MGV25.

X
USER GUIDE
INSTALLATION OPERATION AND MAINTENANCE
MANUAL OF THE GEARLESS MGV25.2 – MGV25.3 Ver. 3.7
MGV25.5

MONTANARI GIULIO & C. S.r.l.

41100 MODENA (Italy) – Via Bulgaria,39 –Tel. +39 059 45.36.11 –Fax +39 059 31.58.90 –Cap.Soc. €520.000 i.v. –Export MO 004935
R.E.A. di MO N. 210108 –Reg.Imprese di MO Cod.fisc. e Part.IVA n. 01047170368 –Identification CEE No. IT 01047170368
www.montanari-giulio.com - E-mail: info@montanari-giulio.com
Aim

The aim of this manual is to provide instructions for the correct installation, use and maintenance of
the GEARLESS type MGV25.2, MGV25.3 and MGV25.5 for use in passenger and freight lifts.

Warning:

This booklet does not contemplate the instructions for the shutting down of the entire system, but
only the instructions relating to the GEARLESS, therefore before starting the installation of the
gearless you must follow the instructions in this operation and maintenance manual and take
precautions in accordance with the current safety standards.

The Gearless motors MGV25 and all the components supplied by Montanari Giulio & C, have been
tested in order to guarantee their correct operation.

The Gearless motor has been tested in both empty and loaded operating conditions, in accordance
with the technical specifications for velocity, car capacity load, car weight, presence or not of
compensation and the type of roping requested when the order was placed.

This ensures the correct operation and a minimum number of set-up operations.

All responsibility is declined for any malfunctions due to installation with different characteristics,
except in the case of specific approval by Montanari G. & C.
Summary:

1. References Standard …………………………………………… 2

2. General notes …………………………………………… 2
3. Transport …………………………………………… 2
4. Warehouse storage …………………………………………… 3
5. Installation …………………………………………… 3
6. Use …………………………………………… 11
7. Maintenance …………………………………………… 11
8. Declaration of Conformity …………………………………………… 13
9. Brake Certificate …………………………………………… 14

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MGV25 USER GUIDE MONTANARI GIULIO & C. S.r.l

1 References Standard.

1.1 The following standards are to be considered as references and are not necessarily entirely
applicable to this technical instruction. (Table N°1)

N Reference Type of standard Description

1 UNI 10147 E Maintenance : Terminology

Safety rules for the construction and installation of passenger

2 UNI EN 81/1 E
and freight lifts

Table 1

2 General Notes.

2.1 The operations described in this manual must be carried out by qualified personnel,
equipped with the necessary workshop tools.
2.2 Before all interventions the entire system must be put out of commission to prevent it from
being used.
2.3 For all requests for spare parts or for particular instructions it is always necessary to specify
the serial number, which can be found stamped next to the electrical connection terminal
board.

3 Transport.

3.1 The entire gearless are packed in cases or crates.

In some cases they are mounted upon wooden platforms, in order to be transported
correctly on the lorry. The cases and crates are not load bearing and therefore cannot be
stacked upon each other.

3.2 The unloading of the material, from the transport vehicle, must be done with equipment
that is suitable for both the weight and the dimensions of the load.
All the packing is designed for movement by fork lift and low lift platform trucks.

3.3 Upon the receipt of all material, check its condition.

In the event of any damage do not proceed with the installation unless authorised otherwise
by Montanari Giulio & C.

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4 Warehouse storage.

4.1 Preserve the gearless, even if it is still packed, in a dry place where it is protected from bad
weather.
4.2 Once the packing has been removed take the necessary precautions to avoid the settling of
any dust.

5 Installation.

5.1 Operating Conditions.

- The gearless machine must be installed in a building or closed hoist-way.

- Do not operate the gearless in an explosive atmosphere.
- The ambient temperature must be within 0°C and +40°C.

5.2 Handling.

The gearless MGV25 can be lifted using the holes already present on the base for the fitting
of belts or chains. (Figure N°1)

Lifting sample:

Figure 1

Care must be taken to ensure that the gearless doesn’t get knocked as the brake disc, the brake
callipers and the electrical connection terminal board are particularly delicate.

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5.3 Assembly.

The gearless are ideal for assembly either with or without a machine room. The roping and
therefore the load must always be orientated versus the base of the machine as shown in the
diagram. (Figure N°2)

MGV25.2 MGV25.3 MGV25.5

Figure 2

In the case of assembly with the machine down, and therefore with the roping and load upward,
you must mount it rotated by 180 degrees. (Figure N°3)

MGV25.2 MGV25.3 MGV25.5

Figure 3

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5.4 Gearless Dimension.

Figure 4 – MGV25.2

Figure 5 – MGV25.3

Figure 6 – MGV25.5

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5.5 Brake.

The gearless is provided with a disc brake that is operated by 2 independent electromechanical
devices which are conform to the EN81-1 standard.

The gripping callipers are pre-calibrated by the manufacturer and therefore don’t require any
further adjustment.

Attention must be paid and if necessary precautions taken to ensure that oil or grease do not
come into contact with the brake disc. Grease or oil on the brake disc can jeopardise the braking
and put people in serious danger.

5.6 Lubrication.

The gearless does not contain oil and is supplied with bearings that are lubricated for the life of
the equipment; therefore no further lubrication is necessary.

5.7 Electric installation.

The Gearless MGV25 has supplied with power cable (Figure N°7):

- 3 Power Cable for U-V-W phases [1-2-3].

- 2 Power Cable for cooling fans supply (230 Vac) [F7-F8].
- 2 Cable for PTC Thermistor [T5-T6].
- 1 Ground Cable (Yellow-Green Cable).
- 1 Shield Cable (Grey Cable).

Figure 7 – Gearless Cable

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With this configuration, the brake power supply and micro switches cables must be connected
separately.

Temporiti’s Brake Device: (For MGV25.2 and MGV25.3 machines)

This Brake has power cable within two cables; that cables can be connected directly at control
panel.

Figure 8 – Brake of Temporiti

In resting state (Electromagnet not supplied), the brake disks are locked from the surfaces
movable (Green arrows in Figure N°9). In that condition the system is motionless. When motor
received a moving command , the electromagnet of the brake is supplied releasing the brake disk
(Green arrows in Figure N°10). Now the motor is free to moving.

In the brake device there are two microswitch with two contacts; one normally open and one
normally closed (Figure N°11). These contacts tell us the actual state of the brake device (See
Truth table N°2).

Figure 9 – Brake Disk Locked Figure 10 – Brake Disk Free

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MGV25 USER GUIDE MONTANARI GIULIO & C. S.r.l

Figure 11 – Microswitch

Brake Disk Locked Brake Disk Free

Contact State Contact State
Com N.O. Disconnected Com N.O. Connected
Com N.C. Connected Com N.C. Disconnected
Table 2 – Microswitch Contacts

Intorq’s Brake Device: (For MGV25.5 machines):

This brake device must be connected to the Booster, an electronic device that provide an
overvoltage of 207 Vdc for one second and an hold voltage of 104 Vdc (Figure N°12).

For major information see Booster Basic User Guide.

Overvoltage 207 Vdc Power of single coil 270 W.

Hold Voltage 104 Vdc Power of single coil 68 W.

Figure 12 – Booster Half Bridge Basic

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In the brake device there are two couples of cables (one pair for coil); these cable must be
connected in parallel and then connected at Booster device (Figure N°12 and Figure N°13).

For major information see Booster Basic User Guide.

Figure 13 – Brake of Intorq

In resting state (Electromagnet not supplied), the brake disks are locked from the surfaces
movable (Green arrows in Figure N°14). In that condition the system is motionless. When motor
received a moving command , the electromagnet of the brake is supplied releasing the brake disk
(Azure arrows in Figure N°15). Now the motor is free to moving.

In the brake device there are two microswitch with two contacts; one normally open and one
normally closed. These contacts tell us the actual state of the brake device (See Truth table N°2).

Figure 14 – Brake Disk Locked Figure 15 – Brake Disk Free

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MGV25 USER GUIDE MONTANARI GIULIO & C. S.r.l

GEARLESS MGV25 TECHNICAL CHARACTERISTICS

Motor Type Pn Speed Vn Cn In Cmax Imax Emf Poles F R L St. Load I Duty Cycle Weight Typical Installation
[kW] [Rpm] [V] [Nm] [A] [Nm] [A] [V*s/rad] [n°] [Hz] [Ohm] [H] [Kg] [kgm^2] [Kg]

MGV25.20160 2.2 80 360 265 9 390 14.5 11 16 10.7 6.3 0.095 3400 0.2 40% 180s/h 120 408Kg 2:1 0.63m/s 320mm

MGV25.22660 2.6 115 210 215 12 270 16 9 16 15.3 2 0.031 3400 0.2 40% 180s/h 120 408Kg 2:1 2m/s 320mm

MGV25.20660 3.3 120 360 265 11 390 18 15 16 16 4.4 0.046 3400 0.2 40% 180s/h 120 408Kg 2:1 1m/s 320mm

MGV25.20760 4.9 180 360 265 15 390 25 11.5 16 24 2.5 0.022 3400 0.2 40% 180s/h 120 408Kg 2:1 1.5m/s 320mm

MGV25.30160 2.9 80 360 350 11 470 16 21 16 10.7 4.4 0.052 3400 0.25 40% 180s/h 180 544Kg 2:1 0.63m/s 320mm

MGV25.30660 4.4 120 360 350 12 470 17 17 16 16 3.5 0.034 3400 0.25 40% 180s/h 180 544Kg 2:1 1m/s 320mm

MGV25.30662 4.7 120 360 375 15 580 24 14 16 16 2.8 0.033 3400 0.25 40% 180s/h 180 680Kg 2:1 1m/s 320mm

MGV25.30760 6.6 180 360 350 15 470 25 15 16 24 1.96 0.025 3400 0.25 40% 180s/h 180 544kg 2:1 1.5m/s 320mm

MGV25.30762 7 180 360 375 20 580 34 13 16 24 1.49 0.022 3400 0.25 40% 180s/h 180 680Kg 2:1 1.5m/s 320mm

MGV25.30360 10.4 255 360 390 29 580 48 7 16 34 0.75 0.013 3400 0.25 40% 180s/h 180 680Kg 2:1 2m/s 320mm

MGV25.50950 3.7 60 360 590 13.5 850 20 23 16 8 3.8 0.045 3400 0.31 40% 180s/h 240 1000Kg 2:1 0.5m/s 320mm

MGV25.50150 5 80 360 590 14.5 850 22.5 22 16 10.7 2.9 0.04 3400 0.31 40% 180s/h 240 1000Kg 2:1 0.63m/s 320mm

MGV25.50650 6 120 360 590 20 850 30 18 16 16 1.8 0.018 3400 0.31 40% 180s/h 240 1000Kg 2:1 1m/s 320mm

MGV25.50750 11.1 180 360 590 27 850 41 17 16 24 0.98 0.015 3400 0.31 40% 180s/h 240 1000Kg 2:1 1.5m/s 320mm

MGV25.51050 13 210 360 590 37 850 58 9.5 16 28 0.48 0.009 3400 0.31 40% 180s/h 240 1000Kg 2:1 1.6m/s 320mm

MGV25.50350 15.7 255 360 590 38 850 59 8 16 34 0.48 0.009 3400 0.31 40% 180s/h 240 1000Kg 2:1 2m/s 320mm

Table 3

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6 Use.

6.1 General notes.

The gearless are designed and constructed as lifting devices for lifts and hoists and respect the
various sector standards.

Any other use is to be considered improper.

They cannot be used in systems with characteristics that are different to those agreed upon in the
order (e.g. carrying capacity, velocity, etc.),

Qualified and competent personnel must carry out all tests, inspections or manoeuvres that may
be necessary in accordance with the current standards.

6.2 Emergency manoeuvre.

The emergency manoeuvre must be made by an independent electrical device, which is capable of
opening the brake and moving the gearless at a reduced velocity.

It is possible to exploit the characteristics of the synchronous motor as it can slow down the car
when the phases are put into short circuit.

This system has some load limits and it is therefore necessary to observe several precautions.
Montanari Giulio & C. can provide the information necessary to apply the aforementioned solution
upon request.

7 Maintenance.

7.1 Traction/Driving pulley.

Periodically, at least once a year, check the amount of wear on the cable races on the traction
pulley.

In the event of the cables slipping or of excessive wear contact Montanari Giulio & C. for the
substitution instructions, always indicating the serial number.

7.2 Component substitution.

The instructions for any eventual component substitutions must be asked for each time from the
Technical Department, specifying the serial number.

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8 Declaration of Conformity.

DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY

(Directive 2006/42/CE, Annex II, par. B.)

Manufacturer:
Montanari Giulio & C. S.r.l.
Via Bulgaria n.39, 41122 Modena

Person authorized to compile the relevant technical documentation:

Bertoni Stefano, Montanari Giulio & C. S.r.l., Via Bulgaria n.39, 41122 Modena

Model of the partly completed machinery:

Gearless: MG200 – MGV25 – MG25S – MG300 – MG34S – MCG150 – MDD35 - MDD70

The essential requirements of this Directive are applied a fulfilled and the relevant
technical documentation is compiled in accordance with part B of Annex II.

The partly completed machinery comply with the following directives:

95/16/CE, 89/336/CE, 92/31/CE, 73/23/CE

The Montanari Giulio & C. S.r.l. undertakes to provide, in response to a reasoned request
by national authorities, relevant information on the partly completed machinery.

The partly completed machinery must not be put into service until the final machinery into
which it is to be incorporated has been declared in conformity with the provisions of this
Directive: 2006/42/CE or 95/16/CE.
Violation of the dispositions given in these technical instructions will immediately
invalidate any form of guarantee

Note:

With regard to fulfilment of point 9.7 of reference regulation EN81-1 1998, please
remember that Montanari supplies protection devices only if specifically requested by the
customer.

The responsible Ponanti Graziano Firma:

Modena il 22/12/2009

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9 Brake Certificate.

The brake has been designed in conformance with the specific requests of the EN81-1 standard.

This device is therefore usable as a brake to slow down the car in combination with a suitable
speed governor in the case of excessive velocity in the rising direction.

The examination certificates issued by TÜV B.B.

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Temporiti’s Certificates:

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Intorq’s Certificates:

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MONTANARI GIULIO & C. S.r.l.
41100 MODENA (Italy) – Via Bulgaria,39 –Tel. +39 059 45.36.11 –Fax +39 059 31.58.90 –Cap.Soc. €520.000 i.v. –Export MO 004935
R.E.A. di MO N. 210108 –Reg.Imprese di MO Cod.fisc. e Part.IVA n. 01047170368 –Identification CEE No. IT 01047170368
www.montanari-giulio.com - E-mail: info@montanari-giulio.com Manuale_MGV25_ENG_Vs3_7