MFZ Ovitor TVR(FC) 5 Manual

OPERATING AND MAINTENANCE INSTRUCTIONS
DOOR OPERATOR TVR(FC) 5
OVITOR OY
SIENITIE 24
FIN‐00760 HELSINKI
FINLAND
Tel. [phone]
Fax. [phone]
ENG

2 ‐Door operator TVR(FC) 5 / Rev 1.41
1. CONTENT
2. KEY TO SYMBOLS
3. GENERAL INFORMATION
These operang instrucons are part of the door operator
delivery. Always store these instrucons in the vicinity of
the door operator, e.g. with other technical documents of
the door.
Anyone involved in installing, maintaining or repairing the
door operator must be familiar with this manual and ob‐
serve its regulaons and instrucons. The manufacturer will
not take responsibility for damage and operaonal errors
that occur if the regulaons and instrucons contained or
menoned in this manual are neglected.
The door operator described in these operang instrucons
is meant to open and close a door or similar. The door oper‐
ator is described here on the basis of its technical character‐
iscs at the me of prinng the manual.
The manufacturer reserved the right to modify separate
basic unit assembly groups and materials if these modifica‐
ons are considered appropriate for improving the capacity
and safety of the door operator.
The speed and travel of the door determine which gear and
limit transmission values should be used. Different possible
transmission raos are not explained in this manual. The
transmissions for each specific case can be found in the pro‐
ducon informaon, by the serial number.
Serial number:
Fig. 1.
1. Contents ................................................................ 2
2. Key to symbols ...................................................... 2
3. General informaon.............................................. 2
3.1 Safety instrucons ........................................... 3
3.2 Rang plate ..................................................... 3
4. Product range ....................................................... 4
4.1 Opons ............................................................ 4
5. Mechanical installaon ......................................... 4
6. Electrical installaon ............................................. 5
7. Set up .................................................................... 6
7.1 Adjustment of the slipping clutch .................... 6
7.2 Adjustment of the limits .................................. 6
7.3 Digital seng –AVE limits ............................... 7
8. Operaon .............................................................. 8
8.1 Disengagement clutch (not TVR‐type) ............ 8
9. Service and maintenance ...................................... 8
9.1 Changing the fricon lining of the
slipping clutch ....................................................... 9
9.2 Permied load ................................................. 9
9.2 Spare parts ...................................................... 9
9.3 Troubleshoong .............................................. 9
10. Declaraon of incorporaon of partly
completed machinery .........................................12
Danger of personal injury!
The safety instrucons must be
observed
Warning! Danger to property!
The safety instrucons must be
observed!
Informaon
 Special informaon
 Reference to other sources of
informaon

Door operator TVR(FC) 5 / Rev 1.41 ‐ 3
This door operator meets the requirements of 2006/42/EY,
EMC‐direcve 2004/108/EY, LVD 2006/108/EY and standard
EN 13241‐1 and is delivered in safe operaon mode. Self‐
made modificaons that could affect the operaonal safety
of the door operator are not allowed.
Observing the instrucons will improve your safety and that
of your operang environment. It also ensures the opera‐
onal safety of the door and its drive unit and prevents in‐
terrupons in use caused by faulty handling, along with bur‐
dens to the environment.
Observe occupaonal safety and environmental protecon
regulaons, when transporng, seng‐up, installing, oper‐
ang, maintaining and dismantling the door operator.
To ensure operaonal safety, only original components or
parts that have been specifically approved by the manufac‐
turer may be used in or connected to the door operator. All
components of the device have been selected, protected
and constructed so that they are durable and meet the envi‐
ronmental and operaonal requirements specified in this
manual.
Perform maintenance on the door and the door operator
only when the door is not moving. To prevent unintenonal
starng of the door operator, you must e.g. lock the main
switch of the door operator control system in the 0 posion.
3.2 RATING PLATE
Every complete drive unit has two (2) rang plates, one on
the gear box and the other one on the electric motor (fig. 2).
The plate on the gear box shows (fig. 1), in addion to the
technical informaon, also the producon serial number
(e.g. MLN9878/1), on the basis of which all original produc‐
on informaon can be traced later.
 Only authorised and properly trained
personnel may install, maintain or
repair the door operator. In cases of
more demanding repairs, always de‐
liver the door operator to the manu‐
facturer for maintenance.
 Ensure that the persons responsible
for installaon, preparaon for uli‐
saon and maintenance of the door
operator have read this manual and
that they understand and observe the
regulaons and instrucons con‐
tained and menoned therein.
3.1 SAFETY INSTRUCTIONS In all quesons related to service, spare part deliveries or
claims it is extremely important to refer to the serial num‐
ber. With reference to this number it will be possible to
clear up in detail important maers related to producon,
quality control and deliveries. Record the serial number of
the GEAR box e.g. on the second page of this manual.
Fig. 2.
Rang plate of the
motor
Rang plate
of the gear
Mounng 4xM8—
dep. 20

4 ‐Door operator TVR(FC) 5 / Rev 1.41
4. PRODUCT RANGE
4.1 OPTIONS
TVR 5 door operator is delivered in following opons:
F = Disengagement clutch for manual operaon
C = Slipping clutch, dry, on the input sha between motor
and the gear box
Type of the mounng flange:
Z6 = flange IEC 63 B5
Z7 = Flange IEC 71 B5
Z8 = Flange IEC 80 B5
Z9 = Flange IEC 90 B5
X = Flange for Ovitor brake motor, not IEC standard
Type of motor:
M = 3~ electric motor
MY = 1~ electric motor
MD = Dahlander 2‐speed motor
MJ = Motor with built‐in magnec brake (Brake motor)
MDJ = Dahlander 2‐speed brake motor
MT = DC‐motor
E.g. TVRFC 5 Z7M
5. MECHANICAL INSTALLATION
Before installaon, inspect the drive unit visually for possi‐
ble damage sustained during transport. Addionally, the
drive unit must stand on each of its four sides for about one
minute to make sure that no damage to rotary sha seals or
the housing has been sustained during transport. No oil
leaks are allowed. If oil is leaking out, remove it immediately
with an oil‐absorbing substance. Installaon of a drive unit
with oil leaks is forbidden. Deliver a faulty unit to the manu‐
facturer for repair.
The drive unit must be mounted carefully on a solid and
even surface and bolted firmly to the base. If the drive unit
is to be mounted on a steel structure, make sure that this
structure will not bend. If the mounng base is not perfectly
even, the fixing lugs of the drive unit could break when the
fixing screws are ghtened. Do not bend gear when ghten‐
ing the fixing screws. Use fixing screws with a min. strength
class of 8.8. Install the drive unit so that no resonance vibra‐
on will occur and no vibraon can be transferred from ad‐
jacent structures. Do not perform welding on the drive unit
or connect it to welding circuit.
When mounng the drive unit, note the access required for
adjustment of the limit switches, as shown in the adjacent
fig. 2. The dimensions of the drive unit are shown in type
specific drawings 62XX/7XXX (e.g. 6225/7076).
If a chain transmission is used, sprockets should be perfectly
aligned. The fixing of the drive unit must be able to support
min. 5000 N chain tension.
Drive unit must be sheltered against falling objects.
If the drive unit has been detached, e.g. for maintenance, it
must be mounted again using instrucons given above. The
drive unit must be detached, together with its motor. In
cases where more demanding repairs are required, always
deliver the door operator to the manufacturer for mainte‐
nance. An exploded view of the drive unit and the part num‐
bers can be found later in this manual.
Type of motor
Mounng flange of the motor
Slipping clutch on the input sha
Disengagement clutch
Limit switches
Hollow sha worm gear
 Only properly authorised and
trained personnel may dismantle or
repair the door operator.

Door operator TVR(FC) 5 / Rev 1.41 ‐ 5
6. ELECTRICAL INSTALLATION
Perform the installaon and make the connecons accord‐
ing to the wiring and circuit diagrams provided specifically
for this case by control system supplier.
The temperature detectors of the gear unit, the possible
micro switch of the disengagement clutch and the micro
switches of the limits are already connected to the connect‐
ors in the limit switch box according to the fig. 3. Do not
modify these connecons without first consulng the manu‐
facturer.
Open and close the cover of the limit switch box carefully so
that its enclosure class will not decrease in installaon. First
loosen the fixing bolt of the cable gland lead‐through (part
number 569) on the side of the limit switch box. Then loos‐
en all fixing bolts of the cover (1/2 turn) crosswise. Aer
that loosen the bolts completely and take off the cover. In‐
stall the limit cable in the cable gland and ghten it. Check
the cable’s sealing. Make the necessary connecons.
Aer checking the adjustment and operaon of the limit
switches, install the cover of the limit switch box in its place.
Check that the sealing on the gear unit’s side has not
suffered damage during the installaon. Check that no dirt
remains between the cover and the gear unit. If there is a
disengagement mechanism (F) in the gear unit, check that
the slot in the end of the disengagement sha is in the cor‐
rect posion with respect to the shoulder inside the disen‐
gagement lever. If the parts do not match, the cover cannot
be posioned correctly and could be damaged when the
fixing bolts are ghtened. When the cover is correctly in
place, ghten the fixing bolts evenly. Also ghten the fixing
bolt in the cable gland lead‐through. Aer ghtening the
bolts, check that the lever of the disengagement clutch
funcons properly. The lever must turn 90 degrees.
Fig. 4.
 Only properly authorised and
trained personnel is allowed to car‐
ry out electrical installaon.
connecon connecon Terminal for
thermal trip
in motor
winding
Control current
Fig. 3. Connecon example OKTIIF
(GREEN)
(WHITE)
(YELLOW)
(RED)
(RED)
DISENGAGEMENT

6 ‐Door operator TVR(FC) 5 / Rev 1.41
7. SET UP
7.1 ADJUSTMENT OF THE SLIPPING CLUTCH
The torque transmied by the drive unit must always be
adjusted in due consideraon of the safety requirements of
the door operaon. The limitaon of the torque is done by
adjusng the slipping clutch situated between the electric
motor and the gear box. When delivered from the factory
the slipping clutch is le loose so that no torque can be
transmied from the electric motor.
Adjustment:
1. Loosen the M8 lock nut at the end of the worm sha.
2. Hold the worm sha with a spanner.
3. Start turning the adjustment screw inwards (= clockwise)
unl the required torque has been obtained.
The torque should be adjusted so that it is just high enough
to move the door over its complete travel and low enough
to permit the clutch to slip as soon as the door is obstructed
in its movement. A direct safety risk is produced if the
torque is set to a considerably higher level than required for
the door operaon.
7.2 ADJUSTMENT OF THE LIMIT SWITCHES
To ensure correct adjustment, familiarise yourself with the
funconing of the limits in the control system. For further
informaon of the limit switches, check the documentaon
of the control system.
Limit switches are adjusted as shown in fig. 6.
1. The limit switches are adjusted with the locking screw
(N) and fine adjustment screw (M) (Allen key size:2.5
mm).
2. First turn the cam wheel near to the right posion and
ghten the locking screw (N).
3. Fine adjustment can be done by screwing the adjustment
screw (M).
Adjustment of the doors limit posions.
1. Move the door manually to the posion that corre‐
sponds the acvaon posion of the limit switch.
2. Adjust the cam wheel to its correct posion (micro
switch is near to acvaon). Note the rotaon direcon
of the limit sha!
3. It is recommended to perform the final fine adjustment
by operang the door with the drive unit.
4. Check the proper operaon of all protecve and external
devices.
Fig. 6. Adjustment of the limit switches
Fig. 5. Slipping clutch
 Safety regulaons state that the door
movement must not produce a pressing
force exceeding 800 N. If the door can‐
not be moved by hand, due to a fault in
the counterbalancing or for some other
reason, it is not permied to adjust the
slipping clutch to a higher torque. The
reason for the incorrect operaon must
be removed or corrected.
 Before starng to adjust the slipping
clutch, check and make sure that the
door can easily be moved manually in
every part of its travel.
Slipping
clutch lining
Worm sha
Lock nut (M8)
Adjustment screw for
torque of slipping clutch

Door operator TVR(FC) 5 / Rev 1.41 ‐ 7
7.3. DIGITAL SETTINGS ‐LIMIT SWITCH AND SAFE‐
TY CIRCUIT FOR DRIVE
Informaon!
Please refer to the control unit’s oper‐
ang manual for instrucons on seng
the end posions.
Wiring allocaon
The numbers on the plug are also the wire numbers:
4: Safety circuit input
5: RS485B
6: GND
7: RS485A
8: Safety circuit output
9: 7...18 VDC
AVE (absolute value encoder) plug terminal (7‐12)
C. Thermal element in the drive
D. Manual emergency control (crank or chain)
E. Disengagement
Electric interface
A: AVE plug (absolute value encoder plug)
B: AVE plug terminal (absolute value encoder plug
terminal)
At the inial installaon phase, the rota‐
on direcon of the electric motor can
be wrong.
Be prepared to stop the movement to
wrong direcon immediately by using
the STOP buon.
Interchange two phase conductors to
change the rotaon direcon. It is rec‐
ommended to make the change in the
control unit.

8 ‐Door operator TVR(FC) 5 / Rev 1.41
8. OPERATION
Conduct weekly inspecons to determine changes in the
sounds of the gear unit or oil leaks from the gear unit. If you
note oil leaks or unusual sounds during drive unit operaon,
stop the drive immediately and make sure that it cannot be
used. If you cannot determine the cause of the problem,
deliver the drive unit to the manufacturer for repair.
Note that dust may accumulate on the drive unit during its
operaon. If necessary, clean the drive unit regularly. The
dust layer must not be thicker than 5 mm. Do not use high‐
pressure cleaning machines to clean the drive unit.
8.1 DISENGAGEMENT CLUTCH (NOT TVR TYPE)
Disconnecon of the drive unit is done by turning the disen‐
gagement lever. This enables the manual operaon of the
door. To disengage, turn the lever of the clutch 90 degrees,
as shown in fig. 7. For operaon of the lever from floor level,
aach ropes to the holes at the ends of the lever.
The movement of the lever affects a micro switch. While
affected, the micro switch disconnects the control current.
For normal electric operaon, move the lever back to its
original posion.
Note! Switching back to electric operaon is allowed only by
turning the disengagement lever to its posion for electric
operaon and by moving the door manually unl the clutch
dogs are engaged perfectly (→click).
Fig. 7. Disengagement clutch
9. SERVICE AND MAINTENANCE
All service and maintenance work must be carried out care‐
fully and only by thoroughly trained personnel. Perform
maintenance of the door and the door operator only when
the door is not moving. To prevent unintenonal staring of
the door operator, lock the main switch of the control sys‐
tem in the 0 posion.
Semi‐annual service and maintenance:
 Check the condion and adjustment of the slipping
clutch
 Check the ghtness of all fixing bolts in the gear unit and
the electric motor.
 If a chain is used in power transmission, check the align‐
ment of the sprockets.
 Check the condion of the chain and the sprockets.
 Examine the condion of the gear unit visually.
 Check the sounds of the gear unit.
 Check the ghtness of the gear unit.
 Remove the dust that has accumulated on the gear unit
and the motor.
In addion to this, check the condion of the enre gear
every three years.
Correct lubricaon is of primary importance for the func‐
oning of a worm gear. The oil grade for the inial filling is
shown on the rang plate. In the specified operang condi‐
ons, oil changes are not necessary. The oil quanty should,
however, be checked at the me of installaon and at least
once a year during normal maintenance of the door.
The inial filling oil used is suitable for an environment with
temperature variaons from –20 oC to +40 oC. For drive
units that are run with an especially high operang frequen‐
cy such that the surface temperature of the unit is constant‐
ly above +40oC, oil changes are recommended. In such oper‐
ang condions, the first oil change should occur aer ap‐
prox. six months of operaon and subsequently at three
year intervals.
When changing the oil, always use the same type of oil used
previously. It is not allowed to mix oils of different types or
from different manufacturers. Mixing oil types may damage
the rotary sha seals and cause oil leaks
When changing the oil, please note that hot oil may cause
burns. Always use protecve gloves and remove leaking oil
immediately with an oil‐absorbing substance.
Observe the regulaons and instruc‐
ons given in this manual when oper‐
ang the door.
Disengagement
lever
Please note the instrucons in the
”Operaon” secon for observing gear
unit condion.

Door operator TVR(FC) 5 / Rev 1.41 ‐ 9
Fig. 8. Gear side of the clutch and the fricon lining
9.1 CHANGING THE FRICTION LINING OF THE
SLIPPING CLUTCH
Changing the fricon lining of the slipping clutch is the only
special service operaon required. The operaon is done as
follows:
1. Check the thickness of the fricon lining of the slipping
clutch through inspecon hole in the side of the
mounng flange between the gear box and the electric
motor. The inspecon hole is covered with a detachable
plasc plug. If the fricon lining is worn out, carry out
points 2‐6.
2. Unscrew the adjustment screw fully (fig. 5)
3. Detach the motor from the gear
4. The gear side of the clutch has a guide for the correct
alignment of the fricon lining. Make sure the new fric‐
on lining is aligned correctly.
5. Aach the motor with the gear
6. Adjust the slipping clutch according to chapter 7.1
4
9.2 PERMITTED LOAD
The door operator’s maximum permied torque has been
informed in the rang plate. It is not allowed to connect the
door operator to drive a mechanism, the operaon of which
would, e.g. through ineral forces, exert on the output sha
of the gear a torque exceeding the permied maximum
torque.
The permied service life of the door operator is 12 000
operang hours with the maximum permied nominal out‐
put of the electric motor.
9.3 SPARE PARTS
Every separate component manufactured by Ovitor Oy has a
part number composed of three or dour digits. When order‐
ing spare parts, always menon the serial number of the
drive unit (on the gear unit rang plate) and the part num‐
ber shown in the drawing. With the help of the serial num‐
ber, it is possible to determine the correct part from the
producon informaon of the gear unit.
9.4 FAULT TRACING
Very oen, faults in electric door operaon originate from
devices connected to the control system (e.g. from align‐
ment of photo cells). First find out whether the fault is in
the door’s construcon, in the control systems or in the
drive unit.
Turn the disengagement lever of the gear unit to manual po‐
sion and check that the door can be easily moved manually
in both direcons over the complete travel of the door. If
the door cannot be moved at all, the fault may be in the dis‐
engagement mechanism. If the door moves only heavily, the
fault is in the door’s construcon or in its balancing arrange‐
ments. In this case, the door itself must be repaired
If the door can be moved manually, move it to half‐open po‐
sion and turn the lever of the disengagement mechanism
to its electric operaon posion. Move the door manually so
that the clutch dogs are perfectly engaged. Drive the door in
the opening and closing direcons. If the door does not
move in one or both direcons, the fault is probably in the
control system. However, if the electric motor is running but
the output sha of the gear unit is not rotang, the fault is
in the disengagement mechanism of the gear unit.
If the drive unit is not equipped with a disengagement
clutch (type TVR), the door must be released for manual op‐
eraon by some other means so that the movement of the
door can be checked.
If the fault is in the control system, please refer to the con‐
trol system documentaon.
If the fault is in the drive unit, please refer to the following
table.
9. SERVICE AND MAINTENANCE

10 ‐Door operator TVR(FC) 5 / Rev 1.41
9. SERVICE AND MAINTENANCE
Manifestaon Fault Acon
Loud sounds from the fixing point of the
gear unit
Fixing of the gear unit is loose Tighten the fixing bolts; if they are damaged, replace
Unusual sounds from the gear unit Damage to the worm sha or wheel Contact the manufacturer
Unusual sounds from the gear unit Damage to the bearings Contact the manufacturer or replace the bearing
Unusual sounds from the gear unit Not enough oil Check the oil quanty, add more if necessary; find out the
reason for diminished oil quanty, check for possible oil leaks
Vibraon of input sha at the bearing point Damage to the bearing Contact the manufacturer or replace the bearing
Unusual sounds from the drive motor Refer to the documentaon provided by the drive motor
supplier
Thermal protecon of the gear unit stops
the drive unit
Door’s resistance to moon has increased Check the condion of the door and its fixings
Thermal protecon of the gear unit stops
the drive unit
Not enough oil Check the oil quanty, add more if necessary; find out the
reason for diminished oil quanty, check for possible oil leaks
Thermal protecon of the gear unit stops
the drive unit
Damage to the worm sha or wheel Contact the manufacturer
Oil leak from the gear unit frame Mechanical damage in the gear housing Contact the manufacturer
Oil leak from the gear unit frame Fixing bolts of the gear unit halves are loose Check and ghten the fixing bolts
Oil leak from the rotary sha seal Seal has worn out or there is dirt between the
seal and the sha
Contact the manufacturer or check the rotary sha seal and
replace it if necessary
Disengagement mechanism doesn’t work Gear locked when the door was driven with
force against an inelasc obstacle
Rotate the input sha of the gear unit e.g. from the side of
the electric motor
Disengagement mechanism doesn’t work Disengagement mechanism has been damaged Contact the manufacturer
Place where door travel stops has changed Adjustment of the limit switches has changed Check that the adjustment ghtness of the limit cams has not
decreased. Tighten and adjust the limits again.
Limit switches do not stop the door Limit sha is damaged or does not rotate Contact the manufacturer
Limit switches do not stop the door Micro switch for the limit does not funcon Replace the limit switch
Clack between the gear and motor Flexible clutch worn out Replace the clutch
The motor runs, but gear sha is not turn‐
ing
Slipping clutch is slipping Adjust or replace the slipping clutch

Door operator TVR(FC) 5 / Rev 1.41 ‐ 11

12 ‐Door operator TVR(FC) 5 / Rev 1.41
10. DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY
DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY
Ovitor Oy
Sienie 24
00760 Helsinki
Finland
Descripon and idenficaon of the partly completed machinery:
Door operator TVR(FC) 5 with various limit and gear transmissions
The essenal requirements of EC Machinery Direcve 2006/42/EC have been applied and fulfilled for the above menoned
machinery to be used with industrial doors, gates and barriers. The relevant technical documentaon has been compiled in
accordance with Annex VII, Part B of EC Machinery Direcve 2006/42/EC.
In addion the partly completed machinery is in conformity with the EC 2006/95/EC Low Voltage Direcve LVD, 2004/108/
EC Electromagnec Compability EMC and 2002/95/EC the Restricon of the use of certain Hazardous Substances in Electri‐
cal and Electronic Equipment RoHS.
The above listed products are delivered according to the following standards to the extent to which they may be applicable:
EN ISO 12100:2010, EN 60204‐1+A1+AC, EN 60335‐1+A11+AC, EN‐55014‐1+A1, EN 61000‐3‐
2+A1+A2, EN 61000‐3‐3, EN 61000‐6‐2, EN61000‐6‐3+A1, EN 61439‐1, EN 61439‐3, EN 60529+A1,
EN 13241‐1+A1, EN 60335‐2‐103, EN 13241+A1, EN 12453, EN 12445, EN 12604, EN 12605, EN
12978+A1
SFS‐Inspecta Serfioin OY has issued a cerficate ascertaining that the manufacturer's quality system meets the require‐
ments of standard SFS‐EN ISO 9001:2008 and the general guidelines ABC 200, cerficate 1229‐06.
We undertake, in response to a reasoned request, to supply it in electronic form to the market surveillance authories with‐
in a reasonable period.
The party authorized to compile the technical documentaon is:
Ovitor Oy / Engineering Manager
Sienie 24
00760 Helsinki
Finland
The devices are not intended to funcon independently but as a part of an electrically operated machine. In the design, con‐
strucon and servicing of the machinery, it must be ensured that the loads to which the door mechanism is subjected do not
exceed the values given in the instrucon manual of the mechanism, and that the permied service life of a door mecha‐
nism is no more than 12 000 operang hours. As regards the installaon, sengs and servicing of the machinery, the in‐
strucons issued by us for the type of installaon in queson must be observed.
The partly completed machinery must not be put into service unl the final machinery into which it is to be incorporated has
been declared in conformity with the provisions of the Machinery Direcve.
Helsinki, 14th of September 2016
_______________
Juha‐Ma Lyhykäinen
Producon Manager
Ovitor Oy