Montanari MGV25 Series User guide

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REV:3_03_2020
MANUALS
MGV25 RANGE
INSTALLATION, USE AND MAINTENANCE
GEARLESS

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MGV25 S-M-ML-L ENGLISH
Thank you for choosing a Montanari product.
Since 1970, Montanari Group has been focused on
providing its customers with the best traction machines and
components for lifts and escalators.
We are proud to have you as a customer and user of the
Montanari traction machines, and we are confident that we
can work together for a long time.
Thanks again for your choice.
Massimo Montanari
CEO of Montanari Group

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REV. DATE DESCRIPTION EDITED BY VERIFIED BY APPROVED BY
3 25/03/2020 First Redaction Marketing Dept Technical Dept
Alberto Mantovani
STEFANO BERTONI
(DTE)
WARNING SYMBOLS
USED IN THE MANUAL:
TIP
!
!
It indicates that safety measures must
be taken to avoid electric shock.
It indicates that safety measures must
be taken to prevent personal injury.
It indicates that safety measures
must be taken to prevent damage to
components.
It indicates that safety measures must
be taken to prevent burns due to
contact with hot/ overheated surface.
It indicates useful information before
and during the installation step.
It refers to specific parts of the
manual.
It refers to the proper product
disposal.

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MGV25 S-M-ML-L ENGLISH
CONTENTS
1. GENERAL INFORMATION .....................................................................7
1.1 Introduction............................................................................................7
1.2 Copyright ...............................................................................................7
2. SAFETY...................................................................................................8
2.1 Intended use ..........................................................................................8
2.2 User’s obligations ...................................................................................8
2.3 Correct disposal ...................................................................................9
2.4 Specific hazards......................................................................................9
2.5 Legal References ....................................................................................9
3. IDENTIFICATION AND DATA ................................................................9
3.1 Identification plate .................................................................................9
3.2 Dimensions...........................................................................................13
4. TRANSPORT AND STORAGE ..............................................................16
4.1 Handling...............................................................................................16
4.2 Storage.................................................................................................17
5. DESCRIPTION ......................................................................................18
5.1 General description..............................................................................18
5.2 Main components ...............................................................................18
5.3 Brake ....................................................................................................19
6. INSTALLATION.....................................................................................19
6.1 General installation information ...........................................................19
6.2 Installation surface................................................................................20
6.3 Installation procedure...........................................................................20
6.4 Electrical installation - Connections .....................................................22
7. CONNECTION OF THE BRAKE FOR RESCUE SYSTEM......................24
7.1 Connection of the cable to the brake levers........................................24
7.2 Connection of the cable to the hand release lever..............................26
7.3 Rescue System .....................................................................................26

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8. OPERATION .........................................................................................27
8.1 Connections .........................................................................................27
8.2 Additional components........................................................................27
8.3 General operation information.............................................................27
9. TROUBLESHOOTING, MAINTENANCE AND REPAIR ........................27
9.1 General information .............................................................................27
9.2 Traction/return sheave..........................................................................28
9.3 Replacement of components ...............................................................28
9.4 Problems, causes and solutions .........................................................28
9.5 Maintenance and repair .......................................................................29
9.5.1 General indications ...........................................................................29
9.5.2 Description of maintenance activities................................................29
10. SPARE PARTS .......................................................................................30
10.1 General information ...........................................................................30
10.2 How to order spare parts ...................................................................30
11. BRAKE CERTIFICATE ...........................................................................30
11.1 Exam certificate EU-BD 845 MGV25S-M...........................................31
11.2 Exam certificate EU-BD 1014 MGV25ML-L .......................................32
12. COMPLIANCE DECLARATION ............................................................33

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MGV25 S-M-ML-L ENGLISH
1. GENERAL INFORMATION
1.1 Introduction
These operating instructions must always be available for consultation. No
liability is accepted for any malfunction due to installation not conforming to
specifications, except in cases approved by Montanari Giulio & C.
All persons involved in the installation, operation, maintenance and repair of the
unit must have read and understood the instructions.
No liability is accepted for damage, breakage or accident caused by failure to
follow the instructions.
To make technical improvements, Montanari reserves the right, if deemed
necessary, to modify the units and accessories, preserving their essential cha-
racteristics and improving efficiency and safety, without notice.
1.2 Copyright
All rights to these operating instructions belong to Montanari Giulio & C. S.r.l.
The information in this manual may not be reproduced or used in an unauthori-
zed manner or made available to third parties without prior approval.
If you have any questions, please contact:
MONTANARI GROUP
HEADQUARTER - MONTANARI GIULIO & C. Srl
Via Bulgaria 39 - 41122 - Modena - Italia
Tel: [phone] - Fax: [phone]
www.montanarigiulio.com
[email protected]

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2. SAFETY
2.1 Intended use
The MGV25 gearless machine range is supplied ready for safe and reliable use.
Any modification by the user that may affect safety or reliability is prohibited;
it is also prohibited to tamper with devices or functions designed to prevent
accidental contact.
The Montanari MGV25 gearless machine range must be used and
operated in strict compliance with the conditions set out in the supply
contract.
!
Technical specifications considered: speed, cab capacity, cab weight, presence
or absence of compensation, roping at the time of order.
No liability is accepted for any malfunction due to installation not conforming to
specifications, except in cases approved by Montanari Giulio & C.
2.2 User’s obligations
The operator must ensure that all persons involved in installation, operation,
maintenance and repair have read and understood the supplied operating
instructions and have adapted to them in order to:
• Avoid damage to property or persons.
• Ensure safe and reliable operation of the unit.
• Avoid breakage and environmental damage due to misuse.
In particular:
• Always observe the relevant environmental and safety regulations when
transporting, assembling, installing, operating, maintaining and dismantling
the unit.
• The unit must only be used, maintained and repaired by authorized, pro-
perly trained and qualified personnel.
• The gearless must not be cleaned using high-pressure cleaning equipment.
• All work must be carried out with care and with due attention to safety.
• Any work on the unit should only be carried out when it is not in operation.
• A warning must be placed on the main switch to clearly indicate that work
is in progress on the unit.
• No welding must be carried out on the unit.
• Do not use the unit as a grounding point for welding operations.
• If any changes are detected (e.g. overheating or unusual noise) during
operation, switch off immediately.
• Rotating components must be equipped with appropriate guards to pre-
vent contact.
• If the unit is intended for installation in plant or machinery, the manufacturer
of such plant or machinery must ensure that the standards, indications and
descriptions contained in these operating instructions are incorporated into its
own instructions.

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MGV25 S-M-ML-L ENGLISH
N Norm Description
1 UNI 10147 Maintenance: Terminology.
2 EN 81-20 Safety rules for the construction and installation of lifts - Lifts for the transport of persons
and goods.
3 EN 81 -50 Safety rules for the construction and installation of lifts - Examinations and tests.
4 EN 81 - 21 Safety rules for the construction and installation of lifts - Lifts for the transport of persons
and goods - Part 21: New passenger and goods passenger lifts in existing building.
3. IDENTIFICATION AND DATA
3.1 Identification plate
The data on the plate are:
• The information on the warning or identification plates must be complied
with. These plates must be kept clean and legible at all times. Missing plates
must be replaced.
• All spare parts can be obtained from Montanari Group.
2.3 Correct disposal
Respect the environment and dispose of the product according to the
regulations in force in the country of installation.
2.4 Specific hazards
Depending on the conditions of use, the surface of the unit can become very
hot.
Fig. 1
Danger of burning!
!
Manufacturer
Manufacturer’s
address
Year of production
Serial number
Gearless
machine
code
Model
Speed
Rated
voltage
Frequency
Power rating
Cycle type
Rated torque
Motor
pole no.
Rated current
Weight
QR code to access
the relevant
documentation.
2.5 Legal References Tab. 1
- Example of Identification Plate
Download
App

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Tab. 2
Tab. 3
MGV25S Type Pn
Speed Vn Cn In Cmax Imax EMF Poles F Rs Ls Static
Load IDuty
Cycle Weight
Code
machine kW [RPM] [V] [Nm] [A] [Nm] [A] [V∙s/
rad] [N°] [Hz] [Ω] [mH] [Kg] [kg∙m2] [Kg]
MGV25100452B500 MGV25S 1,15 45 210 250 11 380 17 14 16 6 3,5 33 1800 0,2 180S/H 40% 120 MGV25101152B500 MGV25S 2,8 115 210 235 13,5 320 19 10 16 15,3 2 18 1800 0,2 180S/H 40% 120 MGV25100603B500 MGV25S 1,5 60 360 250 8,1 460 15 20 16 8 6,8 64 1800 0,2 180S/H 40% 120 MGV25101203B500 MGV25S 3,1 120 360 250 11 460 21 14 16 16 3,5 33 1800 0,2 180S/H 40% 120 MGV25101923B500 MGV25S 5 192 360 250 14,5 460 28 11 16 25,6 1,85 18 1800 0,2 180S/H 40% 120 MGV25102803B500 MGV25S 7,6 292 360 250 19 460 36 8 16 37,3 1,2 11 1800 0,2 180S/H 40% 120 MGV25103603B500 MGV25S 8,3 360 360 220 19,5 460 43 7 16 48 0,78 8 1800 0,2 180S/H 40% 120 MGV25105103B500 MGV25S 11,7 510 360 220 26 460 56 3 16 68 0,46 4 1800 0,2 180S/H 40% 120
BRAKE CHARACTERISTICS
Model Brake model Power Voltage Current Braking
Force
Certificate
[W] [V] [A] [Nm]
MGV25S RTW250 2X79W 207VDC 0.4A 2X270Nm EU-BD 845
GEARLESS MACHINE TECHNICAL CHARACTERISTICS: MGV25S

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MGV25 S-M-ML-L ENGLISH
MGV25M Type Pn
Speed Vn Cn In Cmax Imax EMF Poles F Rs Ls Static
Load IDuty
Cycle Weight
Code
machine kW [RPM] [V] [Nm] [A] [Nm] [A] [V∙s/
rad] [N°] [Hz] [Ω] [mH] [Kg] [kg∙m2] [Kg]
MGV25150803B700 MGV25M 3,2 80 360 385 12 665 21 20 16 10,7 3,8 40 3400 0,2 180S/H 40% 180 MGV25151203B700 MGV25M 4,8 120 360 385 15 665 27 15 16 16 2,25 25 3400 0,2 180S/H 40% 180 MGV25151923B700 MGV25M 7,7 192 360 385 20 665 36 12 16 25,6 1,4 15 3400 0,2 180S/H 40% 180 MGV25152803B700 MGV25M 11,3 280 360 385 27 665 50 9 16 37,3 0,75 8 3400 0,2 180S/H 40% 180 MGV25153803B700 MGV25M 15,3 380 360 385 35 665 62 7 16 50,7 0,47 5 3400 0,2 180S/H 40% 180
GEARLESS MACHINE TECHNICAL CHARACTERISTICS: MGV25M
BRAKE CHARACTERISTICS
Model Brake model Power
(Pn)
Voltage
(Vn)
Current (In) Force (Cn) Certificate
[W] [V] [A] [Nm]
MGV25M RTW350 2X 82 W 207VDC 0,4 A 2X410 Nm EU-BD 845
Tab. 4
Tab. 5

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MGV25ML Type Pn
Speed Vn Cn In Cmax Imax EMF Poles F Rs Ls Static
Load IDuty
Cycle Weight
Code
machine kW [RPM] [V] [Nm] [A] [Nm] [A] [V∙s/
rad] [N°] [Hz] [Ω] [mH] [Kg] [kg∙m2] [Kg]
MGV25200803BC00 MGV25ML 4,4 80 360 530 15 915 27 20 16 10,7 2,8 32 3400 0,28 180S/H 40% 220 MGV25201203BC00 MGV25ML 6,7 120 360 530 19 915 35 16 16 16 1,8 20 3400 0,28 180S/H 40% 220 MGV25201923BC00 MGV25ML 10,7 192 360 530 25 915 47 12 16 25,6 0,96 11 3400 0,28 180S/H 40% 220 MGV25202553BC00 MGV25ML 14,2 255 360 530 34 915 62 9 16 34 0,62 7 3400 0,28 180S/H 40% 220 MGV25203003BC00 MGV25ML 16,6 300 360 530 37 915 68 8 16 40 0,47 5 3400 0,28 180S/H 40% 220
MGV25L Type Pn
Speed Vn Cn In Cmax Imax EMF Poles F Rs Ls Static
Load IDuty
Cycle Weight
Code
machine kW [RPM] [V] [Nm] [A] [Nm] [A] [V∙s/
rad] [N°] [Hz] [Ω] [mH] [Kg] [kg∙m2] [Kg]
MGV25260603BC00 MGV25L 4 60 360 630 15 1100 27 24 16 8 3,2 37 3400 0,31 180S/H 40% 240 MGV25261203BC00 MGV25L 7,9 120 360 630 22 1100 40 18 16 16 1,5 18 3400 0,31 180S/H 40% 240 MGV25261603BC00 MGV25L 10,6 160 360 630 28 1100 49 14 16 21,3 0,95 11 3400 0,31 180S/H 40% 240 MGV25262103BC00 MGV25L 13,9 210 360 630 32 1100 59 11 16 28 0,65 8 3400 0,31 180S/H 40% 240 MGV25262553BC00 MGV25L 16,8 255 360 630 40 1100 71 10 16 34 0,47 5 3400 0,31 180S/H 40% 240 MGV25263603BC00 MGV25L 23,7 360 360 630 52 1100 91 7 16 48 0,28 3 3400 0,31 180S/H 40% 240
GEARLESS MACHINE TECHNICAL CHARACTERISTICS: MGV25ML
BRAKE CHARACTERISTICS
Model Brake model Power (Pn) Voltage (Vn) Current (In) Force (Cn) Certificate
[W] [V] [A] [Nm]
MGV25ML-L RTW600 2X 372W – 2X 92W 207VDC-PEAK - 104VDC-HOLD 1.8A – 0.9A 2X600Nm EU-BD 1014
Tab. 6
Tab. 7
Tab. 8
GEARLESS MACHINE TECHNICAL CHARACTERISTICS: MGV25 L

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MGV25 S-M-ML-L ENGLISH
3.2 Dimensions
The technical drawings and the overall dimensions follow.
Fig. 2
MGV25S
Gearless Type Traction Sheave[mm]
Ø D F
Dimensions [mm]
A B C E*
MGV25S
160 88
500
300 344 55
210 80
240 80 300 344 55
320 75 342 357 52
Tab. 9
ØD
F
A
E115 ,5 110
49 ,5 67 49 ,5 15331
17 ,5Ø
115 115
264
B
15
149
C
170
Ø8,5

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Fig. 3
MGV25M
Tab. 10
MGV25M
Pulley Ropes Dimensions
ØD F Ø min - max Pitch A B C E
mm mm n° mm mm mm mm mm
210 106 6,5 3 - 8 12
568
301 344 55
9 - 10 9,5
240
70
6,5
3 - 8 12
9 - 10 9,5
106 3 - 8 12
9 - 10 9,5
320
80
8
3 - 6 17
342 357 52
115 7 13
8 12
F
A
ØD
E127160
49 11749 14 831
176
B
Ø8,5
149
C
15
17 ,5Ø
115 115
264

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MGV25 S-M-ML-L ENGLISH
Tab. 11
MGV25ML - L
Pulley Ropes Dimensions
ØD F Ø min - max Pitch A B C E
mm mm n° mm mm mm mm mm
210 106 6,5 3 - 8 12
689
315
362
64
9 - 10 9,5
240
70
6,5
3 - 8 12 55
9 - 10 9,5
106 3 - 8 12 64
9 - 10 9,5
320 115 8
3 - 4 17
342 67
7 13
8 12
ØD
E127 260
50 219 50 199
Ø9
F
A
195
B
167
C
14
115 115
262
17,5Ø
Fig. 4
MGV25ML - L

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Only use lifting systems and equipment with adequate lifting capacity
for handling. The entire packaging is designed to allow movement with
for lift and for lift truck.
!
4. TRANSPORT AND STORAGE
4.1 Handling
All gearless machines are packed in crates or cages.
Different types of packaging can be used, depending on the size and means
of transport. Unless otherwise specified, the packaging complies with the HPE
guidelines.
In some cases, the machines are mounted on wooden pallets to enable them to
be transported correctly on trucks. The packaging may not be stacked in any way.
It is recommended to check the conditions of the material when it is received. In
case of damage, do not proceed with the installation unless expressly authorized
by Montanari Giulio & C. Observe the symbols on the packaging to prevent da-
mage to property or personal injury. Here are the meanings of the symbols that
may appear on the packaging.
Keep dry Handle with care
Upper side Do not use hooks
Fragile Center of gravity
Keep away from
heat sources
Attachment point

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MGV25 S-M-ML-L ENGLISH
For lifting, anchor points (eyebol-
ts) are provided as shown in Fig.
5.
Use only the specified eyebolts to
handle the unit.
Fig. 5
! !
4.2 Storage
The gearless machine must be stored in the position of use on a wooden base
not subject to vibrations, in a covered and sheltered place.
If the unit is stored outdoors, it should be covered, taking care that no
moisture and/or other foreign matter can accumulate on it.
!
Supplies for special environmental conditions during transport (e.g.
by ship) and storage (climate, temperature, etc.) must be contractually
agreed.
!
• Check the correct operation of the motor and brake after installation.
• Repairs may only be carried out by the manufacturer or by authorised per-
sonnel.
• The machine can be red-hot.
• These machines must be connected to inverters.
• When the machine is rotating, both manually and mechanically, it can act as
a generator and produce high voltage.
• During configuration, the machine is powered by high voltage.
! !

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5. DESCRIPTION
5.1 General description
The MGV25 series gearless machines are permanent magnet motors with dou-
ble brake system.
5.2 Main components
The unit consists of the main groups as shown in Fig. 6.
MGV25 range is equipped with a PTC thermal probe inside the windings to
protect against overheating (winding temperature up to 130°C) and with a ther-
mo-contact for the activation of the fans. Refer to the electrical connections for
more details. - See Par. 6.4.
Lubrication
The gearless machine contains no oil and it is supplied with bearings
already lubricated throughout the life of the machine; no further lubri-
cation is required.
!
Standard
guards
Fig. 6
Cooling fans
Pulley
Fixing holes
Motor cable
outlet
Brake levers
MGV25
Brake guard
Brake detail
Movable surface/brake
Encoder
Brake electromagnet

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MGV25 S-M-ML-L ENGLISH
5.3 Brake
The gearless machine is supplied with a brake that conforms to the standards
indicated in paragraph 2.5.
The brake system is pre-calibrated by the manufacturer and no further adjustment
is required.
The brake system operates as follows:
• Not powered (electromagnet not powered): the brake disc is clamped by
the movable surfaces (yellow arrows Fig. 7). In this condition the system does
not move.
• When the brake electromagnet is powered, it releases the brake disc
(yellow arrows Fig. 8); now the motor is released.
!!
AIR GAP 0,5 mm AIR GAP 0 mm
Brake system not powered Brake system powered
Fig. 7 Fig. 8
6. INSTALLATION
6.1 General installation information
The gearless machine must be installed in a building or in a closed travel com-
partment.
Do not use the gearless machine in an explosive atmosphere.
The room temperature must be between 0°C and +40°C.
Assembly and installation must be carried out with great care by qualified and
trained personnel.
The manufacturer cannot be held responsible for damage caused by incorrect
assembly or incorrect installation.
Before starting work, make sure that adequate lifting and handling equipment
is available.
No welding work must be carried out on the unit.
The unit must not be used as a grounding point for welding operations. The
bearings can be irreparably damaged.
All fixing points specified by the manufacturer must be used.
! !

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Fig. 9
The air supply for cooling must not be prevented.
6.2 Installation surface
The installation surface must be uniform and level.
The levelling tolerance is 0.1 mm.
The installation surface must be rigid and robust enough to withstand the forces
involved.
6.3 Installation procedure
The gearless machine can be lifted using the eyebolts for the insertion of the
belts or lifting chains (see also the paragraph on storage and handling). Particular
attention is needed to avoid that the gearless machine receives blows in corre-
spondence of the brake disc; the brake levers and the electrical connections of the
board are very delicate. Lifting example Fig. 9.