Genie GCL-GH User manual

This Installation Manual provides the information required to install, troubleshoot and
maintain a GCL-GH™.rotarepOrooDlairtsudnI/laicremmoC
NOT FOR RESIDENTIAL USE
PROPER APPLICATION
Rolling Steel Hoist
(All Types) (F
Wall Mount)
ront of Hood or
Door Type Operator Type HP/Max Door Weight
Sectional Hoist
1/2HP = 1310 lbs.
(All Types) (Side/
3/4HP = 1450 lbs.
Centermount)
1HP = 1650 lbs.
3HP = 3696 lbs.
WITH EXCLUSIVE FEATURES:
Multivolt®
EZ Limit®
HeavyDutyOperator
GCL-GH™
111837.501539 06-12
HOIST

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-4.5
Rolling Steel Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4.1
Section 5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1-5.8
LineVoltageWiring................................... 5.1
Low Voltage Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
ExternalWireDiagram................................ 5.3
WallControl.......................................... 5.4
InterlockSwitches .................................... 5.5
Monitored Photocell Device Wiring. . . . . . . . . . . . . . . . . . . . 5.6
SensingEdgeSwitch.................................. 5.7
External Radio (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Connecting Motor/Safety Instructions . . . . . . . . . . . . . . . . . 5.9
Section 6 Operator Setup Procedures . . . . . . . . . . . . . . . . . . . . . . .6.1-6.9
Setting Close Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SettingBrakingRate.................................. 6.3
SettingTravelLimits.................................. 6.4
Setting Up Limit Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Setting Down Limit Overrun . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Setting Open & Close Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
(Optional) Transmitter Programming . . . . . . . . . . . . . . . . . . 6.8
(Optiional) Mid-Stop Limit Setting. . . . . . . . . . . . . . . . . . . . . 6.9
Monitored Reversing Devices . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Section 7 Special Operational Features. . . . . . . . . . . . . . . . . . . . . 7.1-7.2.
OperatorCycleCount.................................7.1
GDO & Display Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1
OperatorType........................................7.2
Section 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1-8.5
DisplayOperation.....................................8.1
ErrorCodes.......................................8.1-8.2
RunCodes........................................8.2-8.3
LEDIndicators ........................................8.4
Safe-T-Beam® Self-Diagnostic Troubleshooting Chart . .8.5
Section 9 Service & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1
Periodic Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . .9.1
Section 10 Appendixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1-10.16
AppendixA.................................... 10.1-10.9
Operator Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . .10.1
Section 11 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
TOC
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Heavy Duty Operator
GCL-GH
Wall Mount Kit (Chain Couple) . . . . . . . . . . . . . . . . . . . 10.2
Hoist Shafts Parts Breakdown . . . . . . . . . . . . . . . . . . . . 10.3
MotorOptions................................... 10.4
Brake/Release Assemblies. . . . . . . . . . . . . . . . . . . . . . . . .10.5
Base Electric Box Parts Breakdown . . . . . . . . . . . . . . . 10.6
ElectricBoxLayout .............................. 10.7
Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Screw Terminal Assignments. . . . . . . . . . . . . . . . . . . . . 10.8
AppendixD...................................10.9-10.10
RunCodes.......................................10.9
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10-10.11
Rolling Steel Wall Mount/Side Mount. . . . . . . . . . . . . . . . . . .4.2
(ChainCouple)....................................4-3-4.4
Manual Handwheel/Release Cord . . . . . . . . . . . . . . . . . . . . . 4.5
OptionalClutch....................................... 4.6

1.1
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Failure to correctly perform all steps in sections 4-6 can result in serious injury or death.
Section 1: How to use this manual
The 11 sections of this Installation Manual provide the information required to install, troubleshoot and maintain this 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 3
Details pre-installation concerns/issues/decisions that are recommended to be considered and/or resolved prior to beginning any commercial door
operator installation.
Sections 4-6
Provides step by step installation and set-up instructions for this commercial door operator. Each section is written such that it must be
followed in a step by step order to complete a successful installation.
Sections 7-8
Details important features and troubleshooting information for typical installation and normal operations that may occur.
Sections 9-11
Provides related information on service and maintenance items, operator drawings for use in troubleshooting and service activities, along with
important warranty and returned goods policy information.
WARNING
Heavy Duty Operator
GCL-GH

2.1
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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 depends 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.
To call a local Genie® Dealer, dial 800-OK-GENIE. For Genie® Technical Service, call 800-843-4084.
In this Manual, the words Danger, Warning, and Caution are used to stress important safety information. The word:
DANGER
indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in injury or property damage.
The word NOTE is used to indicate important steps to be followed or important considerations.
IMPORTANT
READ PRIOR TO ANY DOOR OPERATION
POTENTIAL HAZARD EFFECT PREVENTION
Do Not operate unless the doorway is in sight and free of
obstructions. Keep people clear of opening while door is moving.
Do Not allow children to play with the door operator.
Do Not change operator control to momentary contact unless an
external reversing means is installed.
Do Not operate a door that jams or one that has a broken spring.
Could result in
Serious Injury
or Death
Turn off electrical power before removing operator cover.
When replacing the cover, make sure wires are not pinched or near
moving parts.
Operator must be electrically grounded.
Do Not try to remove, repair or adjust springs or anything to which
door spring parts are fastened, such as, wood block, steel bracket,
cable or any other structure or like item.
Repairs and adjustments must be made by a trained service
representative using proper tools and instructions.
HIGH SPRING TENSION
WARNING
MOVING DOOR
1. Read manual and warnings carefully.
2. Keep the door in good working condition.
Periodically lubricate all moving parts of door.
3. If door has a sensing edge, check
operations monthly. Make any necessary
repairs to keep it functional.
4. AT LEAST twice a year, manually operate
door by disconnecting it from the operator.
The Door should open and close freely. If it
does not, the door must be taken out of
service and a trained service representative
must correct the condition causing
the malfunction.
5. The Operator Motor is protected against
overheating by an internal thermal protector.
If the operator ceases to function because
motor protector has tripped, a trained service
technician may need to correct the condition
which caused the overheating. When motor
has cooled, thermal protector will
automatically reset and normal operation can
be resumed.
6. In case of power failure, the door can be
operated manually by pulling the release
cable to disconnect the operator drive system.
7. Keep instructions in a prominent location
near the pushbutton.
Could result in
Serious Injury
or Death
WARNING
Could result in
Serious Injury
or Death
WARNING
ELECTRICAL SHOCK
Heavy Duty Operator
GCL-GH

3.1
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Heavy Duty Operator
GCL-GH
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.
4-Size of door for appropriate operator torque and door travel speed selection.
ssenitsud5-Operator ,ssenpmaddnanoitacolrotarepoedulcniredisnocotsmetI.tnemnorivnegnitnuom and corrosiveness of the location.
6-Door activation needs/requirements. Examples include 3 button control stations, 1 button control stations, radio controls, pull cords, loop detectors, photoelectric controls,
key switches, etc. See “Entrapment Protection” section below.
7-Interlock switches are required under certain conditions for doors with pass doors and door locks. See page 5.5.
8- rofderiuqer(smaebllecotohpro/dnasegdegnisrevereraselpmaxE.tnempiuqeyrosseccA .cte,sthgilgninraw,syalerlortnocyrailixua,),tcatnocyratnemomsaetarepoottessrood
WARNING: DO NOT apply line voltage until instructed to do so.
CAUTION:
Check working condition of door before installing the operator. Door must be free from sticking and binding. If equipped, deactivate
any door locking device(s). Door repairs and adjustments, including cables and spring assemblies MUST be made by a trained service
representative using proper tools and instructions.
Section 3:
Critical Installation Information
ENTRAPMENT PROTECTION
The installation of a fail safe external reversing device (such as a monitored reversing edge or photocell system, etc.) is required on all momentary contact electronically
operated commercial doors. If such a reversing device is not installed, the operator will revert to a constant contact control switch for operation (Closing only).
The Reversing Devices currently UL Approved with are:
MillerEdge ME, MT and series monitored edge sensors used in combination with Timer-Close Module P/N OPABTCX.S or OPAKMEIX.S INTERFACE MODULE.
2) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPE.S.
3) Series II Commercial Safe-T-Beam®, Monitored Photocells P/N OPAKPEN4GX.S.
2) Residential Safe-T-Beam® Monitored Photocells from The Genie® Company, model OSTB-BX (P/N 38176R).
1)

3.2
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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.
.NOITCERIDESOLCEHTNINOITAREPOTCATNOCYRATNEMOMWOLLATONLLIWROTAREPOEHT,DELLATSNISISECIVEDTNEMPARTNELANRETXEDEROTINOMESEHTFOENOLITNU
Heavy Duty Operator
GCL-GH
Type
Mounting
Max.
Door
Weight
(Lbs)
16GA.
Flush
Steel
16GA.
Flush
Steel
Insulated
20GA.
Ribbed
Steel
20GA.
Ribbed
Steel
Insulated
24GA.
Ribbed
Steel
24GA.
Ribbed
Steel
Insulated
Nominal
24GA.
Ribbed
Steel
Nominal
24GA.
Ribbed Steel
Insulated Insulated
PU/FIP Insulated PU/FIP
1.38"
1/8" Glass
1.38" Glass
1.38"
Insulated
PU/FIP
2"
Insulated
PU/FIP
2"
20GA.
Yes
Yes
Yes
S=Jackshaft,SideMount C=Jackshaft,CenterMount
UL L is tedHPModel
T=Trolley
Aluminum
Door S eries ->
Note: Total door weight, and not the square footage, is the critical factor in selecting the proper operator.
Square footage measurements are based on "square doors." (Example=16' x 16')
NOTE: Doors that require special windloading and wide doors, normally require increased strutting (reinforcement). Strutting doors can significantly increase door
weight beyond weight shown. Consult Customer Service for the impact of wind load andstrutting on square foot limits.
NOTE: "PU-FIP" stands for "polyurethane, foamed-in-place." If no notation is present, insulation is "polystyrene, layed-iin-place."
Sectional Door Chart (sq. ft.)
GCL-GH 1/2
GCL-GH 3/4
GCL-GH 1
Yes
GCL-GH 3
216 216 ins. 220 220 ins. 2415 2415 ins. 2411 2411 ins. 125 150 200 200-20 5150 5200 451 452
CommercialSteelInsulated&Non-Insulated Thermospan Thermomark
Exterior
Insulated
PU/FIP
Raised
Panel
1.38"
Insulated 1/4" or 1/2"
PU/FIP
Raised
Panel
2"
Model HP FIRESTAR 3” SLAT FIRESTAR 3” SLAT
INSULATED SHEET DOOR
16GA. 18GA. 20GA. 22GA. 24GA. 26GA. 18GA. 20GA. 22GA. ALUM. STL/SST 20GA. 22GA.
270
N/A
220
355
STEEL, NON-INSULATED STEEL, INSULATED
UL
L is ted
FIRESTAR 2” SLATGRILLESCOUNTER DOOR
ALUM. STL/SST
126 126
Rolling Steel Door Chart (sq. ft.)
Note: Total door weight and not square footage is the critical factor in selecting the proper operator. These Sq.Ft. measurements are based on square doors, e.g. 16' x 16'.
Unbalanced Fire Shutters have a maximum square footage of 52 for 22GA. steel and 42 for 20GA. steel.
GCL-GH 1/2 YES
GCL-GH 3/4 YES
GCL-GH 1 YES
126 126
N/A N/A
16GA. 18GA. 20GA. 22GA.
128 144 166
20GA. 22GA. 26GA.
576
GCL-GH 3 YES N/A N/A
TSC 1310 300 256 410 280 520 400 320 320 256 430 430 350 450 430 400 320
TSC 1450 340 256 450 320 540 410 320 320 256 450 450 400 480 460 400 350
TSC 1650 390 290 510 380 580 410 320 320 256 480 480 420 510 490 400 400
SC 3696 700 500 700 560 770 600 320 320 256 480 900 680 530 680 400 400
250 277 277 333 360 360 194 194 222
283 350 350 442 494 N/A 232 232 283
318 420 420 548 636 N/A 244 244 303
962 1035 1152 1152 1152 N/A 728 728 986
360 280 210
490 350 N/A
580 380 320
982 982 576
N/A
272
120 128 256
N/A N/A N/A
160 180 N/A
N/A N/A N/A
176 188 246
576 300 324 N/A
342 390 576
HTDIWROODELBAWOLLASECIVEDDETSIL
ANY WIDTH
35 FEET
Commercial NEMA4 Monitored Photocells P/N OPAKPEN4GX.S.
MillerEdge ME, MT and CPT series monitored edge sensors used in combination with
Timer-Close Module or OPAKMEIGX.S Interface Module.
30
FEET
Commercial Monitored Photoeye Kit P/N OPAKPE.S 30 FEET
Residential Safe-T-Beam® Monitored Photocells model OSTB-BX P/N 38176R.

3.3
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Section 3: Critical Installation Information
IMPORTANT
INSTALLATION INSTRUCTIONS
WARNING-
Toreducetheriskofsevereinjuryordeath:
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 electronically interlocked to the power unit) that are connected to the door
before installing the operator.
4) Install the door operator at least 8 feet above the floor if the operator has exposed
moving parts.
5) Do not connect the door operator to the power source until instructed to do so.
6) Locate the control station: (a) within sight of the door,(b) a minimum of 5 feet above
the floor so that 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 and in a
prominent location.
8) For products having a manual release,instruct the end user on the operation of the
manual release.
Heavy Duty Operator
GCL-GH

4.1
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Section 4: Installation
Rolling Steel
Heavy Duty Operator
GCL-GH
The Rolling Steel Door Operator can be assembled for right-hand or left-
hand
Front of Hood
mounting Front of Hood.
Each model can also be wall mounted (next pages).
1) Mounting hardware and instruction will be supplied based
on door specifications.
(Typical mounting arrangements shown in figures 1 and 2.)
:
Figure 1 Figure 2
15 1/2"
"A" DIM
13 5/16" 5 1/8"
3 1/2"
4 1/4"
14 5/8"
(WIDTH OF OPERATOR)
4 5/16"
TO HEADPLATE
(OPERATOR SIDE
ROOM REQ'D.)

4.2
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Heavy Duty Operator
GCL-GH
Rolling Steel/Sectional
Wall Mount/Side Mount
4
3
/
4"
(1/2, 3/4, 1HP)
5"
(1/2, 3/4, 1HP)
Figure 6
EDGE OF
LOCK DOWN
HOLES
OPENING
4
3
/
4"
(1/2, 3/4, 1HP)
5"
(1/2, 3/4, 1HP)
Figure 7
The Hoist unit can be wall mounted when required. Fig. 5, 6 & 7.
1) Attach optional wall mount bracket to operator (optional) using the 4
mounting bolts and nuts supplied. Fully tighten. Position the operator
with the bracket as shown.
2) Attach 12 tooth sprocket to operator output shaft.
3) Align keyways and insert key into sprocket and door shaft keyway.
Do not tighten set screw at this time.
4) Attach door sprocket to door shaft. Do not tighten at this time.
5) Assemble chain using chain master link.
6) Position operator near door shaft with sprockets aligned.
7) Place assembled chain over door and operator sprockets.
8) Lift or lower the operator as needed to tension
drive chain.
9) Secure operator to wall.
10) Check
11) Lock the operator in place using the LOCK DOWN HOLES
indicated in Fig. 5. These MUST BE USED to prevent any
shifting of the operator due to the torque applied
during operation. (These are in addition
to the slotted mounting holes.)
vertical alignment of the drive chain/sprockets
and tighten sprocket set screws.
Figure 5
Optional Bracket

www.geniecompany.com 0 -12 4.3
For Hollow Counterbalance Door Shaft:
1) Use non-threaded hole in door shaft sprocket as a guide and
drill a 3/8" diameter hole through one side of the door shaft.
Fig. 4A.
2) Insert clevis pin through sprocket and shaft to hold sprocket
in position.
3) Drill through opposite side of shaft to obtain proper hole
alignment. Fig. 4B.
4) Insert clevis pin through both holes and secure with cotter pin.
Fig. 4C.
For Solid Counterbalance Door Shaft:
1) Insert key into door shaft keyway.
2) Slide sprocket into place and secure with set screws.
To Complete the Installation:
If needed, realign operator sprocket with door sprocket. If you have
excessive door shaft movement, an optional chain tension plate is
available, pg 4.4.
I
L
Figure 4A
Figure 4B
Figure 4C
6
Heavy Duty Operator
GCL-GH
Chain Couple