CornellCookson SDC-7545 Troubleshooting guide

07/17
INSTALLATION INSTRUCTIONS
AND
OPERATION MANUAL
SDC-7545
UL325-2010 Compliant
Commercial and Industrial Door Operator
Logic Control
Duty Cycle – 10 Cycles per Hour

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IMPORTANT INSTALLATION INSTRUCTIONS
WARNING – To reduce the risk of severe injury or death to
persons:
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. If the operator must be mounted less 8 ft (2.44 m) above the floor, then exposed moving
parts must be protected by covers or guarding. Contact the manufacturer.
5. Locate the control station: (a) within sight of the door, and (b) at a minimum height of 5 feet above
floors, landings, steps, or any other adjacent walking surface and (c) away from all moving parts of
the door.
6. Install the Entrapment Warning Placard next to the control station in a prominent location.
7. 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.
8. 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.
9. 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.
10. Always disconnect power whenever installing or servicing the door operator or door.
11. All wiring must be permanent and comply with National Electrical Code (NEC) and local code
requirements.
12. Any change in mounting position may result in a change of operator rotation and consequently in a
change of control functions. Consult factory for any changes.
13. If the operator is provided with an auxiliary chain operator, the hand chain should be kept inside
the chain bag when operating electrically.

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SPECIFICATIONS
MOTOR
Duty Cycle: 10 Cycles per hour
Horsepower: 3/4 hp
Speed: 1700 RPM
Voltage: 24VDC
Current: See motor nameplate
ELECTRICAL
Transformer: Power 21VAC 530VA, Control 25VAC 120VA
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: 57:1
Output Shaft Speed: 30 RPM
Door Speed: 6 - 8” per sec. average (typical)
Brake: Solenoid actuated brake
Emergency Chain Hoist: Standard
ENTRAPMENT PROTECTION
Sensing Edge*: (Optional) Sensing device attached to the bottom edge of the door.
Non-Contact Device*: (Optional) Photo eye device.
* Per the requirements of UL Standard 325, the door operator is setup for constant
pressure to close the door. As an alternative, the door may be provided with a monitored
entrapment protection device that will reverse the door upon contact with or detection of
an obstruction during closing. Adding an entrapment device would enable momentary
close operation.
*Note:
1. Non-contact device (photo eye) can be used on doors up to 45 ft. wide (or maximum rated range of
device if less than 45 ft.). Use a sensing edge to provide entrapment protection on doors over 45 ft.
wide.
2. Sensing edge can be used on all doors.

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INSTALLATION INSTRUCTIONS
INSTALLATION POSITIONS
RS
LS
RA
LA
Consult factory for changes in installation positions.
Illustrations only, consult door manufacturer for install details.
NOTE: Any change in mounting position may result in a change of operator rotation and
consequently in a change of control functions. Consult factory for any changes. (LH=LS and
RA, RH=RS and LA)
Please see page 11 for Left and Right Switch.

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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 layout of the mounting holes on the bracket are correct.
3. Bolt the operator mounting plate to the door bracket plate.
4. Attached and tighten mounting blots to the mounting plate.
5. Finally, mount the operator to the mounting plate.
Illustrations only, consult door manufacturer for install details.

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6. When the operator assembly is attached to the door bracket, be sure the door driven sprocket is
properly aligned with the operator drive sprocket before securing the driven sprocket to the shaft.
7. The shelf or bracket must provide adequate support for the operator. Prevent play between the
operator and the door shaft. The operator must be securely attached with the drive shaft parallel to
the door shaft. It may be necessary to field brace the operator/bracket.
Incorrect
Correct
Door
Sprocket
Operator
Output
Sprocket
Illustrations only, consult door manufacturer for install details.
DRIVE CHAIN ADJUSTMENT
NOTE: Use correct type, size and proper length of roller chain.
1. Adjust the drive chain by tilting or move 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. (See figure - T1 and T2).
2. Once the drive chain has been tightened and the base leg screws have been set, and then tighten
the operator screws.
Drive Chain
Door Sprocket
Drive Sprocket
1/4"
T1
T2
Drive Chain
Door Sprocket
Drive Sprocket
1/4"
T1
T2

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HAND CHAIN ADJUSTMENT
Cut and reconnect chain with different color link provided.
BRAKE RELEASE LEVER
Release
Releasing the door operator brake, or loosening or removing any part of the
door operator drive system, can cause the door to close and cause death or
serious injury. Do NOT release the brake, or loosen or remove any part of
the door operator drive system, unless the door is closed, or the curtain is
secured in the open position to prevent uncoiling.
1. Pressing the brake release lever will release the motor brake and can cause the door to move
uncontrolled.
2. Open-close-stop controls do not function while the brake release lever is pressed.
NOTE: A door sprung for emergency egress can open when the brake release lever is pressed.
WARNING

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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.
Disconnect power before adjusting 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.
A
D
B
C
F
G
E
NOTE: “C” is usually the opening side and “D” is usually the closing side.
WARNING

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WIRING INSTRUCTIONS
Disconnect power at the fuse box 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 connected 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 circuit of adequate capacity is needed for the operator.
7. The operator must be properly grounded. The ground screw, painted 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
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, an entrapment protection
device must be installed on the door. Failure to install an entrapment
protection device may result in serious injury or death to person(s) trapped
beneath the door.
1. Complete limit switch adjustments before making any sensing edge/non-contact device wiring
connections to the operator.
Sensing Edge
Photo Eye
6" max. above floor
Illustrations only, consult door manufacturer for install details.
Entrapment Device Options:
Sensing Module Device Manufacturer Model
ELR
2-wire resistive
sensing edge
(TB3 9 & 10)
Miller Edge Inc.
* End of Line resistor type edge
must have model number with
Suffix T2.
ME110*, ME111*, ME120*, ME123*, ME112*, ME113*,
ME116*, ME117*
MT21*, MU21*, MT22*, MU22*, MC22*, MU33*,
MC271*, CPT223*
MEL-TXYY, MEL-RXYY
ASO GE225, GE125, GE245, GE F45, GE F50, GE F56,
GE F65, GE F85, GE F115
IR
Monitored photo
eye
(TB3 7 & 8)
FRABA Inc.
Optical Edge Sensors and Photo Eyes, Models
OPTOEYE, OPTOEDGE; Part Nos. OSE-T, OSE-R,
OSE-P, OPE.
Reflective Photo Eye, Models Ray/RT -1004, -2004
Martec Access Products Inc. 1266
Miller Edge Inc. IG2, MIRM
Note: Please refer to sensing device manufacturer for specific installation and maintenance requirements.
WARNING

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Disconnect power at the fuse box before proceeding with any wiring.
2. Locate the control station where the user can
clearly see the operation of the door. Mount the
enclosed placard adjacent or near the door.
Controls shall be far enough from the door, or positioned such that the
user is prevented from coming in contact with door while operating the
controls.
3. Do not run control wiring in the same conduit as power wiring.
4. Any wire connected 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.
Changing from left hand to right hand or vice versa could result in change
of control wiring. Consult factory for details.
5. After installation, be sure that the operator, controls, and sensing edge or other entrapment
protection devices have been tested and function properly.
WARNING
WARNING
WARNING
WARNING

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CONTROL OVERVIEW
To Motor Wires
To Brake Wires
Limit Switch
Connections
CN 103
Door Power
Indicator
LED100
POWER
LED100
Control Power
Display
Hand Direction
LH
RH
LH
RH
Buzzer Switch
ON
OFF
Buzzer Connections
Battery Load
Test Resistor
Terminal Connections
Motor Power Input
Battery
Connections
ERROR
BUTTOM SAFE IR ELR PUSHA ALARM
Lock Board
Connections
AUTO LOCK
BUTTOM SAFE IR ELR PUSHA ALARM
ERROR
Control Power
Input (24VAC)
LED 102
AC\DC Power
LED 101
Sensing Device
Charging IC Fuse
(0.2A Fast)
I
nput Power Fuse of the
Board (2.5A Fast)
F 3
F 1
Battery Output Fuse
(30A Slow)
Switches Indication
Hand Direction ON
OFF
Buzzer Switch
“LH”: Left hand
“RH”: Right hand
“ON”: Audio alarm on.
“OFF”: Audio alarm off.

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Lights Indication
LED100
Input Power
LED1 Brake
LED1
LED100
LED101
LED3 LED5 LED7
LED9
LED8 LED 4 LED 6 LED13 LED102
LED101
Sensing Device
LED3
AC Failure
LED9
MCU Failure
LED8
Charge Voltage Failure
LED4
Overload
LED5
Battery Failure
LED7
Aux. Close Limit Contact
LED13
Auto Lock
LED102
AC/DC Power
LED6
Aux. Open Lim it Contact
Light Function Color ON OFF
LED1 Brake Red Activated Not Activated
LED3 AC Failure Red Normal Abnormal
LED4 Overload Red Normal Abnormal
LED5 Battery Failure Red Normal Abnormal
LED6 Aux. Open Limit Contact Red Not at open limit Door reached open
(T41&42 output)
LED7 Aux. Close Limit Contact Red Not at close limit Door reached close
(T43&44 output)
LED8 Charge Voltage Failure Red Normal Abnormal
LED9 MCU Failure Red Normal Abnormal
LED13 Auto Lock Red Lock Unlock
LED102 AC/DC Power Red Abnormal (Flashing) Normal
LED101 Sensing Device Green Normal Abnormal
LED100 Input Power Green Normal Abnormal
Sound Warnings
Description Sound
Battery failure warning signal B_____ B.B.B. B_____ B.B.B. B_____ B.B.B. …..
AC power loss warning signal B_____ B.B. B_____ B.B. B_____ B.B. …..
Overload warning signal B_____ B. B_____ B. B_____ B. …..
Stop key press warning signal B.B.B.B. B.B.B.B. B.B.B.B. …..

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FIELD PROGRAMMING
(1) Constant/Momentary pressure setting of OPEN/CLOSE Button
z Press “SET” for three seconds to enter setting mode. Use “SELECT” to choose “Constant
Pressure”. Use “+” and “-” to Constant Pressure or Momentary Pressure. Press “SET” again to
save setting. “SAVE SUCCESS” will appear if setting is complete.
(2) Clock
z Press “SET” for three seconds to enter setting mode. Use “SELECT” to choose “Clock-Set time”.
Use “+” and “-” to set hour. (00~24 hours)
z Press “SELECT” again to set minute. Use “+” and “-” to set minute. (00~59 minutes)
z Press “SET” again to save setting. “SAVE SUCCESS” will appear if setting is complete.
Complete
Clock-Set time 10:00
HOUR(00→23) ：10
Clock-Set time 10:10
MINUTE(00→59)：10
Clock-Set time 10:10
SAVE SUCCESS!!
Complete
＞Constant Pressure
Momentary Pressure
Constant Pressure
SAVE SUCCESS!!
Complete
Constant Pressure
＞Momentary Pressure
Momentary Pressure
SAVE SUCCESS!!
Choose
AC Power
Counter
Battery Power
Current Time
AC 000V DC 00.0V
CNT: 0000056 00:06

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(3) Battery load test time and setting: (Every 24 hours and 10 seconds of load test.)
z Press “SET” for three seconds to enter setting. Use “SELECT” to choose “Battery test time”.
Use “+” and “-” to set hour. (00~23 Hours)
z Press “SELECT” again to set minute. Use “+” and “-” to set minute. (00~59 Minutes)
z Press “SELECT” again to set condition. Use “+” and “-” to enable or disable battery load test.
z Press “SET” again to save setting. “SAVE SUCCESS” will appear if setting is complete.
(4) Battery low auto OPEN
Press “SET” for three seconds to enter setting mode. Use “SELECT” to choose “Auto OPEN”. Use
“+” and “-” to Yes or No. “SET” again to save setting. “SAVE SUCCESS” will appear if setting is
complete.
(5) Reverse distance
z Press “SET” for three seconds to enter setting mode. Use “SELECT” to choose “Reverse
distance”. Use “+” and “-” to Rev Top or Rev 3s. Press “SET” again to save setting. “SAVE
SUCCESS” will appear if setting is complete.
Complete
Battery test time
HOUR(00→23)：10
Battery test time
MINUTE(00→59)：20
Battery test time
SAVE SUCCESS!!
Complete
AC fail and DC fail
Auto OPEN: Yes
AC fail and DC fail
SAVE SUCCESS!!
Complete
Reverse distance
＞Rev Top Rev 3s
Rev Top
SAVE SUCCESS!!
Complete
Reverse distance
Rev Top ＞Rev 3s
Rev 3s
SAVE SUCCESS!!
Choose

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TERMINAL CONNECTIONS
DOOR POWER
INDICATOR
DOOR POWER INDICATOR
CHECK AC/DC POWER
WHEN RED LIGHT FLASHING
EAP101A V3
TB1
SDC-7545 Terminal Connections
WARNING : DISCONNECT ALL POWER BEFORE WORKING ON CONTROLS
Control Station Key Switch
or 3-button control station
TB3
IR
Exit Hardware
Sensing edge
connection N/O
ELR
NOTE:
INPUT : 16AWG (WITHIN 50FT)
NOTE:
CONTROL : MIN. 18AWG (WITHIN 50FT)
CN103
LOCK1
TB2
LOCK1
AC power warning
Battery voltage warning
LH-Open limit
RH-Close limit
LH-Close limit
RH-Open limit
Power Output
Auto-Locking at close limit
Alarm
Input Power
120VAC
L N
TB3
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Control Station Key Switch
or
3-button control station
Sensing edge
connection N/O.
IR Photo Eyes Sensing edge -
ELR
EXIT Hardware
Emergency
open
Alarm
connection
dry contact
Stop Open Close Com
TB2
35 36 39 40 41 42 43 44 24V+ 24V- LOCK1 LOCK2
AC power
warning dry
contact,
24VAC/DC, 0.5A
Max.
Contact open
when abnormal.
Battery voltage
warning dry
contact,
24VAC/DC, 0.5A
Max.
Contact open when
abnormal.
LH-Open limit
RH-Close limit
dry contact,
24VAC/DC,
0.5A Max.
Contact open when
door reaches limit.
LH-Close limit
RH-Open limit
dry contact,
24VAC/DC,
0.5A Max.
Contact open when
door reaches limit.
Power Output
24VDC/1A Max.
Auto-Locking at
close limit,
dry contact
output.

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WIRING CONNECTIONS
DOOR POWER
INDICATOR
DOOR POWER INDICATOR
CHECK AC/DC POWER
WHEN RED LIGHT FLASHING
EAP101A V3
TB1
Battery Compartment
GR
R
BK WH
GR
COM
NO
Emergency Open Button
COM NO
OPENCLOSE
WH
OPEN CLOSE
KEY REQUIRED TO REMOVE COVER
NC
NO
C
NC
NO
C
Key Switch 1
OPENCLOSE
WH
NC
NO
C
NC
NO
C
Key Switch 2
GR
WHBK
SDC-7545 Wiring Connections
WARNING : DISCONNECT ALL POWER BEFORE WORKING ON CONTROLS
Input Power
120VAC
CN103
NOTE:
INPUT : 16AWG (WITHIN 50FT)
NOTE:
CONTROL : MIN. 18AWG (WITHIN 50FT)
L N

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WIRING DIAGRAM

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BATTERY SPECIFICATION
Type Battery Rating
Lead Acid Rechargeable Battery 12VDC, Max. 17.2Ah
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. After adjusting either the force or the
limit of travel, retest the door operator’s safety features. Failure to adjust the operator properly
may cause severe injury or death.
5. For products having a manual release, if possible, use the manual release only when the door
is closed. Use caution when using this release when the door is open. Weak or broken springs
may cause the door to fall rapidly, causing severe injury or death.
6. KEEP DOORS PROPERLY OPERATING AND BALANCED. See Door Manufacturer’s
Owner’s Manual. An improperly operating or balanced door could cause severe injury or death.
Have trained door systems technician make repairs to cables, spring assemblies, and other
hardware.
7. SAVE THESE INSTRUCTIONS.