Cookson MGRL Series Troubleshooting guide

04/08
INSTALLATION INSTRUCTIONS
AND
OPERATION MANUAL
Cookson MG Operator
MGRL / MGHL Series
(with internal lock sensor feature)

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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.
3. Remove all pull ropes and remove, or make inoperative, all locks (unless mechanically and/or
electrically interlocked to the power unit) that are connected to the door before installing the
operator.
4. Install the door operator at least 8 feet or more above the floor if the operator has exposed
moving parts.
5. Do not connect the door operator to the source of power until instructed to do so.
6. Locate the control station: (a) within sight of the door, (b) at a minimum height of 5 feet so
small children cannot reach it, and (c) away from all moving parts of the door.
7. Install the Entrapment Warning Placard next to the control station in a prominent location.
8. For products having a manual release, instruct the end user on the operation of the manual
release.
9. The door is under extreme spring tension. Have qualified door mechanics make all necessary
adjustments and repairs to the door.
10. Make sure the available power supply to be connected to the operator is of the same voltage,
frequency, phase and wattage as indicated on the nameplate of the operator.
11. Read and understand the wiring diagram of the operator and the control station
(open-close-stop push button), and any other equipment to be connected to the operator.
12. To avoid damage to the door and operator, make all door locks inoperative. Secure locks in the
unlocked position, or install external electrical interlocks to prevent operation with the locks
engaged.
13. Always disconnect power whenever installing or servicing the door operator or door.
14. All wiring is to comply with National Electrical Code (NEC) and local code requirements.
15. Any change in mounting position may result in change of operator rotation and consequently
in change of control functions. Consult factory for any changes.
16. Hand Chain must be kept inside plastic bag when operating electrically.

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SPECIFICATIONS
MOTOR
Type: ……………………… Restricted cycle duty
(25 cycles per day)
Horsepower: ……………… 1/3hp, 1/2 hp
Speed: …………………….. 1700 RPM
Voltage: …………………… 115, 230 – 1 phase
208/230, 460 – 3 phase
230 volt 3 phase motor is suitable for use with 208 volts
Current: ………………….. See motor nameplate
ELECTRICAL
Transformer: …………….. 24VAC
Wiring Type: …………….. Momentary pressure open, stop, constant pressure close
(provided standard), with provision for momentary
pressure close*
Limit Adjustment: ………. Linear driven, fully adjustable screw type cams.
MECHANICAL
Drive reduction: …………. 43:1
Output shaft speed: ……... 40 RPM
Door Speed: ………………. 6 - 9” per sec. average (typical)
Brake: …………………….. Solenoid actuated brake
Release Mechanism: ……... Floor level pull-cable release standard
Emergency Chain Hoist: .... Optional (Standard on MGHL)
ENTRAPMENT PROTECTION
Sensing Edge*: …………… (Optional) Sensing device attached to the bottom edge of
the door.
* Per the requirements of UL Standard 325, the door operator must be provided with an
actuating device requiring constant pressure to close the door. As an alternative, the door
may be provided with a device that will reverse the door upon contact with an obstruction
during closing.

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INSTALLATION INSTRUCTIONS
INSTALLATION POSITIONS
Illustration only. Consult factory for changes in installation positions.
NOTE: Any change in mounting position may result in change of operator rotation and
consequently in change of control functions (i.e. lock sensor). Consult factory for any
changes.

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OPERATOR MOUNTING
1. Before the operator is installed, verify that the door is properly operating and balanced.
2. Make sure the dimensions of mounting holes on the bracket are correct.
3. Attach and tighten the three legs (2) to the mounting plate.
4. Bolt the operator mounting plate (1) to the door bracket plate.
5. Finally, mount the operator (3) to the three legs (2) and tighten.

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6. When the operator is mounted on the bracket, be sure the door driven sprocket is properly
aligned with the operator drive sprocket before securing to the shaft. The clearance (B) must be
the same as the height (A).
7. The shelf or bracket must provide adequate support for the operator. Prevent play between
operator and door shaft. Permit operator to be fastened securely and with the drive shaft
parallel to the door shaft. It may be necessary to field brace the operator/bracket.

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DRIVE CHAIN ADJUSTMENT
NOTE: Use correct type, size and proper length of roller chain.
1. Adjust the drive chain by tilting the operator so that there is about 1/4” of slack when the chain
is depressed.
Note: The set screw included in the operator may be used for adjustment (S1 location).
2. Once the drive chain has been tightened and the base leg screws have been set, and then tighten
the operator screws.

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MANUAL RELEASE
Cut and adjust cable length.
EMERGENCY HAND CHAIN ADJUSTMENT (OPTIONAL on MGRL Series)
Cut and reconnect chain with different color link provided.
WARNING: When using hand chain, a dis/engagement cable is not required and should not be
used. Use cable only on operators without an auxiliary hand chain (MGRL) or when a pull handle
egress device is used in conjunction with an auxiliary hand chain on the MGHL.
Note: Chain hoist can be added in the field. Consult factory for details.

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LIMIT SWITCH ADJUSTMENT
Make sure the limit cams are positioned between the limit switch actuators before
proceeding with adjustments.
1. Open / Remove the control panel cover.
2. Open or close door to determine the moving direction of the limit switch cams.
3. Open or close door to the desired position.
If the door is opened or closed electrically, to avoid serious injury or death,
disconnect power before manually moving limit switch cams.
4. While pressing the spring-loaded lever (G), which holds the limit switch cams in place, adjust
the limit switch cam (E or F) until the micro switch (C or D) clicking sound is heard.
5. If the limit switch cam cannot be rotated to its desired position, release the lever and move the
door away from the desired position, then adjust the limit switch cam to its desired position.
It may be necessary to repeat this step until the exact position has been reached.
6. Repeat step 3 and 4 for the opposite position. Adjust close limit cams so that actuator is engaged
as door fully seats at the floor.
7. Micro switch (A or B) can be adjusted to accommodate sensing edge cut-off position.
8. Micro switch (H) can be adjusted to lengthen or shorten lock sensor distance.
Warning: Factory default for lock sensor is 4~6 inches. Door might be damaged if adjusted
too short. Operator might be inoperative if adjusted too long.
NOTE: “C” is usually the opening side and “D” is usually the closing side.
WARNING

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INTERNAL LOCK SENSOR
NOTE: All units are adjusted to the most sensitive level ex-factory. A RED paint seal is applied
on the hex nut and the shaft. Once the seal has been broken, interlock sensitivity has been changed.
Door and /or door lock may be damaged.
To adjust sensitivity of lock sensor.
1. Loosen Hex Nut.
2. Adjust screw at the drive shaft for sensitivity. Adjustment range: 0~6 turns. More than 6 turns
of adjustment is not recommended; part(s) might fall out. More sensitivity will result in less
pull against the locking device but less capacity to lift the door - less sensitivity will result in
more pull against the locking device but more capacity to lift the door. Use included tool to
make adjustment.
3. Tighten Hex Nut.
NOTE: 6 turns of the lock sensor adjustment will result in the lock sensor in the least possible
sensitivity, which means the greatest amount of pull against the locking device. If the door is still
not functioning properly, check spring tension, overall door installation and consult door
manufacturer.
NOTE: Lock sensor is hand sensitive. See illustration for reference. Consult factory for hand
changes and other details.

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WIRING INSTRUCTIONS
Disconnect power at the fuse box and the operator before proceeding with
any wiring.
1. Do not install any wiring or attempt to run this operator without checking the wiring diagram
located on the inside of the control box cover.
2. Do not turn on power until you have finished making all power and control wiring connections.
3. Do not run power and control wiring in the same conduit.
4. Any wire connecting to the control panel must be protected by conduit or other means to ensure
the safety and permanency of the wiring.
5. Use copper wire inside the control panel.
6. A separate fuse line of adequate capacity is needed for the operator.
7. The operator must be properly grounded. The ground screw, plated green, is located inside the
control panel.
Failure to properly ground the operator could result in electric shock and
serious injury or death.
To avoid damage to door and operator, make all door locks inoperative.
Secure lock(s) in the unlocked position, or install electrical interlocks to
prevent operation with the lock engaged.
WARNING
WARNING
WARNING

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CONTROL WIRING
Disconnect power at the fuse box before proceeding with any wiring.
1. Locate the control station where the user can clearly see the operation of the door. Mount the
enclosed placard adjacent to the 3-button control station.
If the door is not visible from the control station, or if any device other
than the control station is used to activate the door, a sensing edge must
be installed on the bottom of the door. Failure to install a sensing edge
may result in serious injury or death to person(s) trapped beneath the
door.
Complete limit switch adjustments before making any sensing edge wiring connections to
the operator.
2. Do not run control wiring in the same conduit as power wiring.
3. Any wire connecting to the control panel must be protected by conduit or other means to ensure
the safety and permanency of the wiring.
Do not use radio controls with your operator unless some type of
entrapment protection device has been installed. Failure to do so may
result in serious injury or death to person(s) trapped beneath the door.
Do not change closing control from constant pressure to momentary
pressure without installing a sensing edge. This could result in serious
injury or death to person(s) trapped beneath the door.
Changing from left hand to right hand or vice versa could result in
change of control wiring and lock sensor settings. Please consult factory
for details.
4. After installation, be sure that the operator, lock sensor, controls, and sensing edge or other
entrapment protection devices have been tested and function properly.
WARNING
WARNING
WARNING
WARNING
WARNING

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