Chamberlain GJ User manual

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The Chamberlain Group, Inc.

A DUCHOSSOIS ENTERPRISE

845 Larch Avenue

Elmhurst, Illinois 60126

OWNER'S MANUAL

MODEL GJ

SOLID STATE

INDUSTRIAL DUTY

GEARHEAD JACKSHAFT OPERATOR

NOT FOR RESIDENTIAL USE

Serial #

(located on electrical box cover)

Installation Date

Wiring Type

41B6

LISTED

DOOR

OPERATOR

LR78500

CERTIFIED

DOOR

OPERATOR

4-3/4"

14"

8-7/8"

5-1/2"

MECHANICAL

DRIVE REDUCTION:.............40:1 Reduction

Heavy duty bronze worm

gear reducer

OUTPUT SHAFT SPEED:.....43 R.P.M.

DOOR SPEED:......................4 - 10" per sec.

depending on door

BRAKE: .................................Solenoid actuated disc

brake

HOIST WHEEL:.....................Standard mounting on

left or right side

SAFETY

DISCONNECT:.............Floor level chain hoist with elect-

rical interlock for emergency manual door operation

CLUTCH: (optional)....Adjustable torque limiter type

REVERSING EDGE:.....(Optional) Electric or pneumatic

sensing device attached to the bottom edge of door.

A REVERSING EDGE IS STRONGLY

RECOMMENDED FOR

ALL

COMMERCIAL

OPERATOR INSTALLATIONS.

REQUIRED

WHEN

THE 3 BUTTON CONTROL STATION IS OUT OF

SIGHT OF DOOR OR ANY OTHER CONTROL

(AUTOMATIC OR MANUAL) IS USED.

MOTOR

TYPE:.....................................Continuous duty

HORSEPOWER:....................1/2, 3/4 & 1 Hp

Single or Three phase

1-1/2 & 2 HP Three

phase

SPEED:..................................1725 RPM

VOLTAGE:.............................115/208-230 Single

phase

208-230 Three phase

CURRENT: ............................See motor nameplate

SPECIFICATIONS

ELECTRICAL

CONTROL VOLTAGE: ....5V dc

AUXILIARY VOLTAGE:...24V dc

CONTROL STATION: .....NEMA 1 three button station.

OPEN/CLOSE/STOP

WIRING TYPE:.................B2 (Standard)

Momentary contact to OPEN/CLOSE/STOP plus wiring

for sensing device to reverse and auxiliary devices to

open and close with open override.

(Other types available. See chart, Pg. 14)

LIMIT ADJUST:................Linear driven, fully

adjustable screw type cams. Adjustable to 30 feet.

WEIGHTS AND DIMENSIONS

HANGING WEIGHT:.........80-110 LBS.

GJ OPERATOR

CLUTCH

DIMENSION - A

DIMENSION - B

DIMENSION - C

1/2 HP

YES

28-11/16”

14-5/16”

13-1/16”

24-15/16”

10-9/16”

13-1/16”

3/4 HP

YES

28-13/16”

14-7/16”

13-1/16”

25-1/16”

10-11/16”

13-1/16”

1 HP

YES

29-1/16”

14-11/16”

13-1/16”

25-5/16”

10-15/16”

13-1/16”

1 1/2 HP

YES

29-3/16”

14-13/16”

13-9/16”

25-7/16”

11-1/16”

13-9/16”

2 HP

YES

29-13/16”

15-7/16”

13-9/16”

26-1/16”

11-11/16”

13-9/16”

CAUTION

CONNECT REVERSING EDGE

SWITCH - SEE INSTALLATION

INSTRUCTIONS

FOR INDOOR USE ONLY

INSTALL MORE THAN 8 FT. ABOVE DOOR

LOCATE CONTROL STATION SO THAT DOOR IS WITHIN

SITE OF PERSON OPERATING THE CONTROL. DOOR

MUST BE CONTROLLED BY 3 BUTTON STATION

Cotterpin

Disconnect Lever

Cutout for Rollpin

(typical both sides)

Hand

Chain Wheel

Chain Guide

2-1/4"

FIGURE 1

Shaft Support Bracket

with Bearing (Not Supplied)

Door Sprocket

TO AVOID DAMAGE TO DOOR AND OPERATOR,

MAKE ALL DOOR LOCKS INOPERATIVE. SECURE

LOCK(S) IN "OPEN" POSITION.

IF THE DOOR LOCK NEEDS TO REMAIN

FUNCTIONAL, INSTALL AN INTERLOCK SWITCH.

DO NOT CONNECT ELECTRIC POWER UNTIL

INSTRUCTED TO DO SO.

KEEP DOOR BALANCED. STICKING OR BINDING

DOORS MUST BE REPAIRED. DOORS, DOOR

SPRINGS, CABLES, PULLEYS, BRACKETS AND

THEIR HARDWARE MAY BE UNDER EXTREME

TENSION AND CAN CAUSE SERIOUS PERSONAL

INJURY. CALL A PROFESSIONAL DOOR

SERVICEMAN TO MOVE OR ADJUST DOOR

SPRINGS OR HARDWARE.

WARNING

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

SITE PREPARATIONS

It is imperative that the wall or mounting surface

provide adequate support for the operator.

This surface must:

a) Be rigid to prevent play between operator and

door shaft.

b) Provide a level base.

c) Permit the operator to be fastened securely and

with the drive shaft parallel to the door shaft.

The safety and wear of the operator will be adversely

affected if any of the above requirements are not met.

For metal buildings, fasten 2” x 2” x 3/16” (or larger)

angle iron frames to the building purlins. Retain

2-1/4” between frames. See Figure 1.

The GJ operator may be mounted on either the right (standard) or left side of door, and in either a vertical

(standard) or horizontal mounting position. Refer to the steps below if you require the hand chain and/or

disconnect chain to be on the opposite side of the operator; Or if the operator is being mounted in a horizontal

position.

MOUNTING CONVERSIONS

Hand Chain Right/Left Conversion

Remove the two snap rings (1 pc. outer, 1 pc inner)

on hand chain shaft assembly. Position roll-pin to fit

through cutout in frame and slide complete shaft

assembly through housing and bevel gear. Insert

shaft assembly on opposite side of housing, and

replace bevel gear, bearing, hardware, and snap rings

on the opposite side of shaft in the same manner.

Disconnect Lever Right/Left Conversion

Remove cotter pins on the ends of the disconnect

shaft (square shaft), move the disconnect lever arm to

the opposite side, and replace the cotter pins. Be

sure to keep two(2) 12ga. washers on the side without

the lever arm.

Horizontal Mounting Conversion

Remove cotter pins on the ends of the disconnect

shaft (square shaft), and remove lever. Replace lever

using square hole on opposite end of lever.

Reposition sash chain to opposite end of lever also.

Replace cotterpins.

IMPORTANT SAFETY NOTES

FIGURE 2

1a.

Wall Mounting

The operator should generally be installed below

the door shaft, and as close to the door as

possible. The optimum distance between the door

shaft and operator drive shaft is between 12” - 15”.

On concrete buildings, attach a shaft support

bracket to the wall of the building. Refer to Figure 3.

OPERATOR MOUNTING

IMPORTANT:

An additional wall mounting

plate (P/N 10-9098) or equivalent is

recommended to provide additional support

and to allow for adjustment of the drive chain.

IMPORTANT:

The shelf or bracket must

provide adequate support, prevent play

between operator and door shaft, and permit

operator to be fastened securely and with the

drive shaft parallel to the door shaft.

1b. Bracket or Shelf Mounting

The operator may be mounted either above or

below the door shaft. The optimum distance

between the door shaft and operator drive shaft is

between 12” - 15”. Refer to Figure 4.

1c. Place door sprocket on the door shaft. Do not

insert the key at this time.

2. Place drive sprocket on the appropriate side of

the operator. Do not insert the key at this time.

3. Wrap drive chain around door sprocket and join

roller chain ends together with master link.

4. Raise operator to approximate mounting position

and position chain over operator sprocket.

5. Raise or lower operator until the chain is taut (not

tight). Make sure the operator output shaft is

parallel to door shaft and sprockets are aligned.

When in position, secure the operator to wall or

mounting bracket.

6. Align sprockets and secure, (see Figure 5).

Mount Door Sprocket to Door.

Sprocket Supplied with Door,

(Not with Operator).

Refer to Door Owner's Manual

for Installing Door Sprocket

Installation of Operator to

Sheet Type Rolling Doors

or Rolling Doors without

Live Drive Shaft

Door

Sprocket

Mounting

Bracket

(Optional)

Drive

Sprocket

Direction of Output Shaft

Rotation for OPEN

FIGURE 4FIGURE 3

The standard GJ operator is setup for mounting on right side of the door and in vertical position. If necessary,

refer to the operator mounting conversions on page 3. Refer to the illustrations and instructions below that suits

your application.

Be sure door sprocket

is properly aligned with

drive sprocket before

securing to shaft.

FIGURE 5

SENSING EDGES

All types of sensing edges with an isolated normally

open (N.O.) output are compatible with your

operator. This includes pneumatic and electric

edges. If your door does not have a bottom sensing

edge and you wish to purchase one, contact the

supplier of your operator.

If not pre-installed by the door manufacturer, mount

the sensing edge on the door according to the

instructions provided with the edge. The sensing

edge may be electrically connected by either coiled

cord or take-up reel. Refer to the steps below

Important Notes:

a) Proceed with Limit Switch Adjustments before

making any sensing edge wiring connections to

operator as described on page 8

b) Electrician must hardwire the junction box to the

operator electrical box in accordance with local

codes.

TAKE-UP REEL: Take-up reel should be installed

12" above the top of the door.

COIL CORD: Connect operator end of coil cord to

junction box (not supplied) fastened to the wall

approximately halfway up the door opening. 5

FIGURE 5

FIGURE 7

Installation of Operator

to Sectional Door

(Metal Building)

Make-up Box

(Not Provided)

Take-up Reel

(Optional)

Coil Cord

(Optional) Pneumatic Air Switch:

Not required or supplied

when electric sensing

edge is used

Air Hose

Sensing Edge

Wire (24V)

ENTRAPMENT PROTECTION ACCESSORIES (OPTIONAL)

7. Install Hand Chain

Place hand chain around hand chain wheel. Be

sure to pass it through both openings in the chain

guide. Remove enough links so chain hangs

approximately two feet above the floor.

8. Mount Chain Keeper

Using suitable hardware mount the chain keeper

approximately 4 feet above the floor, near the free

hanging chain. Remove disconnect sash chain

from bag and place the end through the keyhole

in the the chain keeper. Remove excess links if

necessary.

EMERGENCY MANUAL HOIST OPERATION

IT IS STRONGLY RECOMMENDED THAT A

SENSING EDGE OR OTHER ENTRAPMENT

PROTECTION DEVICE BE USED IN

CONJUNCTION WITH THIS OPERATOR.

a) Pull the disconnect chain (small chain) to engage

the hoist mechanism. The disconnect chain may

be locked in position by slipping the end through

the keyhole of chain keeper mounted on the wall.

b) Operate the door in the desired direction by

pulling on one side or the other of the continuous

loop hoist chain (large chain).

In case of emergency or power failure, the operator has provision for manually operating the door. An electrical

interlock will disable the electrical controls when manual hoist is used. To operate the hoist:

c) The disconnect chain must be released from

chain keeper before door will operate again

electrically.

Mount Chain Keeper

approx. 4 feet above

floor

FIGURE 6

INSTALL CONTROL STATION

WARNING

TO PREVENT ENTRAPMENT

DO NOT START DOOR DOWNWARD

UNLESS DOORWAY IS CLEAR

OPEN

STOP

Control Station

WARNING Notice

Push

Buttons

The Chamberlain Group, Inc.

Install Control Station (Three Button Art)

MJ CDO #2 (Green)

6/20/91

WARNING

CAUTION

WARNING

CAUTION

WARNING

DISCONNECT POWER AT THE FUSE BOX BEFORE

PROCEEDING.

OPERATOR MUST BE PROPERLY GROUNDED AND

CONNECTED IN ACCORDANCE WITH LOCAL

ELECTRICAL CODES. NOTE: THE OPERATOR

SHOULD BE ON A SEPARATE FUSED LINE OF

ADEQUATE CAPACITY.

ALL ELECTRICAL CONNECTIONS MUST BE MADE

BY A QUALIFIED INDIVIDUAL.

WARNING

CAUTION

WARNING

CAUTION

WARNING

TO AVOID DAMAGE TO DOOR AND OPERATOR,

MAKE ALL DOOR LOCKS INOPERATIVE. SECURE

LOCK(S) IN "OPEN" POSITION.

IF THE DOOR LOCK NEEDS TO REMAIN

FUNCTIONAL, INSTALL AN INTERLOCK SWITCH.

WARNING

CAUTION

WARNING

CAUTION

WARNING

INSTALL THE CONTROL STATION WHERE THE

DOOR IS VISIBLE, BUT AWAY FROM THE DOOR AND

ITS HARDWARE. IF CONTROL STATION CANNOT BE

INSTALLED WHERE DOOR IS VISIBLE, OR IF ANY

DEVICE OTHER THAN THE CONTROL STATION IS

USED TO ACTIVATE THE DOOR,

A REVERSING

EDGE MUST

BE INSTALLED ON THE BOTTOM OF

THE DOOR.

FAILURE TO INSTALL A REVERSING

EDGE UNDER THESE CIRCUMSTANCES MAY

RESULT IN SERIOUS INJURY OR DEATH TO

PERSONS TRAPPED BENEATH THE DOOR.

1. Complete electrical connections to the operator

and the control station. Fasten the control station

to the wall and MOUNT THE WARNING NOTICE

BESIDE OR BELOW THE PUSH BUTTON

STATION.

2. Apply power to the operator. Press OPEN push

button and observe direction of output shaft

rotation. See Figure 4, page 4. Press the STOP

button.

If shaft does not rotate in the correct direction,

check for improper wiring at the control station or

between operator and control station.

If the operator is three phase and control station

wiring is correct, exchange any two of the three

incoming power leads.

If electrical problems persist, call our Toll Free

number for assistance (1-800-528-6563).

CABLE CONNECTION NOTE:

Be sure to use the control box opening with the

1-1/16" hole for the POWER cable. All control wires

use the 7/8" hole.

Refer to Master Wiring Diagram. Make connection

through holes labeled for power and control. Do

not run control wires in the same conduit as

power wires.

Before installing control station be sure to follow all warnings described below. Failure to so may result

in severe injury to persons and/or damage to operator. Do not install any wiring or attempt to run the

operator without consulting the wiring diagram. Install the optional Reversing Edge before proceeding

with the Control Station installation.

IMPORTANT: Mount WARNING NOTICE beside or

below the push button station.

IMPORTANT SAFETY NOTES CONTROL STATION WIRING

MOUNT WARNING NOTICE

7/8" Hole (far side)

for low voltage

CONTROL WIRES

1-1/16" Hole (near side)

for high voltage

POWER WIRES

MAKE SURE THE LIMIT NUTS ARE POSITIONED BETWEEN THE LIMIT SWITCH ACTUATORS BEFORE

PROCEEDING WITH ADJUSTMENTS.

1. To increase door travel, spin nut away from actuator. To decrease door travel, spin limit nut toward actuator.

2. Adjust open limit nut so that door will stop in open position with the bottom of the door even with top of door

opening.

3. Repeat Steps 1 and 2 for close cycle. Be sure close limit actuator is engaged as door fully seats at the floor.

If other problems persist, call our toll-free number for assistance - 1-800-528-6563.

CLOSEOPEN

Open Limit

Nut Close Limit

Nut Travel Nut

Retainer

Close Limit

Switch

Open Limit

Switch

OLS CLS

SLS

Actuator

The Chamberlain Group, Inc.

Travel Nut Retainer 

2/22/94 - 2/27/94

Press Travel Nut Retainer Down

Toward Frame TO DISENGAGE.

TO AVOID SERIOUS PERSONAL INJURY OR DEATH

FROM ELECTROCUTION, DISCONNECT ELECTRIC

POWER BEFORE MANUALLY MOVING LIMIT NUTS.

WARNING

CAUTION

WARNING

CAUTION

WARNING

ADJUST LIMITS

Remove clutch cover and adjust clutch so that it is

tight enough to open and close the door but will slip

when the door meets an obstruction. Either loosen or

tighten the clutch nut with 1/4 turn increments. After

adjustment is completed, tighten locking set screw

and re-install clutch cover. Reconnect power to

operator and test for proper operation. The clutch will

require periodic inspection and adjustment.

Motor

Clutch

Adjusting

Nut

The Chamberlain Group, Inc.

GJ CDO Adjusting Clutch

Disk #3 (Red)

9/19/91

The operator has been pre-wired to accept

connection of a reversing edge device. Connect the

normally open contacts to terminals T4 and T8 on the

low voltage terminal block. A cut-off switch will de-

activate the safety device during the last few inches

of the door's downward travel.

WARNING

CAUTION

WARNING

CAUTION

WARNING

IF CONTROL STATION CANNOT BE INSTALLED

WHERE DOOR IS VISIBLE, OR IF ANY DEVICE OTHER

THAN THE CONTROL STATION IS USED TO ACTIVATE

THE DOOR,

A REVERSING EDGE MUST

BE INSTALLED

ON THE BOTTOM OF THE DOOR.

FAILURE TO INSTALL

A REVERSING EDGE UNDER THESE CIRCUMSTANCES

MAY RESULT IN SERIOUS PERSONAL INJURY OR

DEATH TO PERSONS TRAPPED BENEATH THE DOOR.

WARNING

CAUTION

WARNING

CAUTION

WARNING

TO AVOID SERIOUS PERSONAL INJURY OR DEATH

FROM ELECTROCUTION, DISCONNECT ELECTRIC

POWER TO OPERATOR BEFORE ADJUSTING SLIP

CLUTCH.

CAUTION: The torque limiter clutch is NOT an

automatic reversing device. An electric or

pneumatic reversing edge can be added to bottom

edge of door if desired.

ADJUST CLUTCH (OPTIONAL)

CONNECT REVERSING EDGE DEVICE (OPTIONAL)

NOTICE:

This equipment has been tested and found to comply with the limits for a Class A digital

device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference when the equipment is operated in a

commercial environment. This equipment generates, uses, and can radiate radio

frequency energy and, if not installed and used in accordance with the instruction

manual, may cause harmful interference to radio communications. Operation of this

equipment in a residential area is likely to cause harmful interference, in which case the

user will be required to correct the interference at his own expense.

✳

Use SAE 30 Oil (Never use grease or silicone spray).

✳✳ Use Mobil SHC75W90 all climate synthetic oil.

✔Repeat ALL procedures.

■ Do not lubricate motor. Motor bearings are rated for continuous operation

■Do not lubricate clutch.

■Inspect and service whenever a malfunction is observed or suspected.

■CAUTION: BEFORE SERVICING, ALWAYS DISCONNECT OPERATOR FROM POWER SUPPLY.

EVERY EVERY EVERY

ITEM PROCEDURE 3 MONTHS 6 MONTHS 12 MONTHS

Drive Chain Check for excessive slack.

Check & adjust as required.

Lubricate.*

● ✔

Sprockets Check set screw tightness ● ✔

Clutch (Optional) Check & adjust as required ● ✔

Gear Reducer** Check for leaks and replace

seals as needed ● ✔

Fasteners Check & tighten as required ● ✔

Manual Disconnect Check & Operate ● ✔

Check at the intervals listed in the following chart.

OUR LARGE SERVICE ORGANIZATION

SPANS AMERICA

INSTALLATION AND SERVICE INFORMATION

ARE AVAILABLE 6 DAYS A WEEK

CALL OUR TOLL FREE NUMBER – 1-800-528-6563

HOURS 7:00 TO 3:30 p.m. (Mountain Std. Time)

MONDAY Through SATURDAY

IN CANADA

CALL OUR TOLL FREE NUMBER – 1-800-654-4736

WHEN ORDERING REPAIR PARTS

PLEASE SUPPLY THE FOLLOWING INFORMATION:

PART NUMBER DESCRIPTION MODEL NUMBER

ADDRESS ORDER TO:

THE CHAMBERLAIN GROUP, INC.

Electronic Parts & Service Dept.

2301 N. Forbes Blvd., Suite 104

Tucson, AZ 85745

MAINTENANCE SCHEDULE

HOW TO ORDER PARTS

awaiting page 10

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