Genie GCL-GH/T Manual
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Genie GCL-GH/T Manual

Genie GCL-GH/T Manual

Heavy duty operator
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GCL-GH/T
Heavy Duty Operator
NEMA 7/9 Explosion Proof
PROPER APPLICATION
Door Type
Operator Type
Sectional
Hoist
(All Types)
(Sidemount,
Chain Couple)
Rolling Steel
Hoist
(All Types)
(Front of Hood,
Top of Hood,
Wall Mount)
This Installation Manual provides the information required to install,
troubleshoot and maintain a GHX® Explosion Proof Operator.
112602.503533
HOIST MODEL
HP/Max Door Weight
1/2HP = 1310 lbs.
1HP
= 1650 lbs.
3HP
= 3696 lbs.
NOT FOR RESIDENTIAL USE
CLASSES:
FLAMMABLE GASES
CLASS 1, DIVISION 1, GROUP D, T2C
COMBUSTIBLE DUST
CLASS II, DIVISION 1, GROUP F & G, T2C
PROPER APPLICATION
Door Type
Operator Type
Sectional
Trolley
(Standard or
(Standard, Sidemount
Low Headroom
or Dual Trolley)
Track Only)
TROLLEY MODEL
HP/Max Door Weight
1/2HP = 1310 lbs.
1HP
= 1650 lbs.
02/2017

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  • Page 1 GCL-GH/T Heavy Duty Operator NEMA 7/9 Explosion Proof CLASSES: FLAMMABLE GASES CLASS 1, DIVISION 1, GROUP D, T2C COMBUSTIBLE DUST CLASS II, DIVISION 1, GROUP F & G, T2C HOIST MODEL TROLLEY MODEL PROPER APPLICATION PROPER APPLICATION Door Type Operator Type...

  • Page 2: Table Of Contents

    Table of Contents Section 1 How to use this manual ..........................1.1 Section 2 Safety Information & Instructions ....................2.1-2.2 Section 3 Critical Installation Information ......................3.1-3.2 Section 4 Installation Typical Installation Diagram ........................4.1 Rolling Steel Weld Plate ..........................4.2 Rolling Steel Top of Hood/Front of Hood ....................4.3 Rolling Steel Bench Mount ........................

  • Page 3: How To Use This Manual

    Section 1: How to use this manual The 10 sections of this Installation Manual provide the information required to install, troubleshoot and maintain a NEMA 7/9 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/instruc- tions detailed in this manual.

  • Page 4: Safety Information & Instructions

    If you have any questions or do not understand the information presented, call your nearest service representative. Contact Genie at 1-800-843-4084. In this manual the words Danger, Warning, and Caution are used to stress important safety information.
  • Page 5 Genie appelez le +1 (800)-843-4084. Dans ce manuel, les mots Danger, Avertissement, et Attention sont utilisés pour faire ressortir d’importantes informations relatives à...

  • Page 6: Critical Installation Information

    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. Reversal of Limit Box (4.18). 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.

  • Page 7: Installation

    Section 3: Critical Installation Information 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.
  • Page 8 Section 4: Operator Installation Typical Installation HOIST A=Motor Feed C=Power Input Feed E=NEMA 7/9 Explosion G=Limit Switch/Safety Up to 7 Wires. Explosion Proof Up to 4 Wires. Explosion Proof Proof Enclosure Feed Junction Box Conduit not included. Conduit not included. Low Voltage Intrinsically Safe Feed.
  • Page 9 Section 4: Operator Installation HOIST Rolling Steel - Front of Hood The Rolling Steel Door Operator can be assembled for right-hand or left-hand mounting Front of Hood Each model can also be wall mounted. 1) Mount the powerhead to the head-plate mounting bracket using fasteners provided. (Typical mounting arrangements shown in Figures 1 and 2.) REFER TO SHOP DRAWINGS FOR SPECIFIC DIMENSIONING INFORMATION...
  • Page 10 Section 4: Operator Installation HOIST Rolling Steel - Front of Hood (cont’d) 1) Attach 12 tooth sprocket to operator output shaft. 2) Align keyways and insert key into sprocket and output shaft keyway. Do not tighten set screw at this time. 3) Attach door sprocket to door shaft.

  • Page 11: Rolling Steel/Sectional Wall Mount

    Section 4: Operator Installation Wall Mount Rolling Steel & Sectional - Wall Mount The Hoist unit can be wall mounted when required. 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.
  • Page 12 Section 4: Operator Installation Chain Couple Tension Bracket Bracket is available as an optional kit, P/N 111005.0001.S & 111005.0002.S Installation of optional chain spreader bracket: Fig 8. 1) Place sprocket, upper plate and bearing assembly on door shaft as shown. 2) Place lower plate, bearing assembly and sprocket on operator shaft as shown.
  • Page 13 Section 4: Operator Installation Unpacking and Configuring Release Cord: Fig. 11 1) The cord comes shipped connected to the Release Lever and looped around the end of the hoist shaft opposite the handwheel, with the bulk of the cord taped to the handwheel side of the brake enclosure (SIDE A).
  • Page 14 Section 4: Operator Installation Adjusting the Clutch (Optional) P/N 111817.0002 1/2 & 1HP Only NOTE: The clutch is intended to provide protection for the door, operator and associated equipment. It is not intended for entrapment protection. The Clutch does not require any disassembly to adjust. 1) All adjustments should be made in very small increments (e.g.
  • Page 15 Section 4: Operator Installation Trolley Trolley Models The Trolley Operator consists of the: Power Unit (A) Drawbar Track (B) Chain Guides (C) Header Bracket (D) Idler Pulley (E) Drive Chain (F) Drive Sprocket (G) Drawbar Arm (H) The Drawbar track length, chain length and quantity of chain guides will vary by door heights.
  • Page 16 Section 4: Operator Installation Trolley Drawbar Assembly CAUTION Verify that bolts are properly seated in track. Failure to seat bolts can cause carriage to bind in door track. ATTENTION Vérifiez que les boulons sont bien en place dans la piste. Si les boulons sont mal logés, le chariot peut se coincer dans la piste de la porte.
  • Page 17 Section 4: Operator Installation Trolley Drawbar Assembly 1) 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. 2) Place the header bracket in position around the drawbar track. Do not insert the track bolts and lock nuts at this time.
  • Page 18 Section 4: Operator Installation Trolley Drawbar Assembly WARNING AVERTISSEMENT DO NOT apply line voltage until instructed to do so. NE PAS mettre sous tension tant que l’instruction n’est pas donnée de le faire. 1) 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.
  • Page 19 Section 4: Operator Installation Trolley Drawbar Installation WARNING AVERTISSEMENT Repairs and adjustments, including particularly to Les réparations et les réglages, plus cables and spring assemblies under high tension, particulièrement ces qui sont destinés aux must be made by a trained service representative câbles et ensembles de ressort sous tension using proper tools and instructions.
  • Page 20 Section 4: Operator Installation Trolley Drawbar Installation 1) Use a level, as shown in Fig. 8 to find the highest point of travel for the door. 2) Mark a horizontal line across the vertical line you made on the header at 5” above the highest point of door travel.
  • Page 21 Section 4: Operator Installation Trolley Attach the Door 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 header bracket using the two (2) track bolts (1 /4”-20 x 9/16”) and two (2 ) locknuts.
  • Page 22 Section 4: Operator Installation Trolley Connection 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).
  • Page 23 Section 4: Operator Installation Adjusting the Clutch P/N 111583.0001 NOTE: The clutch is intended to provide protection for the door, operator and associated equipment. It is not intended for entrapment protection. The Clutch does not require any disassembly to adjust. 1) All adjustments should be made in very small increments (e.g.

  • Page 24: Enclosure Mounting

    Section 4: Operator Installation Limit Switch Box Reversal (Hoist Models Only) Some installations may require the reversal of the Limit Switch Assembly box to facilitate installation. 1) Remove limit switch chain and sprockets as an assembly. 2) Loosen, but do not remove, cover screws (4) to remove limit switch cover. 3) Remove limit switch assembly mounting screws (2).

  • Page 25: Typical Installation Diagram

    Section 5: Line Input & Motor Wiring TYPICAL INSTALLATION Limit/Interlock Wires Motor Wiring Line Input Wiring Sealed Conduit Fittings. (NOT Included) Control Station (Included) Safety Wiring OPEN NEMA 7/9 Enclosure CLOSE (Included) Junction Box STOP (NOT Included) Sealed Conduit Fitting. (NOT Included) Control Wire Junction Box...

  • Page 26: Line Voltage & Motor Wiring

    Section 5: Line Input Wiring Line Voltage and Motor Wiring WARNING AVERSTISSEMENT • DO NOT apply power until instructed to do so. • NE PAS mettre sous tension tant que • It is strongly recommended, and may be l’instruction n’est pas donnée de le faire. required by law in some areas, that line voltage • Il est fortement recommandé...
  • Page 27 Section 5: Line Input & Motor Wiring...
  • Page 28 Section 5: Line Input & Motor Wiring...

  • Page 29: Intrinsically Safe Wiring

    Section 5: Control Wiring TYPICAL INSTALLATION Limit/Interlock Wires Motor Wiring Power Input Wiring Sealed Conduit Fittings. (NOT Included) Control Station (Included) Safety Wiring OPEN NEMA 7/9 Enclosure CLOSE (Included) Junction Box STOP (NOT Included) Sealed Conduit Fitting. (Not Included) Control Wire Junction Box (Not Included) Conduit...
  • Page 30 Section 5: Control Wiring Wall Controls WARNING: • Wall Control(s) must be located so that the door is within sight of the user and is far enough from the door or positioned such that the user is prevented from coming in contact with the door while operating controls. •...
  • Page 31 Section 5: Control Wiring Interlock Switches. Figure 6 1) Optional external interlock switches are required with some Sectional & 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 must be installed to prevent electric operation when the lock is engaged.
  • Page 32 Section 5: Control Wiring Sensing Edge Switch Installation NOTE: Turn dip switch 8 to OFF to enable this feature. NOTE: Do not use take-up reels with safety edges. Use coil cords only. This figure shows an example of a typical sensing edge installation. Right hand side is shown but Left hand is a mirror image of this.
  • Page 33 Section 5: Control Wiring Limit Switch/Hoist Interlock Wiring 1) Route conduit and wires to limit switch box at operator. Remove existing water tight connector and add suitable conduit connectors if needed. Fig. 9. 2) Run 3 suitable wires from junction box to limit switch box. Add two extra wires for hoist interlock connections on HOIST model units.

  • Page 34: Operator Configuration

    Section 6: Operator Configuration DANGER: After power is supplied to the operator, Do not make contact with components inside the control panel except for the Keypad Keys and Programming switches. FIG. 1. DANGER: Après avoir mis l’opérateur sous tension, Ne Pas entrer en contact avec des composants à l’intérieur du panneau de commande, sauf pour les touches du pavé...
  • Page 35 Section 6: Operator Configuration 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 ensure the door is closing and opening according to the input commands. The following instructions are based on the door having been set near mid-travel at installation.

  • Page 36: Setting Limits

    Section 6: Operator Configuration Setting Limits: After the Limit Orientation has been appropriately configured, each of the limit switches must be set for proper door operation. The following instructions are based on the door having been set near mid-travel at installation. 1) Press and HOLD the OPEN key to run the door until up limit is activated.

  • Page 37: Setting Limit Overrun

    Section 6: Operator Configuration Setting Limit Overrun WARNING: The limit overrun will override external reversing devices. Therefor, any externally connected devices will be disabled during that portion of the door travel controlled by the Limit Overrun. The Down Limit Overrun function should be used to close the door no more than the final 2 inches of door travel. AVERTISSEMENT: La fonction de dépassement de limite annulera les dispositifs de renversement externes, y compris les cellules photoélectriques et des systèmes de détection ou d’inversion aux bords.
  • Page 38 Section 6: Operator Configuration Setting Open and Close Modes (Momentary vs. Constant Contact) WARNING: Before momentary contact control can be used on the CLOSE button, a monitored external reversing device sensing edge switch must be used. See page 5.8 for installation of entrapment protection devices. AVERTISSEMENT: Avant d’utiliser la commande à...
  • Page 39 Section 6: Operator Configuration Selecting a 1- Button or 3- Button Control Station The operator can support one or more 3-button (individual Open/Close/Stop) stations or 1-button sta- tions. However, it cannot support combinations of the two at the same time. The type of control station(s) used with the operator must be selected using a Configuration Option Switch.
  • Page 40 Section 6: Operator Configuration Setting Timer to Close Function Rotary Switch Position Time Delay (seconds) Rotary Switch Position Time Delay (seconds) Disabled The Timer-to-Close feature provides the ability to automatically close the door, after a fixed time delay, after the door has been moved to its OPEN limit. This time delay is user adjustable by the on-board Timer- to-Close rotary switch as follows: NOTE: Safety edge must be installed and dip switch 8 set to OFF to use this feature.

  • Page 41: Cycle Count

    Section 7: Operator Cycle Count/Status Displaying the Cycle Count The operator maintains a count of completed open/close cycles and can display this count via an LED, in increments of 1,000 cycles. Figure 9. 1. To display the cycle count, press and hold the on-board Cycle Count Key (CYC/CNT) for at least three seconds.
  • Page 42 Section 7: Operator Status/Error Codes (FIG. 10.) STATUS LED: The on-board Running and Error LEDs provide a visual indication of the general status of the operator controls. The Running LED serves as a heartbeat, and blinks once per second at all times as long as power is supplied to the operator.
  • Page 43 Section 8: Operator Service/Maintenance Maintenance Schedule The following table provides a schedule of recommended Service and Maintenance items to be completed by a trained service representative. Service Item Service Intervals Monthly 6 MO. or 5000 12 MO. or 10,000 36 MO. or 30,000 Cycles Cycles Cycles...
  • Page 44 Section 9: Operator Parts Breakdown Hoist Operator Parts Breakdown 1/2 and 1 HP ITEM PART NO. DESCRIPTION QTY. 112153-0001 PLATE, TOP, OPER, EXPF 112428-0001 COVER, LIMIT BOX, EXPF 107891-0004 LIMIT ASSY 111859-0001 SHAFT ASSY, HOIST, RHXH 111625-0001 COVER, LIMIT, RHXH 086565-1031 CHAIN, RLR, #25 X 92P, LOOP 107803-0001...
  • Page 45 Section 9: Operator Parts Breakdown Hoist Operator Parts Breakdown 3 HP ITEM PART NO. DESCRIPTION QTY. 112153-0001 PLATE, TOP, OPER, EXPF 112428-0001 COVER, LIMIT BOX, EXPF 107891-0004 LIMIT ASSY 111860-0001 SHAFT ASSY, HOIST, RHXH 111624-0001 COVER, LIMIT, RHXH, LH 112676.0109 CHAIN, RLR, #25 X 109P, LOOP 107803-0001 SPRKT, 25T, 1/4P, 1.38 HUB...

  • Page 46: Hoist Shaft Assembly

    Section 9: Operator Parts Breakdown Hoist Shaft Assembly Item Part Number ..Description QTY. 111859.0001 ..Shaft Assembly, Hoist, RHXH 1/2-1HP 111529.0001 ....SHAFT,HOIST,RHXH 110872.0001 ....HANDWHEEL,STANDARD CHAIN 110411.0001 ....CHAIN GUARD ASSY 110819.0001 ....WASHER,PLAIN .651 I.D. 111382.0003 ....RING,RTNG,HIGH GRIP, .50 DIA. 110813.0001 ....

  • Page 47: Trolley Operator

    Section 9: Operator Parts Breakdown Trolley Operator Parts Breakdown 1/2 and 1 HP PART NO. DESCRIPTION ITEM NO. 111515-0001 FRAME, RHXT 112508-0001 SHAFT ASSY, OUTPUT, EXPF, TROLLEY 111584-3059 CHAIN, #41 X 59P, NO LOOP 111583-0001 CLUTCH ASSY, RHXT 086565-1022 CHAIN, RLR, #25 X 56P, LOOP 080884-0003 LINK, CONN #41 CH 112427-0001...
  • Page 48 Section 9: Operator Parts Breakdown Trolley Output Shaft Parts Breakdown PART NO. DESCRIPTION ITEM NO. 112432-0001 SHAFT, .75 DIA, OUTPUT, EXPF 110695-0001 BEARING, .750 ID 110819-0003 WASHER, .770 ID 111382-0001 RING, RTNG, HIGH GRIP STRENGTH 110818-0004 WASHER, WAVE SPRING, .780 ID 110313-0004 PIN, SPRING, .250 DIA.
  • Page 49 Section 9: Operator Parts Breakdown Rail Parts Breakdown Item Part Number Description RAIL ASSY, TROLLEY 080105.0708 BOLT, HH, PLD, 7/16-14 X 1 080352.0714 NUT, HEX, PLD, 7/16-14 080322.0446 WSHR, LK, 7/16 X 25/32 OD 111390.0001 CHAIN GUIDE 110732.1125 TRACK, 8’ DOOR 110732.1149 TRACK, 10’...
  • Page 50 Section 9: Operator Parts Breakdown NEMA 7/9 Enclosure Assembly 10 11 Item Part Number Description QTY. QTY. Number 1 Phase 3 Phase 112845.0001 ENCLOSURE ASSY, NEMA 7/9 38563R PCB, ASSY. NEMA 7/9 112502.0001 CONTACT, FRONT MOUNT 112255.0001 CONTACTOR, REVERSING,24V 112505.0002 SOCKET, DPST 112505.0001 SOCKET, DPDT...
  • Page 51 LIMITED WARRANTY The Genie Company (“Seller”) warrants to the original purchaser of the model (“Product”), GCL-GH, NEMA 7/9 Operator subject to all of the terms and conditions hearof, that the Product and all components thereof will be free from defects in materials and workmanship under normal use for the following period(s) measured from the date of installation: -- Two (2) years.
  • Page 52 The Genie Company 1-800-275-6187 www.GenieCompany.com...

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