded View) 141 12 32 150 157 3 35 13 GCL-GCX 86 99 19 164 Counter Door Operator 158 1 159 109 www.geniecompany.com 32 91 08-12 10.
Section 10: Appendix A Operator Parts Breakdown (Parts List) PARTS LIST TEM NO. 1 3 12 13 19 23 32 35 86 91 99 109 141 142 143 144 145 150 156 157 158 159 164 PART NUMBER 108563.0001 111421.0001.S 112365.0001.S 110846.0001.S 107871.0001.S 108822.0001.S 106062.0002.S 108802.0001 108609.0001 108807.0001.S 108608.0001.S 108796.0001 111629.0001 108855.0001 105961.0001 077852.0000 106124.0007 108819.0001 108802.0001 111933.0001 111679.0002 111932.0001 111932.0002 111950.
Section 10: Appendix A Control Board Area Breakdown SECONDARY FUSE RADIO FUSE REPLACE SECONDARY FUSE WITH GDB-2A OR S500-2A ONLY REPLACE RADIO FUSE WITH GDC-315mA OR S504-315mA ONLY HOIST INTERLOCK CONNECTOR CAL RUN SET CLR SCROLL MOTOR CONNECTOR SCROLL BRAKE CONNECTOR RADIO CONNECTOR EXPANSION PORT CONTROL WIRE TERMINALS O EN C OSE S O GND B N ODC S B ODC S B NO SA E NO SA E EX N K EX N K STB ENAB + 24 VAC EXT NTLK HO ST NTLK N XFMR CONNECTOR LINE INPUT TERMINALS AUX BOARD (OPTIO
Section 10: Appendix B Screw Terminal Assignments INPUT 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. Causes door to open if not at Up Limit or Mid-Stop Limit. Causes door to close if at Up Limit or Mid-Stop Limit. 1-BTN Causes door to stop if opening. Causes a closing door to reverse.
Section 10: Appendix C Run Code Displays Condition Code 0C 0D 0E 0F 10 11 12 13 14 20 21 22 24 2A 2B 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42 43 44 45 GCL-GCX 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 CLOSING > FDM CLS HALT > WALL BUTTON HALT > ONE BUTTON HALT > RADIO HALT > AUX.
Error Code Displays Condition Code 46 47 48 49 4A 4B 4F 50 51 52 53 57 58 59 5A 5B 5C 5D 5E 5F 60 61 62 63 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F GCL-GCX DISPLAY REV > ODC STB > REV N-C SAFETY REV > MON.
Error Codes Displays (continued) Condition Code 70 71 74 75 76 77 80 81 82 83 84 85 86 87 88 89 8A 8B 8C 8D 8E 8F 90 A0 A1 A2 A3 A4 A5 A6 A7 AA AB B0 B1 B2 B3 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 IEM FAILURE TCM FAILURE FDM FAILURE AOM FAILURE SPARE MOD FAILURE LOW SYSTEM VOLTS HI SYSTEM VOLTS REV INTERRUPTED LIMIT MO
GCL-GCX Counter Door 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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