12074.501539 GCL-GT 07-12 Heavy Duty Operator TROLLEY PROPER APPLICATION Operator Type Trolley (Standard, Sidemount or Dual) Door Type Sectional (Standard or Low Headroom Track only) Max Door Weight/HP 1/2HP = 1310 lbs. 3/4HP = 1450 lbs. 1HP = 1650 lbs. WITH EXCLUSIVE FEATURES: Multivolt® EZ Limit® NOT FOR RESIDENTIAL USE This Installation Manual provides the information required to install, troubleshoot and maintain a GCL-GT™ 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 .............................3.1-3.3 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-GT™ 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-GT ™ 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 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 Drawbar Assembly NOTE: Drawbar tracks must be (29) inches longer than the door’s height. Tracks have been sized properly and pre-punched for the chain guide assemblies from the factory. The Trolley Operator consists of the Power Unit (A), Drawbar Track (B), Chain Guides (C), Front Spreader (D), Front Idler Pulley (E), Drive Chain (F), Drive Sprocket (G) and Drawbar Arm (H)**. The Drawbar track length, chain length and quantity of chain guides will vary by door heights. Fig. 1.
Drawbar Assembly (continued) 2) Attach the chain guide assemblies to the drawbar tracks using round head screws and locknuts (provided). Fig. 3. CAUTION Verify that screws are properly seated in track. Failure to seat screws can cause carriage : 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 to bind in door track.
Drawbar Assembly (continued) 3) Insert the carriage into the tracks 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 track. Do not insert the round head screws 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 WARNING : Repairs and adjustments, particularly to cables and spring assemblies under high tension, must be made by a trained service representative using proper tools and instructions. 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.
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. 2" X 6" MARK A HORIZONTAL LINE POINT OF TRAVEL 5" ABOVE HIGHEST ! LEVEL HEADER ! HIGHEST POINT OF TRAVEL Figure 9 Figure 8 GCL-GT Heavy Duty Operator www.
Attach Operator 1) Raise the operator and position it so that the drawbar tracks 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 tracks into the spreader bracket using the two (2) Round Head Screws (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. 2) Position the spring box on the door as shown in Fig. 12, with mounting holes on the door centerline. (Even with or above top door roller). NOTE: Make sure to use reinforcement bracket when attaching spring box to door. Do not attach door bracket directly to door section. 3) For wood doors fasten the spring box to the door using two 1/4” -20 X 2-1/4” carriage bolts and nuts.
Clutch Adjustment Fig. 14 The Trolley 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. These 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 Section 5: Wiring WARNING • DO NOT apply power to operator until instructed to do so. • It is strongly recommended, and may be required by law in some areas, 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 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 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 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. WARNING : If momentary contact control is to be used, an external reversing device such as a photocell system or sensing edge switch must be used. See pages 5.6-5.7 for installation of entrapment protection devices.
Interlock Switches 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 PWR 20 40 VDC @ 250mA MAX CURRENT override external reversing devices, including photocells.
Sensing Edge Switch Installation 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 o perators are equipped with an internal radio, they also provide a universal connection for an external radio. To Add the External Radio 1) Plug the pigtail with the 3 wires attached (provided) onto the plug connector marked “EXT RAD.” Fig. 12. 2) Make wiring connections to the wires per the diagram below.
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 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. 10.9-10.11) 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 SET CLOSE DIR Figure 2 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. 3 ) Briefly press the CLOSE CLOSE key.
Setting Braking Rate 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 braking. 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 CL UP and/or DOWN CAL 1) If operator is in RUN mode, press CAL/RUN RUN to enter calibration mode. SCROL 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 CROLL key to shift to a new function and lock in the limit setting.
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.
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 SCROLLRU until display reads “OPEN MODE>MOM” or “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.
(Optional) Transmitter Programming LEARN NEW XMTR? Adding a Transmitter 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 “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 RUN/CAL will cancel the operation.) SET 3) Press SET CLEAR . • Display will read “PUSH XMTR BUTTON TWO TIMES TO LEARN XMTR.
Optional Mid-Stop Limit Setting 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.
Monitored Reversing Devices CAL CAL Safe-T-Beams® (OPTIONAL) 1) If operator is in RUN mode, press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL CROL (up or down) until display reads “ODC STB>ON” or “ODC STB>OFF” Figure 15. SET 3) Press SET/CLEAR CLEAR key to toggle between ON and OFF. 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.
Section 7: Special Operator Features (No user input) Operator Cycle Count RUN LL 1) Press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL CROL 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 L N 1) Press CAL/RUN RUNCAL to enter calibration mode. 2) Press SCROLL CROL until display reads “GDO V# > ######.
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 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 CROL 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-GT Heavy Duty Operator www.geniecompany.com OFF - STB DISABLED OFF - CHECK AC POWER SUPPLY CHECK FUSES 03-12 8.
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 Basic Operator Parts 140 2 162 26 3 26 A 32 B 52 7 27 40 35 6 24 1 PARTS LIST ITEM NO. 1 2 3 6 7 24 26 26 27 32 35 40 52 140 162 PART NUMBER 111502** 110630.0001 110618** 110620.0003 111520.0001.S. 111503.0001.S. 111042.0001 111073.0001 111611.0001.S 110695.0001.S 110505.0003 111583.0002 110739.0001 111518.0001.S 110515.0001.
Section 10: Appendix A Motor Options 111502.0001—1/2HP, 1 PH, ODP 111502.0002—3/4HP, 1 PH, ODP 111502.0003—1HP, 1 PH, ODP 111502.0004—1/2HP, 3 PH, ODP 111502.0005—3/4HP, 3 PH, ODP 111502.0006—1HP, 3 PH, ODP 111502.0007—1/2HP, 575V, ODP 111502.0008—3/4HP, 575V, ODP 111502.0009—1HP, 575V, ODP 111695.0001—1/2HP, 3 PH, TEFC 111695.0002—1HP, 3 PH, TEFC 111695.0003—1HP, 575V, TEFC GCL-GT Heavy Duty Operator 111548.0001—3HP, 3 PH, FC 111548.0002—3HP, 575V, FC 111696.0001—1/2HP, 1 PH, TENV 111696.
Appendix A (continued) Basic Output Shaft Parts 120 PARTS LIST 32 101 27 52 7 ITEM NO. PART NUMBER 7 27 32 52 97 100 101 120 121 111520.0001.S. 111611.0001.S 110695.0001.S 110739.0001 110881.0001 110819.0003 110818.0004 110313.0004 111382.0001 DESCRIPTION OUTPUT SHAFT ASSEMBLY SPROCKET, #41, 1/2P, 12T BEARING TROLLEY CHAIN SPROCKET DOWEL PIN FLAT WASHER WAVE WASHER SPRING PIN E-RING 32 121 97 100 GCL-GT 120 Heavy H avy Duty Operator t www.geniecompany.com 03-12 10.
Appendix A (continued) Basic Rail Parts 68 69 70 71 72 73 74 60 55 54 58 PARTS LIST ITEM NO. 56 53 53 54 55 56 58 60 NS NS 68 69 70 71 72 73 74 PART NUMBER 111178.0001 110768.0001.S 110744.0001 080302.3240 111078.0001.S. 110999.0001 111669.0001 111670.0001 110732.1126 110732.1150 110732.1174 110732.1198 110732.1222 110732.1246 110732.
Appendix A (continued) Basic Carriage/Door Arm Parts 61 PARTS LIST ITEM NO. 61 NS 63 168 Heavy Duty Operator 111644.0001 111184.0001 108200.0002 111224.0002 DESCRIPTION TROLLEY CARRIAGE ASSEMBLY TROLLEY CARRIAGE PARTS KIT DRAWBAR KIT DRAWBAR BOX ASSEMBLY NS=NOT SHOWN 168 GCL-GT PART NUMBER www.geniecompany.com 03-12 10.
Appendix A (cont’) Basic Electric Box Repair Parts 139 PARTS LIST ITEM NO. 2 2 11 12 13 14 11 14 35 NS NS 139 NS 141 PART NUMBER 111794** 111097.0001 112357.0001.S 112357.0002.S 112357.0003.S 112357.0004.S 111087.0001 111087.0002 111087.0003 36424 112363.0001.S 112363.0002.S 112363.0003.S 110100** 111781.0001.S 110423.0001 111518.0001.S 111101.
Electric Box Layout Appendix A (cont’) Three Phase Single Phase External Radio Connector Expansion Board Port Limit Sensor Connector Hoist Interlock Connector Motor Connectors GCL-GT Heavy Duty Operator Radio Antenna Input (Coax) 208/ 230V 115V 1 PH 1 PH Internal Radio Board Brake Connector 208/ 230V 460V 3 PH 3 PH Motor Connectors Transformer Connectors Transformer Connectors Input Power Connectors Input Power Connectors www.geniecompany.com 03-12 10.
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.
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-GT 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 57 58 59 5A 5B 5C 5D 5E 60 61 62 63 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F GCL-GT 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 GCL-GT 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
GCL-GT Heavy Duty Operator www.geniecompany.com 03-12 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.
One Door Dr. Mt.
