Gates and Doors Inc.

Installation, Operation and Reference Manual for

JDMG and HAML Door Operator Products
ii
 About the Installation Guide

This document is provided for the use of qualified operator installers. The
installer should familiarize themselves with this guide and the GearMotorTM
Options BEFORE starting the Operator installation.

WARNINGS
1. This symbol indicates a potentially hazardous situation, which if
not avoided, may result in injury to personnel and/or damage to
equipment.

2. Do not disconnect or connect wires or connectors while power is

applied to the unit.

3. VERIFY that the AC supply voltage and the voltage selection wire
in the unit are the same BEFORE the power is connected. Failure
to do so may cause equipment failure and personal injury.

4. If the operator has both AC and battery back-up powered BOTH

power sources must be disconnected to fully power down the
equipment.

5. Under NO circumstances can any field modification be made to

the equipment. Failure to observe this may result in personal
injury, electrical shock, improper operation and damage to the
equipment and WILL VOID THE WARANTY.

iii
iv
 Contents

Wiring 1

a. Warnings 1

b. Fusing tables 2

c. AC Power Connections 3

d. Battery Backup wiring (Optional) 4

e. Operator wiring 6

f. Controller Connections 7

g. GearMotor Wiring 8

Programming 10

a. Inputs 10

b. Outputs 13

Calibration 15

a. 40-day PositionTrak ™ 15

b. Obstruction Sensing 18

c. Setting the Close delay timer (timer to close the door) 23

Gear motor options 24

Troubleshooting Guide 29

v
INSTALLATION NOTES

vi
Wiring

a. Warnings

If both AC and DC voltages are available, it is recommended that the AC

hookup and test is completed first.

To connect AC voltage an appropriately rated disconnect or acceptable equivalent

must be provided between the feeder circuit and the operator.
.
Fusing is product model dependent (JDMG and HAML)
Please refer to the appropriate fusing table for your product model. The
tables are provided below.

The GDI operator requires a single phase AC power source. In three phase
environments the GDI operator can be connected to one of the three phases.

Use any two wires from a three phase source (NOT the NEUTRAL) to
deliver a single phase into L1 L2. The third wire (the NEUTREAL) will go
to the NULL connection labeled so in the panel

 If the primary fusing option was purchased for a specific voltage then the
system will include the required fusing for the primary side (feeder circuit
side) of the multi-voltage transformer (if the voltage was specified at the
time of the order)
 GDI systems do not include primary fusing.
 GDI systems include the fusing for the secondary, Utilities and battery
back-up option if purchased

Voltage selection in the Control panel is done by moving the black wire on
the terminal block next to the transformer. The following AC line voltages are
acceptable for all GDI‟s Family of Operators:

 575 VAC, 3 Phase, 50/60 Hz

 460 VAC, 3 Phase, 50/60 Hz
 230 VAC, 3 Phase, 50/60 Hz
 208 VAC, 1 Phase, 50/60 Hz
 115 VAC, 1 Phase, 50/60 Hz

Be sure to use appropriately rated AC disconnects and fusing as required

by your local requirements

1
b. Fusing tables

MODEL - JDMG – FUSING TABLE COMMERCIAL AC VOLTAGE SELECT

AC Req'd Fuse rating Suggested From
Application Supply Fusing (Amps) (Volts) Type Model # Transformer
(factory wired)
Primary Required 115 L1 and L2 10 600 Slow Blow CCMR 10
(External Fusing) 208 L1 and L2 6 600 Slow Blow CCMR 6 RED
575 v
230 L1 and L2 6 600 Slow Blow CCMR 6
460 L1 and L2 3 600 Slow Blow CCMR 3 WHITE
Only this wire 460 v
575 L1 and L2 2 600 Slow Blow CCMR 2 needs to be moved
to select other voltages PURPLE
Secondary S1 10 600 Slow Blow CCMR 10 (115 VAC is factory wired) 230 v
Accerssories (AC) UT1 1 250 Fast Blow ABC-1-R
GREEN
Note: Model # refers to BUSSMAN for ABC series 208 v
Model # refers to LITTLEFUSE for CCMR series Ver. 3.3
115 v BLUE

Table 1 JDMG required fusing and Commercial voltage select

MODEL - HAML – FUSING TABLE COMMERCIAL AC VOLTAGE SELECT

AC Req'd Fuse rating Suggested From
Application Supply Fusing (Amps) (Volts) Type Model # Transformer
(factory wired)
Primary Required 115 L1 and L2 20 600 Slow Blow CCMR 20
(External Fusing) 208 L1 and L2 12 600 Slow Blow CCMR 12 RED
575 v
230 L1 and L2 10 600 Slow Blow CCMR 10
460 L1 and L2 5 600 Slow Blow CCMR 5 WHITE
Only this wire 460 v
575 L1 and L2 4 600 Slow Blow CCMR 4 needs to be moved
to select other voltages PURPLE
Secondary S1 20 600 Slow Blow CCMR 20 (115 VAC is factory wired) 230 v
Accerssories (AC) UT1 1 250 Fast Blow ABC-1-R
GREEN
Note: Model # refers to BUSSMAN for ABC series 208 v
Model # refers to LITTLEFUSE for CCMR series Ver: 3.2
115 v BLUE

Table 2 HAML required fusing and Commercial voltage select

Note: If the primary fusing option has been ordered then the above tables provide the
required fuse amperage rating for the desired voltages. For breaker panels the rating of
the fuses should follow the ratings indicated.

2
c. AC Power Connections

115 VAC – Three wire 1Ø 208 VAC – Three wire 1Ø

Commercial AC Source Commercial AC Source
1Ø - Load 3. L1 wire can be 4. Connect to fuses 1Ø - Load
1Ø - 2 wire + Neutral connected to as indicated. 1Ø 2 wire (no neutral)
High L1 either “High” wire
A
L1 3. Connect to fuses
1Ø 1Ø as indicated.
120v
L2
~ 120v
Neutral

High
F3
F4
~ 208v

B L2
F3
F4

Safety ground Safety ground

1. Connect to the 1. Connect to the

green-yellow green-yellow
DIN rail terminal 575 DIN rail terminal 575

460 460

230 230
2. Factory wired for
115 VAC 208 2. Instasller: 208

115
Move this wire from 115
factory setting (115)
to this position

Figure 1 115 VAC wiring Figure 2 115 VAC wiring

208 VAC – Three wire 3Ø no neutral 230 VAC – Three wire 3Ø no neutral
Commercial AC Source 4. Use two (2) of three (3) phase lines Commercial AC Source
1Ø - Load 1Ø - Load 4. Use two (2) of three (3) phase lines
3Ø 3 wire 3Ø 3 wire
ØA
L1 5. Connect to fuses ØA
L1 5. Connect to fuses
3Ø as indicated. 3Ø as indicated.
208v 208v L2 L2
~
230v 230v

208v
ØB

ØC 3rd wire
F3
F4
~ 230v
ØB

ØC 3rd wire
F3
F4

Safety ground Safety ground

1. Connect to the 1. Connect to the

green-yellow green-yellow
DIN rail terminal DIN rail terminal
575 575
2. Terminate unused 2. Terminate unused
460 460
Phase lines Phase lines
230 230

3. Installer: 208 3. Installer: 208

Move this wire from 115
Move this wire from 115
factory setting (115) factory setting (115)
to this position to this position

Figure 3 208 VAC wiring Figure 4 230 VAC wiring

460 VAC – Three wire 3Ø no neutral 575 VAC – Three wire 3Ø no neutral
Commercial AC Source Commercial AC Source
1Ø - Load 4. Use two (2) of three (3) phase lines 1Ø - Load 4. Use two (2) of three (3) phase lines
3Ø 3 wire 3Ø 3 wire
ØA
L1 5. Connect to fuses ØA
L1 5. Connect to fuses
3Ø as indicated. 3Ø as indicated.
460v 460v L2 575v 575v L2
~ 460v
ØB

ØC 3rd wire
F3
F4
~ 575v
ØB

ØC 3rd wire
F3
F4

Safety ground Safety ground

1. Connect to the
green-yellow 1. Connect to the
DIN rail terminal green-yellow
575 DIN rail terminal 575
2. Terminate unused
460 460
Phase lines 2. Terminate unused
230
230 Phase lines
3. Installer: 208
208

Move this wire from 115

115 3. Installer:
factory setting (115)
Move this wire from
to this position
factory setting (115)
to this position

Figure 5 208 VAC wiring Figure 6 230 VAC wiring

3
d. Battery Backup wiring (Optional)

There are two options for battery back-up wiring depending on the size of the
Control panel ordered (Control panel).

1. Internal to the Control panel; connect the batteries in series as shown on

the label internal to the Control panel`. That diagram is shown below.

2. Separate secondary panel; Follow the `Secondary panel` diagram below.

The batteries are connected in series and there are three connections
between the Secondary panel and the Control panel:

i. Bat + (36VDC)
ii. Bat – (36VDC)

Battery back-up capability

1. Delivers 50 to 200 cycles of operation, depending on door weight, speed

of operation and number of connected peripheral devices and ambient
temperature.
2. In an idle state battery back-up power will last approximately 24 hours,
depending on the number of peripheral devices that are connected.

Note: Battery operation affected by ambient temperature

Internal to Control panel

-
-

12 VDC
12 VDC

12 VDC 12 VDC 12 VDC

+
+

+
36 VDC
Operational
BATT Backup
-
Figure 7 Battery Wiring Diagram

If Battery Backup is used, it is recommended that the AC hookup

operation is completed first.

4
Secondary panel

Battery Backup
AC ground Panel AC ground
To Control Panel

36 VDC DIN rail (Factory Wired)

(Black) -

(Red)
+

Installer
wired
+ - + - + -
12 VDC 12 VDC 12 VDC

Use LITTLEFUSE KLDR 10 (10 AMP slow blow fuse) or equivalent

Figure 8 Battery Backup – Panel Wiring

5
 If factory setting is changed
15
A RECORD CHANGES BELOW
+ Output 1
16
INSTALLER AC Ground 1
17 WIRED 24 VAC With UT1 2
18 Output 3

43 21
3
e. Operator wiring

F @ 36 VAC
B Output 2 10 S1 4
-

1
24 VAC 1A max. UT1 5
Accessories
+ + 9 AC in L1 6

2
40-day AC in L2 7
PositionTrakTM NULL (3rd phase AC) 8
9
Battery Pack Battery Backup + B + 10

76543 21
Note:

1
- (Fused Battery) - B -
Pins 1, 3, 5, and 7 on AC Ground 14
24 VDC supply 15
C “D” connector & 1, 3, - + Output 1 16

2
Vcc and 7 on “E” connector Brake - + Output 3 17
AC Gnd. Open - + Output 2 18

6
Hu Are common Close - +
(Factory wired)

INSTALLER WIRED
Hv 24 VDC when ON

3
Hw 24 VDC total 1A max.

54 3 21
Gnd If factory setting is changed .

Shielded cable
RECORD CHANGES BELOW FUSING TABLE
D Input 1 Connect to D2 & D1
G AC Req'd Fuse rating Suggested

Ground shield to AC ground

Application Supply Fusing (Amps) (Volts) Type Model #

Sensor Wires – 5 conductor

Comm.

Figure 9 Operator Wiring

FROM MOTOR WIRE CAVITY
Open (NO) Input 2 Connect to D4 & D3
AC Gnd. Primary Required 115 L1 and L2 10 600 Slow Blow CCMR 10
(Wire to chassis) (External Fusing) 208 L1 and L2 6 600 Slow Blow CCMR 6
Comm.
230 L1 and L2 6 600 Slow Blow CCMR 6
Close (NO) 460 L1 and L2 3 600 Slow Blow CCMR 3
Input 3 Connect to D6 & D5
Comm. 575 L1 and L2 2 600 Slow Blow CCMR 2
Stop (NC) H . Secondary S1 10 600 Slow Blow CCMR 10
Comm. Accerssories (AC) UT1 1 250 Fast Blow ABC-1-R
Not used

Input 4 Connect to D8 & D7

Green Note: Model # refers to BUSSMAN for ABC series

8765 4321
Chain Hoist (NC)
1 Model # refers to LITTLEFUSE for CCMR series Ver. 3.3

E White (U1) COMMERCIAL AC VOLT SELECT From

Transformer
2

Comm. Input 5 Connect to E2 & E1 (factory wired)

Safety (NC) RED
Red (V1) 575 v
Comm. Only this wire
3

Input 6 Connect to E4 & E3

INSTALLER WIRED – DRY CONTACT

Open/Close (NO) needs to be moved WHITE
to select other voltages 460 v
(115 VAC is factory wired)
(AWG 12, Stranded)

UL235 (Option) Black (W1) PURPLE

MOTOR WIRE CAVITY

230 v
4
INSTALLER WIRED FROM

Comm. GREEN
208 v

8765 4321
Door Lock (NC)
115 v BLUE
Wiring10_Ver. 2.41
f. Controller Connections
(GMC-9334, independent of options)

A If factory setting is changed

RECORD CHANGES BELOW
15 +
To DIN rail

43 21
Output 1
16
17
18 Output 3

F
B Output 2
- 10

1
76543 21

To DIN rail
+ 9

2
40-day
PositionTrakTM
Battery Pack
- Note:

1
Pins 1, 3, 5, and 7 on
FROM MOTOR WIRE CAVITY

C
Ground shield to AC ground
Sensor Wires – 5 conductor

@ 36 VAC
“D” connector & 1, 3,

2
Vcc and 7 on “E” connector
54 3 21

AC Gnd.
Shielded cable

Hu Are common (Factory wired)

Hv

3
INSTALLER WIRED – DRY CONTACT

Hw
Gnd If factory setting is changed .
D
RECORD CHANGES BELOW
Input 1 Connect to D2 & D1
G
8765 4321

Comm.
Open (NO) Input 2 Connect to D4 & D3
AC Gnd.
Comm. (Wire to chassis)
Not used

Close (NO)
Input 3 Connect to D6 & D5
Comm.
Stop (NC) H .
INSTALLER WIRED FROM
Comm.
Input 4 Connect to D8 & D7
Green
MOTOR WIRE CAVITY
Chain Hoist (NC)
1

E White (U1) (AWG 12, Stranded)

2

Comm.
8765 4321

Input 5 Connect to E2 & E1

Safety (NC)
Comm.
Red (V1)
3

Input 6 Connect to E4 & E3

Open/Close (NO)

UL235 (Option) Black (W1)

4

Comm.
Door Lock (NC)

Figure 10 Controller Layout

7
g. GearMotor Wiring

(GM-9441, independent of options)

Earlier models
DO NOT REMOVE

Brk.
DO NOT WIRE HERE

Wire entry
port
(White)

(Black)

(Green)
(Red)

U1 V1 W1 Ground

To Controller To DIN rail „Installer side‟

connector

C
C1 Vcc
C2 Gnd
HU
C3 HV
C4 HW Control wires
C5 connection detail
THA to controller
{ THB
Not Used
Motor Control Wires, from the motor to the “C” connector on the controller

Figure 10 GearMotor Wiring

8
 The signal “C” connector wiring from the motor to the controller is NOT a “one to
one connection” (GND is “C5” at the controller)

If motor to panel wire length is greater than 10 feet, it is recommended that the
Motor sensor wiring and Motor Power wiring be separated after a short run into
separate conduits.

Motor Power Wires, from the motor to the “DIN rail connectors”

Incorrect wiring of the motor phase wires will result in improper operation of the
operator.

Direction change is done by adjusting the direction parameter, NOT by the motor
power wires.

9
Programming

a. Inputs

GDI systems are shipped with a pre-defined set of input configurations (See
above controller wiring diagram)

Input 8 is reserved for door lock, and may only be turned on or off.

Door lock is a unique security feature; if active it will allow the door to close
but not re-open (it is controlled through a normally closed switch)

For instruction on setup and wiring see the “Input Wiring.”

The safety from any Hoist device requires an input programed for Action 8
(stop) and to have the safety wired to that input (D7,D8)

GDI operators are compatible with isolated devices, meaning dry contacts
or relays (all powered devices require 4 wires to be isolated (2 for power,
and 2 for contacts))

Input wiring

Do not run wires for activation devices in the same conduit as the AC
power or the phase wires

If the door operator is to be controlled from the panel mounted buttons, the
panel should be within view of the door for the person operating the
buttons.

10
 INPUT ACTIVATION DEFINITION CIRCUIT CONNECTIONS
1 Activation 2 Open Door Normally D1,D2
open
2 Activation 5 Close Door Normally D3, D4
open
3 Activation 8 Stop Door Normally D5,D6
closed
4 Activation 8 Chain Hoist Normally D7,D8
Cutout switch closed
5 Activation 1 Safety Normally E1,E2
closed
6 Activation 6 Open/Close Normally E3,E4
closed
7 In UL 325 systems the E5,E6
monitored input connects
here, & input remains un-
programmed)
8 RESERVED FOR DOOR When activated will Normally E7,E8
LOCK allow door to close closed
but not open until
circuit is closed

Table 3 Input setup

Inputs can be changed/customized (and any of the existing ones may be changed, with
the exception of UL 325 (Input 7) and Input 8 (See tab;e 3 above)

ACTIVATION DEFINITION CIRCUIT

Act 1 Safety N/C
Act 2 Open door NO safety Brake N/O
Act 3 Safety (Not recommended) N/O
Act 4 Open door (similar to Act2 use Act2) N/O
Act 5 Close Door N/O
Act 6 Open door when closed, Close door when open N/O
Act 7 Partial Open N/O
Act 8 Stop N/C

Table 4 Input Activation types

11
Changing an input

To change an input, using the UP or DOWN button on the controller, scroll until the
display reads “ENT PSWD” (enter password)

 Press the ENTER button

 Enter the password below
(If a mistake is made, continue pressing buttons and begin again, as
an incorrect password will return the user to the “home screen.”)

(PASSWORD: ESCAPE, ENTER, UP, UP, UP, DOWN, UP, DOWN)

 The LCD will now display “Input setup”

 Press ENTER
 Using either the UP or DOWN button select the desired input to change
 Press ENTER
 Using either the UP or DOWN button select the desired activation
 Press ENTER

This process is to be repeated until all changes for all desired inputs are made.
To leave this menu, press the DOWN button until the LCD reads: “Exit” and press the
ENTER button. Use the UP or DOWN button to scroll until the LCD reads “ENT
PSWD.”

Press the ESCAPE button to return to the home screen.

Controller - Output wiring and definition

Controllers have a 24VDC output rated to 1.0 Amp. Voltage may be measured
between “A1” and “G3,” if the measured voltage is less than 22 VDC unplug the
“A” connector and re-measure voltage.

If voltage is still low contact your supplier fpr technical support, if the voltage is
now correct than there may be a short or too much load on the output voltage.
Find the issue by disconnecting all devices being be fed by the output voltage
and reconnect one at a time to find the offending device

12
b. Outputs

Outputs A1, A2, A3 are factory programed. Please see the controller wiring
diagrams (Figure 9 Operator wiring, and Figure 10 Controller Layout).

Output selections

Output 1 - Brake:

o Provides a 12/24 VDC output only during movement

Outpur 2 - Door open:

o Provides a constant 12/24 VDC output at the full open position of the
system

Output 3 – Door close

o Provides a constant 12/24 VDC output at the full close position of the
system

Output programming available:

Close warn:

Provides a 12/24 VDC output when the Close warn timer expires until the
Close delay timer expires

The Close warn timer is set using the Close warn parameter in the OEM
setup menu

“Gates and Doors” is displayed on the LCD (start position)

o Press the DOWN button 6 times until „Ent pswd‟ is displayed on the LCD
o Press ENTER once (to be able to enter the password)

Press the following keys:

Escape, Enter, Up, Up, Up, Down, Up, Down

o The LCD now displays „Input setup‟

o Press the Down button twice

13
 The LCD now displays „Close warn‟
o Press the Enter key to change the value
Use the Up or Down buttons to increase or decrease the
timer value ( A value of zero disables the timer)
o Press the Enter button store the desired value
The system should now be powered down in order for the
changes to take affect

Note: The Close warn parameter works with Close delay

The timer value for Close warn should be less than that of close
delay such that it acts as a warning prior to the automatically
triggered closing of the system

Instructions

„Gates and Doors‟ is displayed on the LCD (start position)

o Press the Down key 6 times until „Ent pswd‟ is displayed on the LCD
o Press the Enter key once (to be able to enter the password)
Press the following keys:
Escape, Enter, Up, Up, Up, Down, Up, Down
o The LCD now displays „Input setup‟
o Press the Down key once
LCD now displays „Output setup‟
o Press the Enter key once
The LCD now displays „Out1, output selection‟

Use the Up and Down keys to scroll through the Outputs

To change an output selection on output 1, 2 and 3

o Press the Enter key on the displayed output

o Use the Up and Down buttons to scroll through to the output selection desired
o Press the Enter key again to select the new output selection.

This process is to be repeated until all changes for all desired outputs are made.

To leave this menu;

o Press the DOWN button until the LCD reads: “Exit”

o Press the ENTER button.
o Use the UP or DOWN button to scroll until the LCD reads “ENT PSWD.”
o Press the ESCAPE button to return to the home screen.

14
Calibration

a. 40-day PositionTrak ™

Plug the 40-day PositionTrak ™ into the “B” connector on the Contoller (see Fig 10
Controller Layout)

40-day PositionTrak ™ Function

To track the movement of the motor (operator) when AC and/or Battery power (DC)
is lost. When the operator has power returned, no re-calibration or setting of “close
reference” is required to continue using the operator.

Setup (use):

Before bringing power to the operator, plug in the “B” connector with the battery
pack connected, and batteries mounted inside the battery pack. For the 40-day
PositionTrak ™ to work, calibration of the operator must be done with the battery
pack connected.

The battery pack must stay connected to power the 40-day PositionTrak ™ during
loss of AC and/or Battery power (DC).

Test:

1. Remove power from the operator and wait 20 seconds

Note: Always leave the 40-day PositionTrak ™ battery pack connected

2. Return power to the operator

3. Once the Controller LCD comes on, activate the operator to either OPEN or
CLOSE

Note: The operator will move towards the selected position without re-calibration or
re-referencing.

Note:
The battery life of the 40-day PositionTrak ™ is estimated at 40 days; once the
power (the tracker‟s batteries are fully drained after AC/DC power has not been
present on the operator for 40 days) is lost the operator will require either re-
calibration or re-referencing the close position for continued operation.

15
 The 40-day PositionTrak ™ batteries are charged automatically once AC/DC is
returned to the operator.

Calibration process for Vertical Doors:

w
Before applying power to the operator please connect the battery-pack which
i is wired directly to the “B” connector
r
e
1. From
d the main screen press the DOWN button until the LCD displays “Calibrate
Now”
2. Press the ENTER button once.
The LCD displays “Jog Door Open, press Enter to complete”
3. Hold the UP button for 5 seconds
a. If the door moves toward the open position continue to hold the UP button
the full open position is achieved.
Once the fully open press the ENTER button, and continue to the
next point
b. If the door moves toward the close position continue to press the ENTER
button until the LCD displays “Calibration Error.”
i. Now change direction (see direction change)
ii. Repeat the calibration process from the beginning
4. The LCD displays “Jog Door Closed, press Enter to complete”
5. Press and hold the DOWN button until the door is at the fully closed position.
6. Press the ENTER button.
The LCD will display “Door sized stored, cycle to complete”
7. The operator now requires an uninterrupted full open, followed by an
uninterrupted full close cycle.
Once complete the LCD will display “Calibration Done”

Direction of Door Movement

Note:

The installer must ensure that when a door operates its direction is
consistent with what the controller displays on the LCD.

A quick check to determine whether direction is set correctly can be down as follows:

1. Using the UP or DOWN buttons scroll until the LCD displays “Calibrate Now”
2. Press the ENTER button
3. Press and hold the UP button
a. The system should move toward the open direction

16
 b. If the system is moving towards the close direction the installer must
change direction
c. Whether the direction is correct or not the installer should power down the
system. Let the LCD go blank and then power it back on.
If the direction was correct continue with calibration, if it was not, direction
must be change

Manage Open Direction

1. Press the UP or DOWN button until display reads “Ent Pswd”

2. Press ENTER
Press the following sequence

ENTER, DOWN, DOWN, ENTER, ESCAPE, ESCAPE, ESCAPE, ESCAPE

3. Press the UP or DOWN button until the display reads “Dir flip”
4. Press ENTER
5. Press the UP button to change value from 0 to 1 or the DOWN button to change
value from 1 to 0
6. Press ENTER to save this value
7. Power Down the system and begin the Calibration Process

If the operator you are working with is NOT UL 325 COMPLIANT then the next
step will be to setup internal obstruction sensing properly.

If the operator you are working with is NOT UL 325 COMPLIANT then the next
step will be to setup internal obstruction sensing properly.

Any changes to the physical operation of the door or to the Close Profile
parameter will require a re-calibration

To re-calibrate the operator:

1. 1st power down the system

2. Wait for 15 to 20 seconds
3. Return power to the system and repeat the calibration process from the
beginning

17
b. Obstruction Sensing

Description

There are two types of obstruction sensing:

1. Force sensitive obstruction sensing which is used during the door close cycle
only, and
2. Speed based obstruction sensing which is operative during both the open
and close door cycles.

Force based obstruction sensing:

NOT applicable in UL325, Rolling Steel and Fabric doors

During the close cycle, if the door meets an obstruction that causes the closing
force to increase beyond the pre-set threshold, the door reverses.

The door will respond to all new obstructions on a closing cycle following an
obstruction. The forced based obstruction threshold is adjustable by the user.

Speed based obstruction sensing

Speed based obstruction sensing operates during both opening and closing
door cycles. If the door is activated to open and does not move for a fraction of
a second, the door stops and an “Open Collision” will have occurred and will be
displayed on the LCD.

This acts as

If a slide lock (door to rail) on a vertical door is in the locked position. If an

OPEN activation is made, the door tries to open but the speed based
obstruction sensing will stop the door and can prevent damage to the door and
the lock and the door frame.

This powerful protection uses factory pre-set timers and does not require any
adjustment.

18
Change Obstruction Sensitivity

Which parameter should be adjusted for obstruction sensing threshold if reversal

occurs for no apparent reason?

If obstructions are happening during the closing cycle, causing the door to reverse
and move back to the open position, without apparent reasons, it is likely that the
obstruction threshold parameters are set too low.

Before adjusting the obstruction sensing threshold it is recommended,

especially if the obstructions seem to be occurring in one specific door
position, to check to see if there is a mechanical problem with the hardware,
railing or other possible source of binding.

Adjusting Obstruction Sensitivity

a. When too much force is required to stop the door before reversal when the
door is closing.

„COMPANY NAME‟ is displayed on the LCD (start position)

1. Press the “Down” button (6 times) until „Ent pswd‟ is displayed on the LCD
2. Press Enter
3.
Press the following buttons;
„Enter, Down, Down, Enter, Escape, Escape, Escape, Escape‟

4. Press the “Down” button once.

„Close over curr%‟ should be displayed on the LCD
The current value of the parameter is on the second line of the display.
5. Press Enter
6. Press and hold the “Down” button until the desired value is reached
7. Press Enter to save the new value.
8. Press the “Down” button once
„Close decel I%‟ should be displayed on the LCD
The current value of the parameter is on the second line of the display.
This parameter can be lowered from its current setting
9. Press Enter
10. Press and hold the “Down” button until the value reaches the desired value.
11. Press Enter to save the new value.

Initially lowering the parameter by 20 to 30 units at a time is recommended

to get a feel for the effect of the change

19
 It is imperative that these TWO parameters
(„Close over curr%‟ and „Close decel I%‟) be changed to the SAME
VALUES.

The obstruction sensing parameter values have been lowered to

reduce the amount of force required to respond to an obstruction.

b. Adjust Obstruction Sensing when too little force is required to stop the
door before reversal when the door is closing.

„COMPANY NAME‟ is displayed on the LCD (start position)

1. Press the „Down‟ button (6 times) until „Ent pswd‟ is displayed on the LCD
2. Press Enter once (to be able to enter the password)
3.
Press the following buttons;
„Enter, Down, Down, Enter, Escape, Escape, Escape, Escape‟

4. Press the “Down” button once.

„Close over curr%‟ should be is displayed on the LCD
The current value of the parameter is on the second line of the display.
This parameter can be increased from its current setting
5. Press Enter
6. Press and hold the “UP” button until the desired value is reached
7. Press Enter to save the new value.
8. Press the “Down” button once
„Close decel I%‟ should be displayed on the LCD
The current value of the parameter is on the second line of the display.
This parameter can be increased from its current setting.
9. Press Enter
10. Press and hold the “UP” button until value reaches the desired value is
reached.
11. Press „Enter‟ to save the new value.

Initially increasing the parameter by 20 to 30 units at a time is

recommended to get a feel for the effect of the change

It is imperative that these TWO parameters

(„Close over curr%‟ and „Close decel I%‟) be changed together and have
the SAME VALUES.

The obstruction sensing parameter values have been increased to

increase the amount of force required to simulate an obstruction.

20
FAQ on Obstruction Sensing

1. How does force based obstruction work?

Every door installation has some difference in the force required to move it along the
tracks. For this reason, during the door calibration cycle, the door operator measures
and records the forces needed to close the door at different portions of the door
closing cycle.

The obstruction sensing threshold uses these measured values and adds the set
threshold level parameter value to give the obstruction force sensing level.

Note: There are two calibration cycles.

st
The 1 sets the door size.
nd
The 2 measures the force required to close the door (at different portions of
the close cycle).

This cycle must not be interrupted by any obstruction or an in-

advertent door opening, such as from a peripheral (infrared,
motion, etc.) sensor.

If this cycle is interrupted before completion, then the calibration

process must be repeated.

2. When is force based obstruction sensing not useable on the closing cycle?

Doors that compress when encountering an obstruction (such as certain type of

rolling steel doors and light fabric or vinyl roll up doors) are not usually suitable for
use with the internal force based obstruction sensing on the closing cycle.

On these types of doors, an alternate means for close obstruction sensing may be
required (e.g. pressure sensitive edge, infrared, microwave, optical, etc.).

3. When should the obstruction sensing threshold be adjusted for the door close
cycle?

a. Too much force or too little force is required to stop the door before a reversal
occurs.
b. Obstruction based reversals occur for no apparent reason.

4. Which parameters control the obstruction threshold?

If too much force or too little force is required when obstruction reversal occurs, then the
following parameters require adjusting.

21
„Close over curr%‟
„Close decel I%‟

Note: Initially changing the parameter by 20 to 30 units at a time is

recommended to get a feel for the effect of the change.

These TWO parameters („Close over curr%‟ and „Close decel I%‟)
should be changed and set to the SAME VALUE.

The obstruction sensing parameter values are lowered to reduce the

amount of force required to respond to an obstruction and increased
to increase the force required to respond to an obstruction.

Any changes to the speeds in the close profile require re-calibration

of the operator for obstruction sensing to function properly.

22
c. Setting the Close delay timer (timer to close the door)

By factory default the close delay timer is disabled (value of zero). The timer is set in
seconds, from 0 to 240. To set the timer:

Scroll using the UP or DOWN buttons until the LCD displays “ENT PSWD”
Press the ENTER button

Now enter the password: ENTER, DOWN, DOWN, ENTER, ESCAPE, ESCAPE,
ESCAPE, ESCAPE

The LCD will now display “Cl delay” (close delay) with a value of “0”

Press the ENTER button to adjust the timer

Use the UP and DOWN buttons to set the desired value

Press ENTER to store the change

NOTE the timer to close should be the last item set, as once the timer is active
NO changes may be made to the operator unless it is in the fully closed position
(timer not active). If at the full open, powering off the operator and powering back
on will temporarily disable the timer (until an activation occurs).

23
Gear motor options
Chain hoist and Brake

Installation of the GDI Brake on to the GDI GearMotor

Coupling:
Disengage label is on the Brake plate
side of the brake plate

Engage label is on the

side of the brake plate Brake
- Using the red handle on the brake move to the “disengage” mode (see picture
above).
o This allows the brake coupling shaft to move freely

Wire Cavity Brake Module

Motor Control Motor Phase Brake wires Brake to motor

wires wires link

24
 - Slide the brake coupling shaft onto the shaft at the back of the motor
o The shaft at the back of the motor is in the wiring cavity of the motor (see
picture above)
o The dowel pin in the brake coupling shaft should be in line with the flat
portion of the motor shaft

- Feed the 2 orange wires from the brake through the wire feed through hole in
motor‟s wiring cavity.

o WARNING: When wires are longer than 20‟, the motor phase and signal
wires will need to be run in separate conduits
 The brake wires should run in the same conduit as the phase wiring
if possible

- Screw down the 4 screws provide with brake

o Screw the aluminum on which the brake is mounted down loosely first (do
the opposing diagonals in pairs)

Disengage label is on the Brake plate

side of the brake plate
Attach brake
Remove
plate to the
mounting
motor back
screws (4) for
using screws
servicing
provided

Engage label is on the

side of the brake plate Brake

Wiring Connection:

- Wire the 2 orange wires to „Brake output‟ on the DIN rail

Note: „Output 1‟ (Brake output) has an upper and lower position, it does not
matter which wire goes in the lower or upper position

25
 o When the controller is powered ON, the controller needs to be programed
to enable the brake function on „Output 1‟ (24VDC to dis-engage the brake
during door movement)

Activate the brake:

- Using the red handle on the brake, move the handle to the “Engage”
position. This will now mechanically lock the brake until the controller provides
24VDC to it to disengage the brake during door movement.

Mounting BCR to Gearmotor

BCR Assembly

Connecting Brake to Controller & Setting the Output

NOTE: Mechanically the brake has two modes of operation that are selected by
the red handle of the brake:

1) Mechanically “disengaged,” here the brake provides NO engagement or safety.

This mode is required to operate the hoist.

26
 2) Mechanically “engaged,” here the brake is mechanically locked and requires the
output signal from the controller to release it during operation. The brake is a
safety brake, in that on power loss in will lock the motor.

Wiring Connection of Brake:

- Wire the 2 orange wires to „Brake output‟ on the DIN rail

Note: „Output 1‟ (Brake output) has an upper and lower position, it does not
matter which wire goes in the lower or upper position
o When the controller is powered ON, the controller needs to be programed
to enable the brake function on „Output 1‟ (24VDC to dis-engage the brake
during door movement)

Connecting the hoist cut-out switch (safety) to Controller & Setting the Input

NOTE: Mechanically the hoist has two modes of operation that are selected by
the pull rods:

1) Mechanically “disengaged,” here the hoist is not coupled to the motor and the
cut-out switch provides a normally closed circuit allowing for normal operation of
the system.
2) Mechanically “engaged,” here the hoist is coupled to the motor and turning the
hoist pocket wheel will move the motor (this is provided that brake is
disengaged). The cut-out switch is now normally open, and if power is returned
to the operator the display will read “emergency stop.”

Wiring connection of Cut out switch

Connect 2 white wires to the Chain hoist cut out inputs, see the controller wiring
diagram.

Note: The controller is expecting a normally closed switch, if the hoist is engaged
(switch is open) the controller will display “emergency stop.”

27
Mounting CR to Gearmotor

Please see the BCR mounting instructions. (CR excludes the brake)

Please see wiring instructions for BCR. (CR excludes the brake)

28
Troubleshooting Guide
Input Status

Definition

Input status is accessible from the main menu without a password. For each input, it
displays the programmed activation (no activation displays “Not used” for the activation
number)

However the input can still be tested) and indicates the status of the input.

The status of the input is either open or closed, and indicates whether there is a short
(closed) between the two contacts of that input or whether it is open; meaning no
connection present between the two contacts of that input.

The display for each input is updated in real time, such that an action to close or open
the contact will be displayed immediately.

Note: The change of state of some activations may result in an action such as opening
or closing a door system. If this is the case the input status screen will change to the
appropriate screen message corresponding to the action triggered.

Use
- Press the “Up” or “Down” button until the display reads “Input Status”
- Press Enter
Display should read “In1, the activation number, input status”
- Press the “Up” or “Down” button to display additional inputs

To exit, press the “Up” or “Down” button until “Exit” is displayed

- Press Enter

29
Activation number What it does Expected rest state Notes
of the circuit
Act1 Safety (prevents and Normally Closed
interrupts closing)
Act2 Open (opens door) Normally Open
Act3 Safety (prevents and Normally Open
interrupts closing)
Act4 X X Similar to Act2
Act5 Close (closes the Normally Open
door)
Act6 Opens the door (when Normally Open
closed), Closes the
door (when open)
Act7 Partial Open Normally Open
Act8 Stop Normally closed Screen will display
“emergency stop
when activated”

Note: If the close delay timer is active, the input status tool may not be used.
f In order to determine if a peripheral is interfering with operation an installer
e may use a voltage meter.
e
d To determine if a circuit from a peripheral is either Open or Closed a voltage
- may be measure on the corresponding input. A measurement of 0 VDC
t indicates a closed circuit, and a measurement of 11 to 12VDC indicates an
h open circuit. Record these values prior to turning off power so that they may
r be checked against the chart above to determine possible issues.
o
u
g
h
Sensor Status

h
Sensor status is accessible from the main menu without a password.
o
Thel sensor status value is used to indicate the correctness of the positional information
e received from the motor by the controller. Information transferred with a high rate
being
of error will result in improper operation.

Information is passed through the “C” connector.

Sensor status values are used to identify loss or corruption of this information.
Loss of information can occur from:
a) a broken wire on the “C” connector
b) damage to a motor sensor (done at time of installation), by connecting a
voltage to one of the sensors

30
 c) A loose connection
Corruption of information can occur from:
a) Incorrectly wiring C2, C3, and C4 (mixing up the connections)
b) Running the motor power wires and sensors wires in the same conduit for
more than 20‟ without grounding the shield of the sensor wires.
Note: A separate conduit is best for long distances, if that is not possible,
then grounding the shield of the sensor wires at one end can
reduce the interference from the motor wires

To check sensor status:

 In the main screen press the UP or DOWN button until the LCD reads “sensor
status,”
Note: Record the value (the value is reset after power loss)
 Open or close the door
 Using the UP or DOWN buttons, exit the screen for sensor status and then go to
“sensor status to refresh the value (leaving the screen and then returning
updates the value).
Record the value.
Note: Any value higher than 3 indicates sensor errors.
 If you are unable to operate the door, unplug the “H” connector to remove any
possible braking from the motor and force movement in the motor by pulling up
or down on the door itself. Movement of around 1ft. to 2 ft. should be sufficient to
show if there are sensor errors.

Common Display (LCD) error messages

Open obstruction:

This is a velocity check, if the system can-not move a pre-defined distance is in a

pre-defined amount of time during the open cycle or during opening movement
the motor stops moving

Fix:
 Each operator has a specific range of power and similar operators may
be able to be used in many different applications, however it is important
to review the sprocket guide and door speed/weight.
 Check for mechanical binding, the “calibrate now” command from the
main screen is a great tool to assist in this action as that power level was
used to set up the door initially (if this is not a new installation) and the
door should be able to travel freely through the track using this option.
 Wiring can also be a source of issue, as a connection error for the phase
wiring (to the “H” connector) will prevent movement, so will a bad

31
 connection or connection error to the “C” connector (see sensor status
document for additional information)

Core flip error:

Sudden changes in direction or movement (when using manual calibrate) can

result in this error

Fix:
 Power down the system for 20 seconds after the screen goes blank and
power back on

Calibration error:

This is an error due to incorrect calibration and/or creating a door size that is
smaller than the minimum door size accepted by the operator

Fix:
 Power down the system for 20 seconds. After the screen goes blank
power back on and re-attempt calibration. If the error persists check
sensor status.

Zero Fault error:

If auto calibration is being used, and the operator is allowed to continue

movement in either the open or close direction beyond the maximum size that
the operator allows this error will appear.

Fix:
 Check sprockets/belt/chain and confirm that movement in the motor
results in movement in the door such that the door will contact an end
stop (or a leaf of a door as with bi-parting doors) and be is able to apply
force to the end stop without moving it (such that the door will stop),
without slipping of the motor or door shaft within the sprocket.

Emergency stop:

This is the result of pressing the stop button

Fix:
 If multiple stop buttons are being wired to one input ensure that they are
wired in series (not parallel) as the connection is normally closed
 Check wiring on the stop button, as it is expecting a normally closed
contact (see the input status section for further information)

32
 C3 (is displayed momentarily during the close cycle, followed by the door
reversing to a full open)

This is a result of the internal obstruction sensing. The obstruction sensing

values are likely too low.

Fix:
 See the Obstruction Sensing section of the Manual

Parameter adjustments for field related issues

Door is closing and reversing for no apparent reason.

Fix:

 Eliminate any peripheral devices that may be causing the reversal

Input status can be used
 Eliminate any binding or mechanical issues with the door

1. If obstruction sensing is active (please refer to “Obstruction

sensing” in this document. if this feature is appropriate for this
application)
Please refer to the Obstruction sensing document for how to make
adjustments
2. Also note that as part of seasonal maintenance the system should
be re-calibrated to take into account any changes that may have
occurred to the mechanical system of the door due to wear or
extreme temperature changes

Door is closing, but not fully and not reversing. When it opens it opens to the
correct position.

Fix:

 The close crawl region is a “grey area” where the door may stop if an
obstruction of any type prevents further movement towards the full close
position

If there is no physical obstruction or binding preventing a full close, then

increase the speed of the close crawl region to a maximum value of 60,
and increase the close crawl torque to a higher value. This will provide
more power in that region

33
 The door is opening, but not close and I am using a single button (activation 6) to
perform this operation

Fix:

Reduce the Open Crawl Gap to a value or 11 or 12

When testing a door for any binding or during seasonal maintenance, the use of
the “calibrate now” function to run the door through the full length of track
provides a great check for any mechanical changes in the door.

Notes:

 New installations

Lack of motor movement is usually due to wiring errors

1. Check motor power connections by un-plugging the “H”

connector and measuring resistance off of the screws on
the “H” plug (using a meter) between H2 and H3, H2 and
H4, H3 and H4 (all values should be around 0.3 ohms

2. Next eliminate sensor wiring as a source of issue by

following the test outlined in the sensor status section of
the debugging section

 Pre-existing installations:

1. An operator stuck in the full open position

- This is likely due to (external) peripheral interference

or loss of power
2. An operator stuck in the full close position

This is likely due to:

- Power loss
- Malfunction open activation
- Door balance issue

34
3. An operator stuck in the mid position

This is likely due to:

- A hardware jam (binding)
- Loss of power
- Door balance issue

35
36
 GDI
Gates and Doors Inc.

GDI reserves the right to modify the contents without prior notification
© GDI Markham, Ontario 2012, 2013, 2014

Ver. 4.16b 2