PRODUCTS AND TECHNICAL SERVICES

DOOR
OPERATOR


PRODUCTS AND TECHNICAL SERVICES

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 DOOR OPERATOR MANUAL

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1
CONTENTS
1.1 PARTS OVERVIEW PAGE 3

1.2 FIXTURES PAGE 4

1.3 DIMENSIONS PAGE 4

1.4 ASSEMBLY PAGE 6

1.5 TOOTHED BELT PAGE 7

2 GENERAL INFORMATION PAGE 8

3 CONNECTIONS PAGE 9

4 START-UP PAGE 10

5 COMMANDS FROM THE CONTROL BOARD OF THE ELEVATOR

5.1 OPEN
PAGE 11
5.2 CLOSE
5.3 NUDGE
5.4 SAFETY REOPENING SYSTEM

6 KEYPAD PAGE 12

7.1 PROGRAMMING MENU PAGE 13

7.2 OPENING AND CLOSING PROFILE PAGE 14

7.3 AUXILIARIES (“TORQUES”) PAGE 15

7.4 COMMANDS PAGE 15

7.5 OPTIONS PAGE 15

7.6 TRANSFER PARAMETERS PAGE 16

7.7 LANGUAGE PAGE 16

7.8 SOFTWARE PAGE 16

7.9 GRAPHIC RECORDER PAGE 16

8 MOTOR HEAT PROTECTION IXT PAGE 16

9 DEFAULT PARAMETRS PAGE 17

10.1 LED DIAGNOSTIC PAGE 18

10.2 TROUBLESHOOTING PAGE 18

DOCUMENT HISTORY PAGE 19

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1.1 PARTS OVERVIEW

1 .1

2.1
7.1
6
7.2
5

2.1

2.2

8
3

2.2 5
9

Part Name TL Part Number Quantity

1.1 Motor bracket TL MOTORBRACKET 1
2.1 Mounting bracket TL MOUNTBRACKET1 2
2.2 Mounting add-on bracket TL MOUNTBRACKET2 2
3 Stop limit bracket TL LIMITBRACKET 2
5 Tension bracket TL TENSIONBRACKET 2
6 Return pulley bracket TL PULLEYBRACKET 1
7.1 Belt bracket TL BELTBRACKET 1
7.2 Belt clamp TL BELTCLAMP 1
8 Door arm TL DOORCONBRACKET 1
9 Stop connect bracket TL STOPBRACKET 1
5mm Toothed belt TL TOOTHEDBELT 5m
Motor ELVI 52W 210RPM (Left or right) TL ELVI52WL or TL EL152WR
KORMAS 100W 230RPM (Left or right) TL KOR100WL or TL KOR100R 1
BRUSHLESS 157W 300RPM TL BRUSHLESS157W
Control box TL CONTROLBOX 1
Keypad TL KEYPADDO 1

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1.2 FIXTURES

Part Quantity Part Quantity

M8x20 FLANGED 12 M6x16 FLANGED 8
M8x16 FLANGED 20 M6 FLANGED NUT 5
M8 FLANGED NUT 14 M6x38 1
M8 NUT 4 M6 FLAT 1
M8x100 BOLT 2 M5x15 1
M8x35 BOLT 1 M5 SPRING 1
M8 STUD CONNECTOR 2 M5 FLAT 1
M8 RUBBER BUFFERS 2
M8 REPAIR WASHER 8

1.3 DIMENSIONS

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1.4 ASSEMBLY
1. Fix Mounting brackets on the car header, making use on the Mounting add-on bracket to reinforce if
necessary.

2. Fix the Motor bracket and Return pulley bracket using the Tension brackets, one end should be fixed in
holes and the other using the slots, allowing for belt tensioning.

3. Fit and tension the Toothed belt. (See Belt tensioning)

4. Mount the Door arm and Belt Bracket & Clamp

5. If there are no permanent existing stops on car door assembly, the Stop limit bracket and Rubber stops
should be fitted to the Mounting brackets. The Stop connect bracket should then be fixed to the Door arm
in the same plane.

6. Fix the Control box on top of the car within reach of the Motor cabling.

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1.5 TOOTHED BELT
Toothed belts must be tensioned to a defined tension. This will ensure optimum force transfer and extend the
service life of the belt and pulley bearings.

At a distance of 1m (a), the deflection

should be 16mm (e) with an applied force
of 18.5N (F)

NOTE
A TOOTHED BELT WITH LOW TENSION WILL CAUSE IT TO JUMP FROM THE PULLEY
IF THE TENSION IS TOO HIGH IT WILL REDUCE THE PERFORMANCE OF THE MOTOR

The Toothed belt must also be properly aligned. Check to ensure the pulleys are parallel. The deviation must not
exceed an angle of 0.7 °

NOTE
IF THE ANGULAR DEVIATION IS EXCEEDED THE PULLEYS MAY BECOME DAMAGED AND THE TOOTHED
BELT WILL WEAR PREMATURLY.

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2 GENERAL INFORMATION
Power supply 230Vac ±10% (50-60Hz)
Dimension 270mm x 106mm x 45mm
Weight 0,7Kg
Degree of protection IP20
On board protection 8A
Output relay switching capacity 24VDC 3A
Certification EN60950
EMC Test EN12015 and EN12016

PINOUT
JP1 Connector for emergency power to 24Vdc (battery)
JP2 Connector for output signal
CLOSED 
 OPENED 
OBSTRUCTED 

JP6 Mains connection 230V (50/60 Hz)
JP8 NOT USED
JP10 Encoder connector
JP11 Motor connector
JP12 Keyboard plug
JP13 Motor plug
JP15 Connector for input (ONLY CLEAN CONTACT, without voltage)
OPEN CLOSE
NUDGE 

SW1 Dipswitch for default configuration
SW2 Push button:
-learn (press for 3 seconds)
-Run (open / close) (quick press).
PWR( led) Normal work GREEN
ErrorRed
OBS(led) ObstructionYellow

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3 CONNECTIONS

SW1 PARAMETER
DEFAULTS
3 2 1 SETTING
0 0 0 General
0 0 1 x
0 1 0 x
0 1 1 x
1 0 0 x
1 0 1 x
1 1 0 x
ELVI JP13
Rated voltage 24 VDC
Maximum speed 220 rpm
Gear ratio 1:26
Encoder resolution (Encoder integrated in GM) 3
Degree protection IP20
Rated torque 1.5 Nm (2.5 A)
Max. Payload 120KG

KORMAS JP10-11
Rated voltage 24 VDC
Maximum speed 220 rpm
Gear ratio 1:15
Encoder resolution (Encoder integrated in GM) 100
Degree protection IP20
Rated torque 5 Nm
Max. Payload 200KG

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4 START-UP
1. Leave the motor and encoder disconnected and power up the board (JP6)

2. Set the motor type to suit the motor being used. ELVI70W is standard supplied

3. Power down and Connect the motor and encoder (JP10/ JP11/JP13) then power up. The doors should go in the
closing direction. If when powering on, the doors go in the opening direction, enter the "OPTIONS" menu on the
programmer and set "Motor rotation" to "Reverse”. Then turn off the door gear and restart.

4. Check that at the power on, the doors will have to go in closing direction. If when powering on, the doors go in
the opening direction, enter the "OPTIONS" menu on the programmer and set "Motor rotation" to "Reverse”. Then
turn off the door gear and restart point 2.

3. Detection of the Point 0 and self-learning

DURING THIS PHASE, VERIFY THAT THE TRAVEL OF THE DOOR IS FREE FROM ANY OBSTACLES AND THAT THE
DETECTED POINT 0 ACTUALLY CORRESPONDS TO FULLY CLOSED DOORS. In case of operator with retractable cam,
the door can be considered as completely closed, when the retractable cam is closed.

4. SELF-LEARNING

The Self-learning function must be set-up by the installer after the REPHASING process. This is required in order to
have the drive memorize the number of encoder pulses corresponding to the door clear opening.

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Self-learning procedure must be performed with completely closed doors. During this phase, make sure that the
doors travel is free from obstruction. Otherwise, repeat the operation. Once completed the door remains open,
waiting for a command. If the learning button is pressed briefly the doors should close or open depending on their
position. This can also be done from the commands menu.

5. Setting the resolution

Resolution(pulse/cm) = 𝐸𝑛𝑐𝑜𝑑𝑒𝑟 𝑝𝑢𝑙𝑠𝑒𝑠 / Door opening (𝑐𝑚)

The encoder pulses is shown on the home screen when the doors are fully open and the door opening is the full
opening distance in cm.

6. The door open and close profiles can now be adjusted to suit.

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5 COMMANDS FROM THE CONTROL BOARD OF THE ELEVATOR
5.1 Open
The door opening can be controlled by the elevator control board through the closing of terminals (10-11) in JP15, or
through the control on the user interface or by pushbutton SW2.
The opening command is ignored in the following cases:
- Searching of Point 0;
- Self-learning phase;
- When the door closing command is active. (in order to accept the open command during the closing phase it is
necessary to first interrupt the door close command);
- Alarm on;
- Door closing with Nudge;
- Door closing command from the user interface.

5.2 Close
Door closing can be controlled by the elevator control board through the closing of terminals (10-12) in JP15 or by
the command on the user interface or through pushbutton SW2.
The closing command is ignored in the following cases:
- Searching of Point 0;
- Self-learning phase;
- When the door opening command is active.(in order to accept the door closing command during the opening phase
it is necessary to first interrupt the door open command).
- Alarm On;
- Door closing with Nudge;
- Door opening command from the programming pad (user interface);
- Safety reopening system is activated;
- Re-opening command from the photocell.

5.3 Nudge
In this mode, the drive performs a forced closing of the door with a safety torque corresponding to the parameter of
the safety reopening system (EN 81.1/2 compliance) and at very low speed. Nudge function is optional and, if
required, must be controlled from by control board of the elevator, after a certain number of closing doors failed
attempts. Normally, along with the nudge function, should be activated an audible signal that warns the passengers
in the car of the forced door closing. The function is controlled by closing terminals (10-13) in JP15 and remains
active only while the command stays on. Nudge can be enabled during the opening state and while the door is in
movement as well. If the command is interrupted before to complete the door closing, the drive performs the
opening or closing command from the elevator control board. Without this command, the door remain waiting.

5.4 Safety reopening system

An obstacle between the closing doors will cause a rise in the current. Exceeding the level of the set torque limit
causes the doors reopening following the set speed profile. (relay “OBSTR”).
OPTIONSSEC. CL TORQUEMASTER
When an obstacle is present during the door closing, the door automatically re-opens. If the close command persists,
the door will close again and if the obstacle has not been removed then the cycle repeats to infinity unless the door
completes the closing operation. The safety reopening is not active in the last 20mm of travel, so if there is an
obstacle in this part, the door stops automatically without re-open, signalling the opening limit switch.
OPTIONSSEC. CL TORQUESLAVE
The door stops activating the safety-reopening (relay "OBSTR") and waits for a command from control panel.

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6 KEYPAD
The user interface consists of 4 buttons (ESC, ENTER, and) and an alphanumeric display to 16 characters, in two
lines.

Using the buttons "" and "" you can select the commands that you want to give and confirm by pressing the
ENTER key.

Code Description Display position

O “11 OPEN” input active 1
C “12 CLOSE” input active 1
N “13 NUDGE” input active 1
ALARM Door in fault 2
IXT-PROT Ixt protection 2
ENC-INC Incoherence encoder pulses 2
ENC-KO Encoder connection interrupted 2
OVERTEMP Current protection engine (C°>90°) 2
OVER-CURR Overload current 2
ENC:xxxxx Encoder position 2
REPHASING Rephrasing to close position to zero encoder count 3
WAITING Door stopped in open/close cycle, waiting for new command 3
RUNNING Door in running 3
LEARNING Self-learning 3
DOOR OPENED “OPENED” relay activation (JP27-8-9) 3
OBSTRUCTION “OBSTRUCTION” relay activation (JP24-5-6) 3
DOOR CLOSED “CLOSED” relay activation (JP21-2-3) 3
S SD-CARD presence (S=unlocked) 4
E Error or reading (micro sd card) 4

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 NOTE
DON’T CHANGE A PARAMETER WITH THE DOOR RUNNING!
7.1 PROGRAMMING MENU

NOTE
DON’T CHANGE A PARAMETER WITH THE DOOR RUNNING!
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7.2 OPENING AND CLOSING PROFILE
The value of each parameter is a percentage of the maximum value, scaled from 0-100 in the open and 100-0 in the
close.
 The position parameters A_a, B_a, C_a, D_a, D_c, C_c, B_c, A_c, Z_c correspond to the points on the
diagram below. The values can be altered to change the speed and acceleration of the open and close cycles.
 The speed parameters v1_a, vH_a, v2_a, v_learn, v1_c, vH_c, v2_c, v_rif are a percentage of the maximum
value, this is 0.4 m/s (calculated for a pulley wheel diameter of 35 mm).
 For torque parameters (Max Torque, Limit Torque, Stat Op. Tor., Stat Cl. Tor., Sec. Cl. Tor., Sec. Op. Tor.) the
maximum value is 8A equivalent to a force of 340 N (calculated for a pulley wheel diameter of 35 mm).
For Min. and Max. values please see 9 DEFAULT PARAMETERS

OPENING PROFILE
Parameters Description Default
Point A_a Start opening acceleration ramp 008
Point B_a End opening acceleration ramp 018
Point C_a Start opening deceleration ramp 075
Point D_a End opening deceleration ramp 099
Speed V1_a Coupling cam opening speed 007
Speed VH_a Maximum opening speed 060
Speed V2_a End opening speed 004
Speed learn Learning speed 015

CLOSING PROFILE
Parameters Description Default
Point D_c Start closing acceleration ramp 099
Point C_c End closing acceleration ramp 085
Point B_c Start closing deceleration ramp 030
Point A_c End closing deceleration ramp 008
Point Z_c Additional run closing for mobile coupling cam 005
Speed V1_c Starting closing speed 005
Speed VH_c Maximum closing speed 050
Speed V2_c End closing speed 003
Speed rif Speed during the initial synchronization 015

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7.3 AUXILIARIES (“TORQUES”)
Represented by five references of current expressed in percent of the maximum value. The maximum value of the
couple's 8 A (Max Force = 340 N).

Maximum Torque default value=095)

This represents the maximum torque that the drive can supply according to the requested speed profile.
Limit Torque (default value=070)
This represents the level of current that must be exceeded in order to acquire the status of completely open or
completely closed door, so that the drive will set itself.
Stationary opening torque (default value=020)
It sets the pushing force needed to keep the door open.
Stationary closing torque (default value=005)
It sets the pushing force needed to keep the door closed. Sets the pushing force.
Security Torque in closing (“default value=070)
The security torque is used as a limit level for the safety reopening system in closing. The programmed value is
expressed as a percentage of the maximum value that is 10 A.
Security Torque in opening (default value=080)
The security torque is used as a limit level for the safety reopening system in opening. The programmed value is
expressed as a percentage of the maximum value that is 10 A.

7.4 COMMANDS
Open and Close: Door opening and closing. They have priority over the elevator control board commands.
Save: all interface data is stored in the permanent memory
Default: restore all original settings. The recalled default parameters will be saved in the permanent memory of the
microprocessor (Eeprom) only by SAVE.
Self-learning: it allows memorizing the number of encoder impulses corresponding to the door clear opening.#

7.5 OPTIONS
Safety reopening system in closing (“SEC. CL TORQUE”)
You can program the working type for the input of safety reopening system in closing:
-Slave: the board indicates the safety reopening system (relay OBSTR) to the control panel and waits for a new
command from the control panel.
-Master: the board indicates the safety reopening system (relay OBSTR) to the control panel and reopens
automatically.
Safety reopening system in opening (“SEC. OP. TORQUE”)
You can enable or disable the reopening system in opening:
ENABLED: If it encounters an obstacle stops signalling the signalling end opening (relay OPENED).
DISABLED: If it encounters an obstacle continues to force the opening until it reaches the limit switch or until the
'activation of IxT protection. 10
Command type (“COMMAND MODE”)
This parameter works on opening and closing inputs (11 and 12);
MASTER: a pulse command suffices for opening and closing door operations;
SLAVE: the board need a continuous command to complete opening and closing door operations.

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Motor rotation (“ENGINE ROTATION”)
This parameter allows you to rotate the engine spin.
Auto-racing (“AUTO RUNNING”)
The board will simulate automatically door opening and closing. The inputs are disabled.

7.6 TRANSFER PARAMETERS

You can export and import board parameters on to a micro sd card to either program more than one unit with the
same parameters, or view all parameters on as a text file on a pc in Notepad.
IMPORT FROM SD: Transfer the parameters from micro sd card to OPR500 using the keypad.
TRANSFER PAR.IMPORT FROM SD
(If present the "par.txt" file).
EXPORT TO SD: Transfer the parameters of the OPR500 to micro sd card of keypad, generating "par.txt" file.
TRANSFER PAR.EXPORT IN SD

7.7 LANGUAGE
It’s possible choose the language at parameter: SELECT LANGUAGE (Italian, English, German)

7.8 SOFTWARE
Once inside the menu, you can see the current firmware version of the board that is currently programmed.
FIRMWARE UPGRADE (OPR500):
1) Insert the "Opr500.hex" file in the Micro SD-CARD (FAT-32 formatted).
2) Insert the micro SD-CARD in the keypad (DISP801) connected to the operator;
3) Enter the Software menu;
4) Press the ENTER key twice (quickly) to enter the Boot menu;
5) Press ENTER to start the update process
6) The update procedure has been completed.

7.9 GRAPHIC RECORDER

Data from the last full open-close cycle can be exported to excel. (grf.cvs file type) Insert the keypad with a micro sd
card to export the file.

8 MOTOR HEAT PROTECTION IXT

This function is always active and protects the motor from overloads due to mechanical hardening or
obstacles hindering the normal door travel. If the current absorbed by the motor is higher than the set level
(5A) for more than 7 sec., the driver is disabled and stands by for 15 sec. , it will then close the door in low
speed mode. If closing fails and the current is higher than 5A again, the above described cycle will be repeated. After
a third failed attempt, the driver will enter the fault state. If the obstacle is removed, after one regular cycle the
counter resets itself.

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9 DEFAULT PARAMETRS
OPENING PROFILE
Parameters Description Default Min.val Max val
Point A_a Start opening acceleration ramp 003 000 (B_a) - 3
Point B_a End opening acceleration ramp 030 (A_a) + 3 (C_a) - 3
Point C_a Start opening deceleration ramp 070 (B_a) + 3 (D_a) - 3
Point D_a End opening deceleration ramp 097 (C_a) + 3 100
Speed V1_a Coupling cam opening speed 005 001 (VH_a) - 3
Speed VH_a Maximum opening speed 050 V1_a + 3 100
Speed V2_a End opening speed 005 001 (VH_a) - 3
Speed learn Learning speed 010 001 025
CLOSING PROFILE
Parameters Description Default Min.val Max val
Point D_c Start closing acceleration ramp 097 (C_c) + 3 100
Point C_c End closing acceleration ramp 070 (B_c) + 3 (D_c) - 3
Point B_c Start closing deceleration ramp 030 (A_c) + 3 (C_c) - 3
Point A_c End closing deceleration ramp 003 (Z_c) + 3 (B_c) - 3
Point Z_c Additional run closing for 000 000 (A_c)-1
mobile coupling cam
Speed V1_c Starting closing speed 005 001 (VH_a) - 3
Speed VH_c Maximum closing speed 050 V1_a + 3 100
Speed V2_c End closing speed 005 001 (VH_a) - 3
Speed rif Speed during the initial 005 001 025
synchronization
TORQUES
Parameters Description Default Max val
Limit Torque Op. Limit Torque in opening 050 95
Limit Torque Cl. Limit Torque in closing 050 95
Stat Op. Tor. Stationary opening torque 020 95
Stat Cl. Tor. Stationary closing torque 010 95
Sec. Cl. Tor. Security Torque in closing 040 95
Sec. Op. Tor. Security Torque in opening 080 95
OPTIONS
Parameters Description Default
SEC. CL. TORQUE Safety reopening system in closing Slave
SEC. OP. TORQUE Safety reopening system in opening Disabled
COMMANDS MODE Command type (Master/slave) Slave
ENGINE ROTATION Engine rotation (forward/reverse) Forward
AUTO RUNNING Auto racing Disabled
PHOTO MODE - Disabled
BATTERY CHARGER - Disabled
NOF CL. RIF-ENC - 0000
MECHANICAL
Parameters Description Default
MOTOR TYPE Motor type and size ELVI 52W
RESOLUTION Resolution = Encoder pulses/Door opening (cm) ****

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10.1 LED DIAGNOSTIC
FLASH CODES
1: ERROR EPROM
2: OVERCURRENT
3: ENGINE NOT CONNECTED
4: ENCODER ERROR
5: IXT ERROR
Normal work: PWRGreen: normal work
6: ENGINE IN OVER TEMPERATURE
Error: PWRRED: error
Flash code: 3 sec. ON + flash code

10.2 TROUBLESHOOTING
PROBLEM SOLUTION
The doors not move / Check that the box is powered by 220 Vac ± 10%
the doors are moving fast and out of control /
ENC-KO error on display / Check the connections between the board and the motor (JP
Led "PWR" (red), 3 flashes. 1-13).
The doors move slowly / Repeat the self-learning procedure (Chapter 3).
ENC-INC error on display /
Led "PWR" (red), 4 flashes.
The door not open Check if the doors are opened through the appropriate
command from keypad (MenuCOMMANDOPEN).
Make sure the first row of the display if there is a letter "O"
that indicates the activation of the opening. (JP1511 OPEN).
The door not close Check if the doors are closed through the appropriate
command from keypad (MenuCOMMANDCLOSE).
Make sure the first row of the display if there is a letter "C"
that indicates the activation of the closing
(JP1512 CLOSE).
The doors move in the opposite direction/ Enter the menu and reverse the direction of rotation changing
At power move in opening the parameter MOTOR ROTATION:
MENUOPTIONS MOTOR ROTAT.REVERSE/FORWARD
The doors slow down late and slam it in opening Repeat the self-learning procedure (Chapter 3).
Enter the menu on the item OPENING PROFILE and decrease
the parameter C_a and D_a.
Verify that the belt is not too slow.
The doors slow down late and slam it in closing Repeat the self-learning procedure (Chapter 3).
Enter the menu on the item CLOSING PROFILE and increase
the parameter B_C and A_c.
Verify that the belt is not too slow.
The doors often reveal an obstacle (OBSTR.) Check that the doors haven’t defect /locks mechanical in
closing.
Increase the “Sec. CL. Tor” parameter (Menu Torques)
Repeat the self-learning procedure (Chapter 3).
Ixt PROT error on display/ Check that the doors haven’t defect /locks mechanical in
Led "PWR" (red), 5 flashes. opening.
Increase the “Sec. OP. Tor” parameter (Menu Torques)
Repeat the self-learning procedure (Chapter 3).

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 Document History Date
First draft 12/11/2018
REV 2.0 19/03/19
REV 3.0 02/10/2019

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