MG300 USER GUIDE. Ver. 3.2 INSTALLATION OPERATION AND MAINTENANCE MANUAL OF THE GEARLESS MG300.4, MG300.6, MGV30.4 AND MGV30.6

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1 MG300 USER GUIDE INSTALLATION OPERATION AND MAINTENANCE MANUAL OF THE GEARLESS MG300.4, MG300.6, MGV30.4 AND MGV30.6 Ver. 3.2 MONTANARI GIULIO & C. S.r.l MODENA (Italy) Via Bulgaria,39 Tel Fax Cap.Soc i.v. Export MO R.E.A. di MO N Reg.Imprese di MO Cod.fisc. e Part.IVA n Identification CEE No. IT info@montanari-giulio.com

2 Aim The aim of this manual is to provide instructions for the correct installation, use and maintenance of the GEARLESS type MG300 and MGV30 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 MG300 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.

3 Summary: 1. References Standard 2 2. General notes 2 3. Transport 2 4. Warehouse storage 3 5. Installation 3 6. Brake 9 7. Use Maintenance Declaration of Conformity Brake Certificate 15 1

4 MG300 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 1) N Reference Type of standard Description 1 UNI E Maintenance : Terminology 2 UNI EN 81/1 E Safety rules for the construction and installation of passenger 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. 2

5 03/09/2012 Ver 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 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 calipers and the electrical connection terminal board is particularly delicate. 3

6 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l 5.3 Assembly and Dimension. The roping and therefore the load must always be orientated versus the base of the machine as shown in the diagram (Figure N 2 and figure N 3). 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. Check that the gearless support base if perfectly flat, a tolerance of 0.1 mm is allowed. The flatness can be checked by placing the gearless on the base and then controlling that all the fastening points meet perfectly with the support surface. If this is not the case then suitable shims will need to be added. MGV30.4 Figure 2 4

7 03/09/2012 Ver.3.2 MGV30.6 Figure 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

8 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l 5.5 Electric installation. Below the motor connector. The two clamps TR are connected to three PTC probes immersed within the coils of the gearless and they are used to control their temperature, connect them to the inverter or electrical control panel. The two clamps F1 and F2 are connected to the internal thermo contact that closing at 70 C start the fan. The clamp N is the star connection and must not to be connected. (See Picture below) [L1 L2 L3 - PE]= Power shield cable from motor to inverter [TR - TR]= Thermistors PTC [C]= Common terminal for Brake to Booster OUT- [BR BR]= Brake Supply terminals to Booster OUT+ [F1 - F2]= Fan supply direct to 230V AC (only MGV version) Table 2 Figure 4 The micro switch is representing from two contacts, one Normally Open (N.O.) and one Normally Close (N.C.). In rested state the gearless brake is closed and there isn t voltage between BR and C clamps (Figure 5). In this condition all lift system is motionless. When motor receive a command of moving, the brake change the status from closed to open and hence the micro switch does the same (Figure 6 and 7). 6

9 03/09/2012 Ver.3.2 Brake Closed Brake Open (Brake without Supply) Figure 5 Figure 6 Figure 7 Micro switch Contact Type Brake Closed Status Contact Contact Type Brake Open Status Contact N.O. -Black Blue Disconnected N.O. -Black Blue Connected N.C. - Black Grey Connected N.C. - Black Grey Disconnected Table 3 7

10 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l GEARLESS MG300 AND MGV30 TECHNICAL CHARACTERISTICS Motor Type Pn [kw] Speed [Rpm] Vn [V] Cn [Nm] In [A] Cmax [Nm] Imax [A] Emf [V*s/rad] Poles [n ] F [Hz] R [Ohm] L [H] St. Load [Kg] I [kgm^2] Duty Cycle Weight [Kg] Typical Installation MG % 180s/h Kg 1:1 1m/s 400mm MGV % 180s/h Kg 1:1 1m/s 400mm MGV % 180s/h Kg 2:1 1m/s 400mm MGV s/h Kg 2:1 1.6m/s 400mm MG % 180s/h Kg 1:1 1m/s 400mm MGV % 180s/h Kg 1:1 1m/s 400mm MGV % 180s/h Kg 2:1 1m/s 400mm MGV % 180s/h Kg 1:1 1m/s 400mm MGV % 180s/h Kg 2:1 1.6m/s 400mm MGV % 180s/h Kg 2:1 2m/s 400mm Table 4 8

11 03/09/2012 Ver Brake. 6.1 Brake characteristics. The brake has been designed in conformance with the specific requests of the EN81-1 standard; in particular it is in conformance with paragraph 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 certificate is an DPS009 type and is issued by TÜV B.B. 6.2 Electrical Connection. The electro-magnet has 2 independent coils with parallel connection. Brake has to be supplied with Booster device in order to give 207 VDC for 1 second while opening and hold at 104 VDC. See Booster Basic Manual for further information (See Figure N 8 and Figure N 9). NOTE: for preserve the brake in presence of a contactor between booster and brake, connect two varistors (Example: S20K275). This component cut off the voltage peaks. Tension in over-excitation 207 Vdc, power of the single coil 270 W. Nominal tension 104 Vdc, power of the single coil 68 W. Figure 8 Booster Basic 9

12 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l Figure Emergency manoeuvre. The emergency maneuver must be made by an independent electrical device, which is capable of opening the brake and moving the gearless at a reduced velocity or manually by brake release lever. 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. 10

13 03/09/2012 Ver Brake adjustment. 1 a) Brake Torque The gripping jaws are calibrated by Montanari in order to be compliant to the EN81 standard par and appendix D.2. Screws (2) therefore don t require any further adjustment to change force. In Table 1 regulation value b) Brake Stroke The jaws must open with the minimum stroke possible to ensure that the braking material doesn t touch the brake drum whilst in motion. By tightening or loosening the regulation screws (1) the stroke can be lengthened or shortened. The stroke is calibrated by Montanari. In gearless machine wear on the brake pads is not common, anyway if space (5) from centre pad and drum, when brake open, is greater than 0.5mm then adjustment is required shortened the stroke unscrewing (1). The jaws must be replaced when the brake pads have a thickness 2 mm 5 c) Micro switch Thanks to the two micro switch (3) (4) with their NA and NC contacts a signal can be received to show whether the jaws of the relative brake are open and closed. (4) is used to check closing jaws while (3) is for the opening. Micro switches are already set. If you want to regulate micro switch you have to unscrew the two screws for each micro switch and move to the left or right in order to get the correct contact signal. The signal cables are situated on the motor connection box in a specific connector block. The contacts can withstand a maximum load of 250 Vca with 1A, for a mechanical duration of over 2 million operations. 11

14 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l L L Figure 10 Gearless Type: MG300.4 / MGV30.4 MG300.6 / MGV30.6 Brake Constant Torque K (Nm/mm) 57,1 57,1 No load length L = L0 (mm) Max load length L = Lmin (mm) 35,7 20 Max breaking torque with Lmin (Nm) Montanari Set (Nm) Breaking Torque with different length L: Mtb = (L0- L) x K Table 5 12

15 03/09/2012 Ver Use. 7.1 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 maneuvers that may be necessary in accordance with the current standards. 8 Maintenance. 8.1 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. 8.2 Brake. At least once a year check the amount of wear on the brake pads. 8.3 Component substitution. The instructions for any eventual component substitutions must be asked for each time from the Technical Department, specifying the serial number. 13

16 MG300 USER GUIDE MONTANARI GIULIO & C. S.r.l 9 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, Modena Person authorized to compile the relevant technical documentation: Bertoni Stefano, Montanari Giulio & C. S.r.l., Via Bulgaria n.39, 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 EN , please remember that Montanari supplies protection devices only if specifically requested by the customer. The responsible Ponanti Graziano Firma: Modena il 22/12/

17 03/09/2012 Ver Brake Certificate. 15

18 MONTANARI GIULIO & C. S.r.l MODENA (Italy) Via Bulgaria,39 Tel Fax Cap.Soc i.v. Export MO R.E.A. di MO N Reg.Imprese di MO Cod.fisc. e Part.IVA n Identification CEE No. IT info@montanari-giulio.com