Mayr ROBA-brake-checker plus AC Quick start guide

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 1 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
11
Guidelines on the Declaration of Conformity
A conformity evaluation has been carried out for the product in terms of the EU Low Voltage Directive 2014/35/
EU, the Electromagnetic Compatibility (EMC) Directive 2014/30/EU and RoHS 2011 / 65 / EU with 2015 / 863
EU.
The Declaration of Conformity is laid out in writing in a separate document and can be requested if required.
Guidelines on the EMC Directive (2014/30/EU)
The product cannot be operated independently according to the EMC directive.
Only after integration of the product into an overall system can this be evaluated in terms of the EMC.
For electronic equipment, the evaluation has been verified for the individual product in laboratory conditions,
but not in the overall system.
Guidelines on the EU Directive 2011 / 65 / EU (RoHS II) with 2015 / 863 EU (RoHS III - from 22
July 2019), which restrict the use of certain hazardous substances in electrical and electronic devices as well
as in products / components (category 11), the proper operation of which is dependent on electric currents
and electromagnetic fields.
Guidelines on the Machinery Directive (2006/42/EC)
The product is a component for installation into machines according to the Machinery Directive 2006/42/EC.
The product can fulfil the specifications for safety-related applications in coordination with other elements.
The type and scope of the required measures result from the machine risk analysis.
The product then becomes a machine component and the machine manufacturer assesses the conformity
of the safety device to the directive. It is forbidden to start use of the product until you have ensured that the
machine accords with the regulations stated in the directive.
Guidelines on the ATEX Directive
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger
of explosion. For application of this product in areas where there is a high danger of explosion, it must be
classified and marked according to Directive 2014/34/EU.
Guidelines on the REACH Regulation (EC No. 1907/2006)
of the European Parliament and of the Council Concerning the Registration, Evaluation, Authorisation and Re-
striction of Chemicals. This regulates the manufacture, placing on the market and use of chemical substances
in preparations, under certain conditions also pertaining to substances in products. mayr ®power transmission
exclusively manufactures products articles: clutches/couplings, electric motors, brakes and the appropriate
rectifiers) in accordance with the definition in Article 3 Section 3 of the REACH Regulation.
11

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 2 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
22
Safety and Guideline Signs
DANGER
Immediate and impending danger, which
can lead to severe physical injuries or to
death.
CAUTION
Danger of injury to personnel and damage
to machines.
Guidelines on important points
General Safety Guidelines
DANGER
Danger of death! Do not touch voltage-
carrying lines and components.
DANGER
Danger of burns when touching hot
surfaces.
CAUTION • Danger of device failures caused by
short-circuits and earth short-circuits at
the terminals
• Electronic devices cannot be guaranteed
During the risk assessment required when designing the ma-
chine or system, the dangers involved must be evaluated
and removed by taking appropriate protective measures.
To prevent injury or damage, only professionals
and specialists are allowed to work on the devices.
They must be familiar with the dimensioning, transport, in-
stallation, initial operation, maintenance and disposal ac-
cording to the relevant standards and regulations.
Before product installation and initial opera-
tion, please read the Installation and Opera-
tional Instructions carefully and observe the
Safety Regulations. Incorrect operation can
cause injury or damage.
General Safety Guidelines
Only carry out installation, maintenance and
repairs in a de-energised, disengaged
state and secure the system against inad-
vertent switch-on.
22

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 3 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
33
Function
The ROBA®-brake-checker plus AC monitoring module is
intended for use with an input voltage of 200 to 480 VAC.
The monitoring module supplies the connected brakes and
regulates to a permanently programmed overexcitation
voltage. After the overexcitation time ends, it regulates to
the permanently programmed holding voltage.
The overexcitation time is set automatically.
The monitoring module monitors the movement of the arma-
ture disk and emits the determined switching condition via
control terminal 3 (signal output).
Critical conditions (line breakages, wear) can be recognized
and the respective signal can be emitted via control terminal
4 (error output).
The movement detection feature of the armature disk is
based on the detection of electromagnetic changes in
the brake. If, due to unfavourable external influences, the
secured detection cannot be ensured, it is possible that the
signal and error outputs do not correspond to the expected
state (plausibility).
CAUTION The ROBA®-brake-checker cannot be used
in all applications (e.g. when operating
noise-damped brakes, it cannot be used
without additional measures). The product’s
suitability should be checked before use.
Application
ROBA®-brake-checker plus AC monitoring modules are
used to connect permitted ROBA®-stop safety brakes to AC
voltage.
Motion monitoring of the armature disk for released ROBA-
stop®safety brakes is possible.
Monitoring module ROBA®-brake-checker plus AC
• Consistently controlled output voltage
• Consumer operation with overexcitation or power reduc-
tion
• Input voltage: 200 – 480 VAC
• Supply voltage with 50 or 60 Hz
• Max. output current IRMS: 2 A
• Sensorless and contactless detection of switching
statuses
• Motion recognition of the brake (release and drop-out
recognition of the armature disk)
• Preventative function monitoring (wear recognition and
error recognition, functional reserve)
• Continuous drop-out recognition
• Simple installation or retrofitting
• Electrical isolation on the output channels
66
14.8
31.5
42.3
15
96
17.8
70.8
Dimensions (mm)
The UL information applies only when the UL mark is
printed onto the product label.
The use of the ROBA®-brake-checker in
combination with brakes of other manuf-
acturers is not intended and expressly not
approved by mayr®power transmission.
In these cases, operation is at your
own risk, the guarantee and service
and support provided by mayr®power
transmission no longer apply.
33

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 4 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
44
Technical data
Brake nominal voltage 104 VDC 180/207 VDC
Supply voltage,
power terminal acc. DIN 50160 UI[VAC] 200 – 480 / 320 1)
Input voltage (control
terminal)
SELV/PELV Ripple
content ≤5 % UI[VDC] 24
(7 - 30)
Output voltage
Reduction
UO[VDC] 104 207 2)
UH[VDC] 52 104
Output voltage
overexcitation
UO[VDC] 185 360 2)
UH[VDC] 104 185 2)
Output current
at ≤45 °C IRMS [A] 2
at ≤60 °C IRMS [A] 1
at ≤70 °C IRMS [A] 1
Terminals
Control terminal Nominal cross-section 0.34 – 2.5 mm² (22 – 14 AWG)
tightening torque screws: 0.29 Nm/3.5 lb-in
Power terminal Nominal cross-section 0.2 – 2.5 mm² (22 – 14 AWG)
tightening torque screws: 0.5 Nm/7 lb-in
Device fuses
Control terminal Fuse 315 mA, slow acting
Power terminal Max. 2 A circuit breaker, characteristic K/Z
(rated brake current)
Device ambient temperature [°C] -25 to +70 / -25 to +60
Storage temperature [°C] -40 to +105
Conformity markings /
Protection IP20
Installation conditions
The installation position can be user-defined.
Please ensure sufficient heat dissipation and air convection!
Do not install near to sources of intense heat!
1) CSA-C22.2 No. 14-18
2) Approx. 0.9 × UI (supply voltage, power terminal)
Preventative function monitoring
Through the monitoring of different parameters, the ROBA®-brake-checker recognises safety critical operating conditions of the
brake in advance, as well as acute faults (e.g. line breakage). These are determined as they occur and are notified to the user
as a warning before the brake can no longer be operated.
Only the mechanical switching function is checked. Conclusions on the braking torque are not possible (e.g. reduced friction
value due to oiling of the brake lining)
Possible causes for the warning:
• Increasing wear
• Rising coil temperature
• Falling supply voltage
• Line voltage drop on feed lines to the brake
Size Type Input voltage
±10 % acc. EN50160
Output voltage
± 10%
Brake volt-
age
Operation mode Article number
[VAC] UO[VDC] UH[VDC] [VDC]
20 029.700.2
200 - 275 104 52 104 power reduction 8269426
230 - 480/320 1) 207 2) 104 207 power reduction 8269424
200 - 480/320 1) 185 104 104 overexcitation 8264926
400 - 480/320 1) 360 2) 185 2) 207 overexcitation 8269425
44

+
-
24 VDC
L1
L2
L3
M
3 ~
+
-
24 VDC
L1
L2
L3
M
3 ~
Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 5 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
55
Electrical connection
Control terminal
1 Input voltage +24 VDC
2 Input voltage 0 VDC
3 Signal (output) max. 100 mA
4 Error (output) max. 100 mA
Electrical connection
Power terminal
11 F/S (see wiring examples)
12 F/S (see wiring examples)
13 Output voltage -
14 Do not assign!
15 Do not assign!
16 Output voltage +
17 Supply voltage VAC
18 Supply voltage VAC
Outputs
Signal 3
0 VDC (low) Brake is not energised, movement of the armature disk for
closing the brake.
24 VDC (high) 2) Brake energised, movement of the armature disk for opening
the brake.
Error
4
24 VDC (high) 2) no errors
0 VDC (low) Brake does not open or close, line interruption, false detec-
tion
Warning 1) Preventative function monitoring (wear recognition and error
recognition, functional reserve)
1) Rectangular signal 10 Hz / 24 Vpp
2) Voltage corresponds to input voltage of control terminal
DANGER Danger of death! Do not touch voltage-
carrying lines and components.
No mains separation!
Voltage control through phase angle control
system
Wiring Example
(400 VAC,
DC-side, fast switching)
Wiring Example
(400 VAC,
AC-side, slow switching)
55

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 6 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
66
Interruption of the voltage at control terminal 1 Supply volt-
age +24 VDC: All outputs (signal, error, warning) are re-set:
• Signal (output) is set to 0 VDC (low)
• Error (output) is set to 24 VDC (high)
Reset
Frequency Change (50/60 Hz)
After a frequency change in the input voltage, the switching-
on process (energisation) is not detected, or an error is
indicated.
• Switch on (energise) the brake again
• After this “initialisation switching“, the ROBA®-brake-
checker can be operated as normal.
Inching Mode
During inching mode (fast sequence of switching on and
off), no reliable detection is possible.
After the end of inching mode, restart the monitoring
function:
• De-energise the brake
• Switch on (energise) the brake again
Repeated switch-on (energisation) before the brake is closed
generates a fault when the maximum current is reached.
Start process
During each individual start process, all outputs (signal,
error, warning) are reset.
The outputs must be assessed for the plausibility of signal
conditions, signal changes and their correct temporal
sequence.
Functional Guidelines
Switch-ON
Switch-on always takes place AC-side, as only then is the
overexcitation activated.
Switch-OFF
If short switching times are required, please
switch DC-side. The AC-side should always
be switched as well, in order to activate the
overexcitation.
If a longer brake engagement time or a quieter switching
noise is required, please switch AC-side. For this, a bridge
must be installed between terminals 11 and 12.
Operation on Transformers
During operation on a transformer, please ensure sufficient
rigidity on transformers (min. 3xPNof the brake).
A filter or external varistor must be installed.
Please ensure that the standard EN 50160 is kept to and
that this is re-checked after installation of the ROBA®-
brake-checker.
Overexcitation
On overexcitation, the brake is initially energised with a
voltage higher than the nominal voltage. This decreases the
separation time t2.
MTTF 140 years at 60 °C
200 years at 40 °C
Duration of use 20 years
The basis of the MTTF calculation forms (if available) the
information of the component manufacturer supplemented
by the information from the Siemens standard SN 29500.
The simplified Parts Count procedure ISO 13849-1 has been
used for the calculation.
The switching time t2of the brake can increase by 20 - 60
ms.
Reliability Nominal Values
Time Delays
Switching Times
Recovery Time 20 ms
Reset >20 ms
Signal delay approx. 40 ms
overexcitation 2 ×t2+ 200 ms
66

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 7 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
77
EMC-compatible Installation
The measure described for compliance with the EMC
directive is examined under laboratory conditions, and cannot
necessarily be bindingly transferred onto the condition of a
machine or system in case of deviations.
Scope of the inspection:
• Monitoring module ROBA®-brake-checker
• released ROBA®-stop safety brake
• Input voltage up to 500 VAC
Measure
Installation of a line filter in the AC-supply line
(e.g. Schaffner FN2415-10-29)
• Avoid antennae effects:
Keep the supply cables as short as
possible;
do not form rings or loops with the
cables!
• Mount good earth connections onto the
metal body of the brake!
• Lay control cables separately from power
cables or from strongly pulsating supply
cables!
• During operation with a frequency con-
verter, please ensure EMC-compatible
installation of the frequency converter!
• Please always check the holding voltage
during operation of all components in the
system!
• For operation in residential and small
business areas, special precautions must
be taken in order to keep to the correct
limit values for these areas with the com-
plete system.
77

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Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 8 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
88
Intended Use
ROBA®-brake-checker products have been developed,
manufactured and tested as electronic equipment in
compliance with the DIN EN 50178 standard and in
accordance with the EU Low Voltage Directive. During
installation, operation and maintenance of the product, the
requirements for the standard must be observed. ROBA®-
brake-checker products are for use in machines, systems
and devices and must only be used in the situations for
which they are ordered and confirmed. The products are
designed for installation into electrical control cabinets and
terminal boxes. Using them for any other purpose is not
allowed.
Basically:
Apply supply voltage 24 VDC (control terminal) before
switching input voltage VAC (power terminal). Otherwise an
error can occur.
Coil Capacity
If the switching frequency is higher than
1 cycle per minute or if the overexcitation
time tOis longer than double the separation
time t2, please observe the following:
P ≤ PN
The coil capacity P must not be larger than
PN or the nominal current IRMS which flows
through the ROBA®-brake-checker must not
be exceeded, as otherwise the coil and the
ROBA®-brake-checker can fail due to ther-
mal overload.
At high input voltage and low brake perfor-
mance, the initial bridge rectification of 50
ms can lead to thermic overload.
Calculations:
P [W] RMS coil capacity dependent on switching fre-
quency, overexcitation, reduction in capacity
and duty cycle
P=
POx tO+ PH x tH
T
PN[W] Coil nominal capacity (catalogue values, Type
tag)
PO[W] Coil capacity on overexcitation
PO= (
UO)² x PN
UN
PH [W] Coil capacity at reduced capacity
PH= (
UH)² x PN
UN
tO[s] Overexcitation time
tH[s] Time of operation with reduction in capacity
toff [s] Time without voltage
ton [s] Time with voltage
T [s] Total time (tO+ tH+ toff)
UO [V] Overexcitation voltage (bridge voltage)
UH[V] Holding voltage (half-wave voltage)
UN[V] Coil nominal voltage
IRMS [A] RMS current dependent on switching frequen-
cy, overexcitation time and duty cycle
IRMS =
P x PN
UN ²
Time Diagram:
T
ton toff
tO tH
U
UO
UN
UH
t
Protection circuit
When using DC-side switching, the coil
must be protected by a suitable protection
circuit according to VDE 0580, which is inte-
grated in mayr® monitoring modules. Never-
theless, the high switch-off voltage produc-
es switching sparks, which lead to contact
consumption.
Therefore, only use the main contacts of a
contactor suitable for inductive loads with
a minimum contact opening of 3 mm for
switching the DC-side contact SDC. Series
connection of main contacts reduces wear.
88

t
H
t
O
t
11
t
2
t t
t t
t
t
U
I
U
I
I
U
O
U
H
U
N
Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 9 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
99
Functional sequence diagram
Start/UI
(Input)
Switch-off
F/S (Input)
Output current
WarningFast switch-offSlow switch-off Error
Output volt-
age
Signal
(Output)
ERROR
(Output)
99

Installation and Operational Instructions for
ROBA®-brake-checker plus AC Type 029.700.2 (B.0297002.EN)
your reliable partner
26/06/2019 HH/GF
Page 10 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
www.mayr.com, E-Mail: [e-mail]
1010
Malfunctions / Breakdowns
Standards
Product standard
VDE 0160 /DIN EN 50178:1998-04
Electronic equipment for
use in power installations
EMC inspections
EN 61000-6-2:2006-03 Interference immunity
EN 61000-6-4:2007-09 Interference emission
Insulation coordination
acc. VDE 0110 / EN 60664:2008-01
Installation space (e. g. control cabinet) IP54
Rated insulation voltage voltage inputs 480 VRMS
Rated insulation voltage Grounding/Protective extra low
voltage 300 VRMS
Reliability nominal values
SN 29500, T = 60 °C / failure rates, components
EN ISO 13849-1
Disposal
Electronic Components
Products which have not been disassembled can be
disposed of under Code No. 160214 (mixed materials)
or components under Code No. 160216 (Code No. acc.
200/532/EC), or can be disposed of by a certified disposal
firm.
Malfunction Possible Causes Measures
Brake does not release
No supply voltage available Check voltage on input terminal
Brake line interrupted Check brake supply line (check passage)
No signal
Brake is not permitted Use released brake
Brake is worn Open and clean the brake, check the air gap;
Replace the brake if necessary
Error (continuous
signal)
Brake release is not recognised Brake is not permitted
Incorrect RBC-module (brake nominal voltage)
Brake drop-out is not detected Brake is not permitted
Check the supply module function
Break voltage drop (supply voltage) Check network stability and reinstate it
Warning
Wear limit reached Check the brake and replace if necessary
Supply voltage too low Check or increase supply/output voltage on the
supply module
Coil temperature of the brake too high Check effective coil power, ext. Temperature, friction
power
Guidelines on the WEEE Directive 2012 / 96 / EU
Avoidance of waste from electrical and electronic devices
and the reduction of such waste through recycling.
Our electromagnetic products (ROBA-stop®/ ROBA-quick®
/ ROBATIC®clutches) as well as the components required
for control and monitoring (rectifier / brake-checker) and the
DC motors (tendo ®-PM) are frequently used in electrical and
electronic devices within the appropriate area of application
of WEEE, independent of the applicable product categories.
The stated products do not fall within the area of application
of this Directive.
They have been classified as electromagnetic / electronic
components (VDE 0580) or as electronic equipment (EN
50178), and have been determined for installation in devices
for "use in accordance with the intended purpose". Only
products which are to be viewed as devices in terms of the
Directive and not as parts or components are subject to
registration obligations.
1010