Installation, Operation and Maintenance Manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Aim
The aim of this manual is to provide instructions for the correct installation, use and maintenance of the
GEARLESS type MDD035 and MDD070 for use in passenger and freight lifts.

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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 MDD035 and MDD070 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 .................................................................................................................................3
3 Transport........................................................................................................................................3
4 Warehouse storage ........................................................................................................................3
5 Installation......................................................................................................................................3
6 Use .................................................................................................................................................24
7 Maintenance .................................................................................................................................24
8 Declaration of Conformity ..........................................................................................................26

Rev. Date Description Drawn up Checked Approved


01 13/01/2003 1. Issue Bertoni S. Bertoni S. Montanari M.

1 References Standard.
1.1 The following standards are to be considered as references and are not necessarily entirely
applicable to this technical instruction.

N Reference Type of Description


standard
1 UNI 10147 E Maintenance : Terminology
2 UNI EN 81/1 E Safety rules for the construction and installation of passenger and
freight lifts

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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 All the 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.

Table of weights
Gearless Type Maximum weight (kg.)
MDD035 400
MDD070 420
Note: Weights indicated are to be considered as maximum, and therefore they do not include any
eventual bases or protections linked to the gearless.

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.

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 Handling
The gearless can be lifted using the holes already present on the base for the fitting of belts or chains

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Lifting example:

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.

5.2 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.

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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.

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Wall assembly
If the gearless must be mounted on a wall then you must use all the fastening holes, both the upper
and lower ones.
Two sufficiently robust shelves must be available to support the load of the system.

Insert design

The “Halfen” type guides are recommended for the fastening.

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.

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

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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.

A brake opening device that can be remotely operated is available upon request from the supplier.
It consists of a flexible cable and a lever that can be positioned on the wall.
Alternatively an auxiliary electrical device (NOT SUPPLIED) must actuate the brake opening.
The electrical characteristic data for the brake coil are shown in the “ELECTRICAL
CONNECTIONS” chapter.

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5.4 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.

5.5 Electrical connections


IMPORTANT INFORMATION NOTE
Unless otherwise indicated the gearless is supplied ready for the “CONTROL TECHNIQUES”
inverter therefore, the instructions and the diagrams illustrated in this manual are applicable
only if this actuator is used.

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For connection instructions for other types of inverters please contact our Technical
Department.

5.6 General electrical diagram

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5.7 Power connection diagram

MDD070 Electrical diagram; Power connection; Star mode; UNI 2-3 40 1-2-3
From Main
contactor
PE L1 L2 L3

FUSE

motor zone
Star connection
(2) U1
X1 phase 1'
W
phase 1
PTC Y 130TB EMI
Tr 130 C°
X
U
(Blue-Blue)
Filter
U
Y1
phase 2' V1
Y phase 2 V
V

Z1
Giallo/Verde
W1
phase 3'
Z W
phase 3 U

ITB3106A24-10SN1 V
F A F A
W
E G B E G B
40Ω
Total 40 Ohm,

Total 10 Ohm,
Size 3 wiring

D C D C 40Ω
5,2kW

5,2kW
40Ω
40Ω
40Ω
40Ω

Size 2 wiring
CP
40Ω
ITB3102A24-10P 40Ω

to 8 e 11 of C.T. signal terminal strip,


or to the PLC of the Lift control

CP CONNECTOR.
In the “CP” motor power connector, the A, E, & F terminals correspond to the three-phase inputs U,
V, W whilst the B, C terminals, connected to the 8 and 11 inverter terminals, correspond to the three
PTC temperature control probes that control the inside motor coil temperatures ("Control Techniques"
parameter 7.15=th). In the event that the PTC probes are not controlled by the inverter but by the
electrical control panel then refer to the relative manual.

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The terminal G is the earthing terminal. The terminal D is free. The fixed male connector is of the
type ITB3102A24-10P. The mobile female connector is of the type ITB31106A24-10SN1.
PTC. There are three PTC Y 130TB Tr=130 °C (Blue-Blue) probes immersed within the coils of the
gearless and they are used to control their temperature.

5.8 Signal connection

The “CS” connector of the sincos forwards the signals from the sincos encoder to the inverter
(Control Techniques, in the UD52 optional model, in the terminals 40, 41, 42, 43, 44, 45, 46, 47). The
connection is carried out according to the table and the following diagrams. The fixed male connector
is of the type IPT02A12-8P. The mobile female connector is of the type IPT06A12-8S.
The sincos is a SRS 50/70 Stegmann.

UD52 TERMINALS
SINCOS SIGNAL CS CONNECTOR
Control Techniques
SININ ( Sine input signal ) A 40
SINREF ( Sine reference input signal ) G 41
COSIN ( Cosine input signal ) B 42
COSREF ( Cosine reference input signal ) C 43
DATA + ( + Serial communication EIA485 ) D 46
DATA – (- Serial communication EIA485 ) H 47
+8V ( Input DC ) E 45
0V ( Common ) F 44

SININ

SINREF
STEGMANN
SRS 50/70;
COSIN

COSREF G A
F H B
DATA + E D C

DATA – VEAM plug


CSCCONNECTOR
S
IPT02A12-8P
+8 V ON THE MOTOR
0V

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As can be seen in figure 1 the cable presents a double shield; a shield for each couple of crossed wires
and an external shield for all of the eight wires.

Braking resistor connection


The braking resistors “R” are of 40 Ω 1300W each and must be connected as follows:
- for the size 24xx inverter it is necessary to connect the four resistors in series, two by two and then
Total 40 Ohm,
5,2kW

Size 2 wiring
40Ω
40Ω

40Ω
40Ω
in parallel to obtain an overall resistance of 40 Ω, see figure

- for the size 34xx inverter it is necessary to connect the four resistors in parallel to obtain an overall
resistance of 10 Ω. See figure

40Ω
40Ω
40Ω
40Ω
Size 3 wiring
Total 10 Ohm,
5,2kW

All of these must be connected to the + terminals of the power terminal board of the inverter.

5.9 Connection of the input filter


The RFI filter must be connected between the L1, L2, L3 power terminals of the inverter and powered
by the mains 380-:-460V 50-:-60Hz.

5.10 installation and configuration of the gearless MDD070FD with inverter CONTROL
TECHNIQUES

The inverter has been configured with the parameters shown in the following tables 1 and 2.
The parameters in table 1 allow the perfect operation of the motor in accordance with the technical
specifications of the system. If any of these parameters are modified, then there may be a malfunction
or the motor may not work. Before altering any of the parameters in table 1 contact the technicians at
Montanari Giulio & C.
The parameters in table 2 are the intermediate velocity values that can be modified, depending upon
the installation requirements and following the technical guide UNIDRIVE / UD70 BV 76/10-E61-04.

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All the remaining parameters not shown in the tables 1 and 2 enable the optimisation of the motor
operation, their configuration must be done by experts using the installation guide attached to the
inverter.

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CONFIGURATION PARAMETERS SET ON THE
DRIVE CONTROL TECHNIQUES FOR MDD070 FD

PAR. MDD070 FD Description (Control Techniques Service: 0039 - 02 575751; 3378474972)


0.03 0,5 s Acceleration time
0.04 0,8 s Deceleration time
%A Set the current limit in % (If the drive is LFT set 150, if the drive is
0.06 150 -:- 175 not LFT set 175)
0 = cancels the distance error; 1-:-1000 expresses the error limit tolerated in
0.24* 0 in mm. (*accessible with 0.12=1)
0 = cancels the velocity error; 1-:-1000 expresses the error limit tolerated
0.29 0 in mm/1’ (accessible con 0.12=0)
2.04 FAST Activates the braking circuit
3.31 1 Eliminates possible error “ENC.PH9” if =1
4.12 0 Current supply delay from 0 to 3 sec
4.15 10 Motor thermal time constant (I2T); from 0 to 400 sec.
12 / 16 / 25 I-Nom of the inverter: UNI2401 In = 12; UNI2402 In = 16;
5.07
34 / 40 UNI2403 In = 25; UNI3401 In = 34; UNI3402 In=40
5.11 20 No. of poles (in the event of 80 poles 20 is still needed)
5.18 12 Chopper frequency in KHz (reduce to 9 KHz for other currents)
Activates pin 8 and 11 to receive the PTC from the motor (If the PTC are
7.15 Th controlled by the electrical panel it must be between 0 -:- 20 mA)
8.13 18.31 Brake output
16.12 256 No. of sinusoidals per turn of the SinCos encoder (divided by 4 for MDD35
an and 70)
16.15 1 8 V input to the SinCos.
18.25 2000 Velocity increase (Run P.)
18.26 1000 Velocity increase (Run I.)
18.27 2000 Velocity increase (Start P.)
18.28 1000 Velocity increase (Start I.)
RPM of the motor when the car travels at the contractual velocity.
18.29 424 -:- 676 (with MDD035 and 070 real rpm x 4)
mm/s Nominal car velocity (at which it travels with the rpm mentioned
18.30 1000 -:- 2000 in 18.29)
19.29 360 -:- 400 mm, Pulley diameter
19.30 1 Transmission ratio
19.32 0-1 Pull/Roping: 0=1:1; 1=2:1

Table 1

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N.B. In the 18.29 parameter the real motor velocity multiplied by four is set. This correction factor is
necessary because the CT inverter is capable of recognising a maximum of 20 poles and as the MDD
motor has 80, it is therefore necessary to multiply this 18.29 parameter by four in order to obtain the
revolutions desired.
For the same reason the parameter 5.11 shows 20 poles although the motor has 80 and in the
parameter 16.12 there are 256 sinusoids indicated per rotation of the SinCos encoder when in realty
there are 1024.

CONFIGURATION PARAMETERS SET ON THE


DRIVE CONTROL TECHNIQUES FOR MDD

PAR. MDD070 FD Description ("Control Techniques" service: 0039 - 02 575751;


3378474972)
8.14 1 Logic on the brake relay (0= negative logic, 1= positive logic)
8.27 0 Selects the common of the inputs: if =0 it is the 31; if =1 it is the 22.
18.11 200 -:- 1600 Intermediate car velocity in mm/s
18.12 200 -:- 1600 Intermediate car velocity in mm/s
18.13 200 -:- 1600 Intermediate car velocity in mm/s
18.14 200 -:- 1600 Intermediate car velocity in mm/s
18.15 200 -:- 1600 Intermediate car velocity in mm/s
18.16 200 -:- 1600 Intermediate car velocity in mm/s
18.17 200 -:- 1600 Intermediate car velocity in mm/s
18.18 200 -:- 1600 Intermediate car velocity in mm/s
19.25 500 -:- 1000 ms, brake release delay in milliseconds

Table 2

The CT inverter protection fuses must be dimensioned according to the following table.

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INVERTER FUSE
MODEL RATING

UNI2401 16 A

UNI2402 20 A

UNI2403 35 A

UNI3401 40 A

UNI3402 50 A

For more details regarding the installation and the configuration of the inverter it is possible to
download instruction manuals from the web site http://www.montanari-giulio.com/download or to
consult the official Control Techniques web site http://www.controltechniques.com

Attention: The drive-gearless supplied by ourselves, leave the Montanari


establishment already “phased”, and therefore do not need to undergo the automatic search procedure
for the magnetic poles which is normally used by setting the Control Techniques inverter parameter
#0.40 to “1”.
If re-calibration is necessary, because there have been dismantling activities or the encoder or the CT
drive have been replaced, then it is important to remember that this operation must be carried out with
the gearless without cables and without load, otherwise there is a risk that there will be a decline in
the phasing and a considerable decrease in the performance or even the complete failure to function.
In the event of rephasing, the indications in the CT manual must be respected or the Montanari Giulio
& C. S.r.l. technicians should be consulted.
It is also important to remember that after having changed the #0.40 to “1” and after having enabled
the drive (terminals 30 and 31 on the CT signal terminal board), the rotation that follows must be in a
clockwise direction looking at the motor from the pulley side. If this is not the case it means that a
power cable between the CT and the gearless has been inverted.

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MDD070 TECHNICAL CHARACTERISTICS
Winding connection Star Delta

Type of motor Brushless

Number of polar couples 40

(*) Rated power (kW) 11,2 14,4

(*) Rated revolutions RPM (n/min) 106,1 169,8

Rated current (A) 25,8 34,7


(*) Rated torque (Nm) 826 661

(*) Maximum revolutions (RPM) 170

Revolutions at 50 Hz 75
(*) Peak current at max torque and max RPM
53 78
(A)
(*) Maximum torque (Nm) 1700 1500

Torque constant (Nm/A) 32 19


Voltage c.e.m.f. at 100 RPM (V)
210 125
(contact electromotive force ???)
Approximate phase resistance (ohm) 0,71

Inverter voltage input (V) 380 – 460

Inverter input power frequency (Hz) 50 – 60

Inverter output power frequency (Hz) 0 – 70,7

Static load (kg) 3500 0 – 113,2

Moment of inertia (kgm^2) 8,2

Weight (kg) 420

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GEARLESS MDD035 TECHNICAL CHARACTERISTICS
Winding connection Star Delta

Type of motor Brushless

Number of polar couples 40

(*) Rated power (kW) 4,3 5,4

(*) Rated revolutions RPM (n/min) 106,1 169,8

Rated current (A) 15,8 22,1


(*) Rated torque (Nm) 330 278

(*) Maximum revolutions (RPM) 170

Revolutions at 50 Hz 75
(*) Peak current at max torque and max RPM
40,6 47,6
(A)
(*) Maximum torque (Nm) 850 600

Torque constant (Nm/A) 20,9 12,6

Voltage f.c.e.m at 100 RPM (V) 273,6 157,9

Approximate phase resistance (ohm) 0,95

Approximate phase inductance (ohm) 4,27

Inverter voltage input (V) 380 – 460

Inverter input power frequency (Hz) 50 – 60

Inverter output power frequency (Hz) 0 – 70,7 0 – 113,2

Static load (kg) 3500

Moment of inertia (kgm^2) 8,2

Weight (kg) 400

NOTE (*): The above mentioned characteristics are to be considered as absolute values. In other
words they are certainly achievable individually but not necessarily simultaneously.

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A few examples:
• The maximum torque will not be achievable at the maximum number of revs with the star
connected motor because the voltage limits will be reached.
• The rated torque is considered in an environment at 20C°.

Note:
1. The power terminal board of the CT Drive shown in this diagram is for drives of the size 3 (3401
and 3402). The smallest drives have a screw terminal board with the same layout and
nomenclature.
2. The delta or star connection (as shown in the figure), carried out on the motor terminal board,
must for no reason be modified with respect to the Constructor’s initial settings.
3. The connection diagrams shown in these pages are purely indicative and do not include all the
auxiliary circuitry that is necessary for the lift to function correctly and to respect the current
standards in the End-User countries. It is the responsibility of the installer
1.1.1.1.1.1 R to interpret these
F
requirements and to adapt our circuit examples to these various applications.
I

5.11 ELECTRICAL CONNECTIONS OF THE BRAKES ON THE GEARLESS MDD070-035


FD

The two disc brakes on the gearless MDD070-035 FD are supplied with two wires for the supply of
continuous current to the coil and two wires that are connected to a NC contact situated within the
brake itself. NC contact means that a microswitch is closed when the brake is closed (motor braking)
and opened when vice versa the brake is open (coil energised). The brake coils are separate and can be
linked in series or in parallel depending upon the characteristics of the system input.
If the PWM booster is used then they must be connected in series.
This device is calibrated according to the amount of time and the current necessary for the correct
operation of the brakes. The modification of the calibration of the booster current and time trimmers is
absolutely forbidden.

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Electrical characteristics of each single brake

Input: 45 Vdc. – 33 Watt.


Overexcitation: 95 Vdc. – 148 Watt.

5.12 PWM BOOSTER

The PWM Booster is a device that enables the control of the magnetic brake and manages the
overexcitation. This booster must be powered at 220 Vac 50 -:- 60 Hz in it’s J1 input terminals.
The Booster output must be connected, using the J2 terminals, to the motor’s electromagnetic brake
terminals, see figure.
The booster is protected at input by a 4A internal fuse.
When the booster is powered in J1, we have a continuous current output equal to I-Boost for the
T-Boost time. After the T-Boost time the current assumes a constantly I-Nom value until the booster
is powered.

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In the figures the block diagrams of the PWM assembly and its operating diagram are shown.

Brake
command
relay

220Vca

Solenoid brake

PE

Operating diagram

220Vca of
input

I-boost I-nom

Output
Brake
Current
Time
T-boost

The current amplitude, in the extra current opening phase is adjustable from 0 to 2,8 A (I-BOOST).
The current amplitude, in the opening maintenance phase is adjustable from 0 to 2,8 A (I-NOM).
The duration of the extra current opening phase is adjustable from 100 to 1100 msec (T-BOOST).
These three parameters, two currents and one time, can be adjusted by means of the three trimmers,
TR2, TR3, TR4 situated on the booster. These trimmers have a value of zero when they are rotated
completely in a clockwise direction. The boosters come already supplied with the necessary
calibration. All responsibility is declined for any incorrect functioning of the brake due to tampering
with the PWM booster trimmers.
The PWM chopper frequency is 500 Hz.

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The brake current output is speeded up during the opening to increase the brake closing velocity by
means of the suppression with MOV rather than a circulation diode, only during the release of the 220
control Vca.
The maximum load allowed is relative to a duty cycle of 50% on a cycle of 60 s.
The delay in the brake release, from 220 Vca at input to released brake, is 30 ms.
The brake current descent ramp is of 80 ms from I-nom to I<10 mA .

Graphical representation of the PWM

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107 mm

Not
used

220 Vca
Earth
220 Vca
2,5 – 1 A dc To the brake

195 mm

Not
used

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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 Brake
The brake has been designed in conformance with the specific requests of the EN81-1 standard, in
particular it is in conformance with paragraph 9.10.
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 ABV589 type and is issued by TÜV B.B.
6.3 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 Brake
At least once a year check the amount of wear on the brake pads carrying out a braking test as
described in the EN81-1 standard, appendix D.2.

AAAAA
Via Bulgaria,39 - 41100 MODENA (Italia)
Tel. +39-059 453611 - Fax +39-059 315890
www.montanari-giulio.com - montanari@montanari-giulio.com
7.3 Component substitution
The instructions for any eventual component substitutions must be asked for each time from the
Technical Department, specifying the serial number.
7.4 Table of the tightening torque for screws and bolts

Screws with an ISO large pass class 8.8.


thread
Diameter Torque (Nm.)
M8 25
M10 50
M12 86
M14 135
M16 215
M18 290
M20 410
M22 560
M24 710

AAAAA
Via Bulgaria,39 - 41100 MODENA (Italia)
Tel. +39-059 453611 - Fax +39-059 315890
www.montanari-giulio.com - montanari@montanari-giulio.com
8 Declaration of Conformity

DECLARATION OF CONFORMITY
(Directive 98/37/CE, Art. 4.2 and Attachment II, par. B.)

We hereby declare that the gearless models:


MDD035 – MDD070.

- are constructed to be incorporated within an existing system or to be assembled with other


components during the construction of a new system in accordance with the 98/37/CE
directive and successive modifications;
- are nevertheless not in conformance with all the single regulations of the aforementioned
directive;
- are in conformance with the conditions of the following directives
95/16/CE and 89/336/EEC
and that
- the following Harmonised standards (parts/clauses of) have been applied:
EN81.1 ; EN55011 ; EN55014 ; EN50081-2 ; EN12015/6.

We also declare that


- the operation of the gearless is not permitted until the existing or new system of which it will
be a part, has been tested and declared in conformance with the 95/16/CE Directive or the
98/37/CE Directive as well as the respective National legislation, in other words, until the
gearless mentioned in this documentation has become a single assembly together with the
system in which it is inserted.

The violation of the provisions laid out in these technical instructions will result in the
immediate expiration of all the product warranties.

Note:
With regards to the fulfilment of point 9.7 of the EN81-1 1998 reference standard, you are
reminded that Montanari provides the protective devices only upon explicit request from the
customer.

Signature of authorised Representative…………………………………………

Date, the …………

AAAAA
Via Bulgaria,39 - 41100 MODENA (Italia)
Tel. +39-059 453611 - Fax +39-059 315890
www.montanari-giulio.com - montanari@montanari-giulio.com

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