Mayr ROBA-quick Quick start guide

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 1 of 9 www.mayr.com, E-Mail: [e-mail]
Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to brake failure, resulting in damage to other parts.
These Installation and Operational Instructions (I + O) are part of the brake delivery.
Please keep them handy and near to the brake at all times.
Contents:
Page 1: - Contents
- Safety and Guideline Signs
- Guidelines on EU Directives
Page 2: - Safety Regulations
Page 3: - Safety Regulations
Page 4: - Safety Regulations
Page 5: - Brake Illustrations
- Parts List
- Technical Data
Page 6: - Scope of Delivery / State of Delivery
- Function
- Design
- Explanation of Terms
- Torque Characteristics
Page 7: - Run-in Conditions
- Installation Examples
Page 8: - Installation
- Electrical Connection
- Maintenance and Inspection
- Disposal
Page 9: - Malfunctions / Breakdowns
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.
Please Observe!
Guidelines on important points.
___________________________________________________
According to German notation, decimal points
in this document are represented with a
comma (e.g. 0,5 instead of 0.5).
Guidelines on the Declaration of Conformity
A conformity evaluation has been carried out for the product (electromagnetic pole face brake) in terms of the EC low
voltage directive 2006/95/EC. The Declaration of Conformity is laid out in writing in a separate document and can be
requested if required.
Guidelines on the EMC Directive (2004/108/EC)
Guidelines on the Machinery Directive (2006/42/EC)
is a component for installation into machines according to the Machinery Directive 2006/42/EC.
The brakes 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 brake 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 94/9/EC.

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 2 of 9 www.mayr.com, E-Mail: [e-mail]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
General Guidelines
DANGER
Danger of death!
Do not touch voltage-carrying cables and
components.
Brakes may generate further risks, among other things:
Hand-
injuries
Danger of
seizure
Contact with
hot
surfaces
Magnetic
fields
Severe injury to people and damage to objects may result if:
the electromagnetic brake is used incorrectly.
the electromagnetic brake is modified.
the relevant standards for safety and / or installation
conditions are ignored.
During the required risk assessment when designing the
machine 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, installation, inspection
of the brake equipment, initial operation, maintenance and
disposal according to the relevant standards and regulations.
Before product installation and initial operation,
please read the Installation and Operational
Instructions carefully and observe the Safety
Regulations. Incorrect operation can cause injury
or damage.
At the time these Installation and Operational Instructions go to
print, the electromagnetic brakes accord with the known
technical specifications and are operationally safe at the time of
delivery.
Technical data and specifications (Type tags and
Documentation) must be followed.
The correct connection voltage must be connected
according to the Type tag and wiring guidelines.
Check electrical components for signs of damage before
putting them into operation. Never bring them into contact
with water or other fluids.
Please observe the EN 60204-1 requirements for electrical
connection when using in machines.
Only carry out installation, maintenance and
repairs in a de-energised, disengaged state and
secure the system against inadvertent switch-
on.
Guidelines for Electromagnetic Compatibility
(EMC)
In accordance with the EMC directives 2004/108/EC, the
individual components produce no emissions. However,
functional components e.g. mains-side energisation of the
brakes with rectifiers, phase demodulators, ROBA®-switch
devices or similar controls can produce disturbance which lies
above the allowed limit values. For this reason it is important to
read the Installation and Operational Instructions very carefully
and to keep to the EMC directives.
Application Conditions
The catalogue values are guideline values which
have been determined in test facilities. It may be
necessary to carry out your own tests for the
intended application. When dimensioning the
brakes, please remember that installation
situations, braking torque fluctuations, permitted friction work,
run-in behaviour and wear as well as general ambient
conditions can all affect the given values. These factors should
therefore be carefully assessed, and alignments made
accordingly.
Mounting dimensions and connection dimensions must be
adjusted according to the size of the brake at the place of
installation.
Use of the brake in extreme environmental conditions or
outdoors, directly exposed to the weather, is not permitted.
The brakes are designed for a relative duty cycle of 100 %.
The braking torque is dependent on the present run-in
condition of the brake.
The brakes are only designed for dry running. The torque is
lost if the friction surfaces come into contact with oil,
grease, water or similar substances or foreign bodies.
The surfaces of the outer components have been
phosphated manufacturer-side to form a basic corrosion
protection.
CAUTION
The friction surfaces may rust up and seize up
in corrosive ambient conditions and/or after
longer downtimes.
The user is responsible for taking appropriate
countermeasures.

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 3 of 9 www.mayr.com, E-Mail: [e-mail]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Ambient Temperature: -20 °C up to +40 °C
CAUTION
At temperatures of around or under freezing
point, both condensation and the special
characteristics of the linings (lower friction
values at lower temperatures) can strongly
reduce the braking torque.
The user is responsible for taking respective countermeasures,
e.g. selecting brakes with higher nominal braking torques.
Frequent and extensive temperature fluctuations at high
humidity promote the formation of corrosion, which can lead to
seized linings. The brake function must be inspected both once
attachment has taken place as well as after longer system
downtimes, in order to prevent the drive starting up against
possibly seized linings. The customer is responsible for
providing a protective cover against contamination caused by
construction sites.
Intended Use
mayr®-brakes have been developed, manufactured and tested in
compliance with the DIN VDE 0580 standard and in accordance
with the EU Low Voltage Directive as electromagnetic
components. During installation, operation and maintenance of
the product, the requirements for the standard must be
observed.
mayr®-brakes are for use in machines and systems and must
only be used in the situations for which they are ordered and
confirmed. Using them for any other purpose is not allowed.
Earthing Connection
The brake is designed for Protection Class I. This protection
covers not only the basic insulation, but also the connection of all
conductive parts to the protective conductor (PE) on the fixed
installation. If the basic insulation fails, no contact voltage will
remain. Please carry out a standardised inspection of the
protective conductor connections to all contactable metal parts!
Class of Insulation F (+155 °C)
The insulation components on the magnetic coils are
manufactured at least to class of insulation F (+155 °C).
Protection
(electrical) IP54: Dust-proof and protected against contact as
well as against water spray from any direction.
Valid for coil, casting compound and connection strands.
On the design with a connection terminal, the connection
terminal itself corresponds to Protection IP 00.
Brake Storage
Store the brakes in a horizontal position, in dry rooms and
dust and vibration-free.
Relative air humidity < 50 %.
Temperature without major fluctuations within a range
from –20 ° up to +60 °C.
Do not store in direct sunlight or UV light.
Do not store aggressive, corrosive substances (solvents /
acids / lyes / salts etc.) near to the brakes.
For longer storage of more than 2 years, special measures are
required (please contact the manufacturer).
Handling
Before installation, the brake must be inspected and found to
be in proper condition.
The brake function must be inspected both once attachment
has taken place as well as after longer system downtimes, in
order to prevent the drive starting up against possibly seized
linings.
User-implemented Protective Measures:
Please cover moving parts to protect against injury
through seizure.
Place a cover on the magnetic part to protect against injury
through high temperatures.
Protection circuit: When using DC-side switching, the coil
must be protected by a suitable protection circuit according
to VDE 0580, which is integrated in mayr®-rectifiers. To
protect the switching contact from consumption when using
DC-side switching, additional protective measures are
necessary (e.g. series connection of switching contacts).
The switching contacts used should have a minimum
contact opening of 3 mm and should be suitable for
inductive load switching. Please make sure on selection that
the rated voltage and the rated operating current are
sufficient. Depending on the application, the switching
contact can also be protected by other protection circuits
(e.g. mayr®-spark quenching unit, half-wave and bridge
rectifiers), although this may of course then alter the
switching times.
Take precautions against freeze-up of the friction
surfaces in high humidity and at low temperatures.

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 4 of 9 www.mayr.com, E-Mail: [email protected]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Regulations, Standards and Directives Used
DIN VDE 0580 Electromagnetic devices and
components, general specifications
2006/95/EC Low voltage directive
CSA C22.2 No. 14-2010 Industrial Control Equipment
UL 508 (Edition 17) Industrial Control Equipment
EN ISO 12100 Safety of machinery –General
principles for design - Risk assessment
and risk reduction
DIN EN 61000-6-4 Interference emission
DIN EN 61000-6-2 Interference immunity
EN 60204-1 Electrical equipment of machines
Liability
The information, guidelines and technical data in these
documents were up to date at the time of printing. Demands on
previously delivered brakes are not valid.
Liability for damage and operational malfunctions will not be
taken if:
- the Installation and Operational Instructions are ignored or
neglected.
- the brakes are used inappropriately.
- the brakes are modified.
- the brakes are worked on unprofessionally.
- the brakes are handled or operated incorrectly.
Guarantee
The guarantee conditions correspond with
the Chr. Mayr GmbH + Co. KG sales and delivery
conditions.
Mistakes or deficiencies are to be reported to mayr®at
once!
CE Identification
according to the
Low voltage directive 2006/95/EC
Identification
mayr® components are clearly marked and described on the Type tag:
Product Designation Serial number Article Number
CE marking Size/Type Voltage Power Braking torque DataMatrix code
only for voltages > 72V

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 5 of 9 www.mayr.com, E-Mail: [email protected]
1.1
1
2
1.2
5
4
3
Parts List
(Only use mayr original parts)
Item
Name
1
Coil carrier assembly with type tag
1.1
Magnetic coil
1.2
Friction lining
2
Armature disk assembly incl. transmission spring
3
Cap screw
4
Spring washer
5
Flange hub (dependent on Type)
Table 1: Technical Data
Size
3
4
5
6
7
8
9
Nominal torque M21) [Nm] [mm]
8,5
17
45
80
160
320
640
Air gap "a" (Figs. 2 / 3) [mm]
Max. permitted working air gap "a" [mm]
0,6
0,8
1,0
1,2
1,5
1,8
2,0
Max. permitted centre offset "V" (Figs. 4 / 5) [mm]
0,05
0,05
0,05
0,05
0,1
0,1
0,1
Max. permitted centre offset "V1" (Fig. 4) [mm]
0,1
0,15
0,15
0,15
0,2
0,2
0,25
Tightening torques (±10 %) for fixing screws (cap screws Item 3) for the armature disk (Item 2)
Type 520.1_ _ [Nm]
1,1
2,9
5,7
9,9
24
48
83
Type 520.20_._ [Nm]
2,9
5,7
9,9
24
24
-
-
Type 520.21_._ [Nm]
1,1
2,9
5,7
9,9
24
-
-
Tightening torques (±10 %) for fixing screws 2) for the coil carrier (Item 1)
All Types [Nm]
2,9
5,7
9,9
9,9
24
24
48
1) Please observe run-in specifications and minimum speed acc. Table 2
2) Not included in the standard scope of delivery
Fig. 1

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 6 of 9 www.mayr.com, E-Mail: [email protected]
Scope of Delivery / State of Delivery
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the
goods.
mayr®will grant no guarantee for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.
Function
ROBA®-quick brakes are “energised to engage”, electromagnetic
pole face brakes.
When DC voltage is applied to the magnetic coil in the coil
carrier (1), a magnetic field is built up. The armature disk (2) is
attracted to the coil carrier (1).
The braking torque is transmitted by friction between armature
disk (2) and the iron poles and the friction lining surfaces of the
coil carrier (1). The coil carrier (1) is screwed onto the machine
wall and centred on the shaft bearing, see Figs. 2 and 3 on
page 7.
The air gap “a“ is defined via a distance ring between the shaft
bearing and the drive element (Fig. 2) or inner hub (Fig. 3).
In new condition, torque transmission first takes
place via the metal outer pole on the coil carrier
(1) and, after a short operation period, then
additionally via the inner pole.
After the entire run-in procedure, an even
frictional combination occurs on the metal poles
and on the friction lining (1.2) lying between
them.
The full transmittable nominal torque is not
achieved until after the run-in procedure has
been carried out as described below.
Design
ROBA ®-quick brakes have Electrical Protection IP 54 and
Insulation Material Class F (up to 155 °C) for coil, casting
compound and connection strands.
On the design with a connection terminal, the connection
terminal itself corresponds to Protection IP 00.
The surfaces on the coil carrier (1) and flange hub (5) are
phosphated, the armature disk (2) is gas nitro-carburized or
plasma-nitrided (friction surfaces are ground), and the
transmission spring is made of stainless steel.
The drive elements should be made from a material which is a
poor magnetic conductor in order to prevent magnetic loss due
to leaking flux and therefore loss of force.
Explanation of Terms
The nominal torque M2is the largest transmittable torque (after
run-in has been completed), with which the closed brake can be
loaded without slipping occurring.
The relative duty cycle is the ratio of duty cycle to cycle time in
percent (% duty cycle).
Torque Characteristics
In new condition, approx. 50 % of the catalogue nominal
torque (M2) is transmitted.
The components reach the catalogue nominal torque when the
friction surfaces are run in. As a rough guideline value, approx.
100 –200 switchings in dynamic operation, a typical speed
(approx. 500 to 1000 rpm) and a medium friction work (see
Table 2) can be given.
Longer slipping of the brake is to be avoided, especially at low
speeds, as this can cause scoring formation and therefore
damage to the friction surfaces.
Brakes used in static or virtually static operation do not reach the
nominal torque (M2) stated in the Technical Data.
If requested, the brakes can also be run in at the place of
manufacture. For this, please ensure exact installation customer-
side according to the specifications in order to reproduce the
friction conditions as precisely as possible. At the same time, the
“friction carbon” produced must not be rubbed off.
If the brakes are run in to the nominal torque at the place of
manufacture and then operated in static or virtually static mode,
please allow for a drop to approx. 60 –70 % of the nominal
torque. This is the case if the brake falls bellow the speed or
friction work (Qa) stated in Table 2.
Table 2:
Size
Friction work
Qa
[J]
Brake speed nmin
[rpm]
3
16
300
4
29
250
5
55
200
6
105
160
7
200
130
8
380
120
9
600
100

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 7 of 9 www.mayr.com, E-Mail: [email protected]
Run-in Conditions
The Items 6 to 9 are customer-side mounting
parts which are not included in the standard
scope of delivery.
For running in, different procedures can be used according to the
Type design. The respective application should always be taken
individually into account.
An "artificial" run-in is to be carried out if a run-in procedure is
not possible in the machine due to the type of application (see
section “Torque Characteristics”), e. g. due to insufficient friction
work, speed or switching frequencies.
For Types 520.2_ _.0:
Run-in Possibility 1
Apply a voltage approx. 1/2 –1/3 of UNenn.
Speed approx. 200 –500 rpm
Synchronise against blocked output
Cycle approx. 50 –100 ms (dependent on Size);
No prolonged slipping; break approx. 200 ms;
Synchronise approx. 2 –3 minutes (100 –200 cycles)
Only carry out the torque inspection in static
operation - no slipping (danger of scoring)
Run-in Possibility 2
Synchronise against unblocked output by producing a larger
rotating mass and / or by synchronising at higher speed
(values should lie above the minimum values, Table 2)
Allow to synchronise approx. 2 –3 minutes
For Types 520.1_ _ :
Run-in Possibility 1
Apply a voltage approx. 1/3 of UNenn
(do not apply nominal voltage!).
Speed on Sizes 3 –6: approx. 50 rpm,
on Sizes 7 –9: approx. 30 rpm
Approx. 2 –3 minutes slipping against blocked output
Run-in Possibility 2
Synchronise against unblocked output by producing a larger
rotating mass and / or by synchronising at higher speed
(values should lie above the minimum values, Table 2)
Allow to synchronise approx. 2 –3 minutes
Installation Examples (Figs. 2 and 3)
In operation, the armature disk (2) is attracted to the coil carrier
(1). The braking torque is transmitted via frictional locking from
the coil carrier (1) via the armature disk (2) with the transmission
spring and the V-belt disk (Item 6 / Fig. 3) or the flange hub (Item
5 / Fig. 4) onto the drive shaft (7).
The coil carrier (1) is screwed onto the machine wall, centred
onto the shaft bearing (8).
The air gap "a" between the coil carrier (1) and the armature disk
(2) is defined via the distance ring (9) between the shaft bearing
(8) and the V-belt disk (6) or flange hub (5).
Axial securement of the V-belt disk (6) or flange hub (5) takes
place via a press cover and a screw, screwed into the shaft
threaded centre hole.
Fig. 2
Fig. 3
a
8 7
2
1
9
6
3/4
a
2
1
5
9
3/4

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 8 of 9 www.mayr.com, E-Mail: [email protected]
Fig. 4 Fig. 5
Installation
1. Mounting the coil carrier (1):
Screw the coil carrier (1) onto the machine wall (observe the
tightening torque acc. Table 1).
Centred by a ball bearing (8), Figs. 2/3.
Centred on diameter "Z", Fig. 4.
Centred on outer diameter "H", Fig. 4.
The maximum permitted centre offset "V1" acc. Table 1 may not
be exceeded (Figs. 4 and 5).
2. Installation of the armature disk (2):
2.1. Lay the spring washers (4) under the cap screws (3).
The cap screws (3) must be secured with Loctite 243.
2.2. Mount the armature disk (2) onto the mounting part or onto
the flange hub (5) (observe the tightening torque acc.
Table 1).
2.3. Align the armature disk (2)
(max. permitted radial run-out 0,15 mm).
The friction surfaces must be kept free of oil
and grease.
3. Installation of the mounting part or the flange hub (5):
3.1. Adjust the air gap "a" according to Table 1 and Figs. 2/3.
3.2. Secure the mounting part or flange hub (5) axially backlash-
free.
Axial backlash changes the air gap "a" and can lead to the
armature disk (2) rubbing against the coil carrier (1) (see
Installation Examples Figs. 2 and 3).
Please observe the maximum permitted centre offset "V"
according to Table 1 and Figs. 4 and 5.
Electrical Connection
The brake magnetic coil is connected to a DC voltage supply.
The level of coil voltage is engraved into the coil carrier (1).
A 24 V coil is integrated into the brake on standard designs.
When electromagnetic devices are switched off, cut-off peaks
may occur. These can lead to destruction of the device and must
therefore be damped.
This damping can have a negative effect on the connection
times given in the catalogue.
Ensure that the voltage supply is fused acc. the current values..
The brakes are designed for a relative duty cycle of 100 % in
static operation at nominal voltage.
Maintenance and Inspection
The friction surfaces must be kept free of grease and oil,
otherwise drastic drops in torque will occur.
Please inspect the air gap "a" and the permitted centre offsets
“V" and "V1" (Figs. 4 and 5) at regular intervals. Bearing backlash
and wear on the friction surfaces alter the permitted Table values
and can cause brake failure.
Apart from this, ROBA®-quick electromagnetic brakes are
maintenance-free.
Disposal
Our electromagnetic brake components must be disposed of
separately as they consist of different materials. Please also
observe the relevant authority regulations. Code numbers may
vary according to the disassembling process (metal, plastic and
cables).
Electronic components
(Rectifier / ROBA®-switch):
Products which have not been disassembled can be disposed of
under Code No. 160214 (mixed materials) or components under
Code No. 160216, or can be disposed of by a certified disposal
firm.
Steel components:
Steel scrap (Code No. 160117)
Coil carriers (steel pads with friction linings):
Brake linings (Code No. 160112)
a
V1V V
Ø Z
Ø H
a

Installation and Operational Instructions for
ROBA®-quick Type 520.1_ _ and Type 520.2_ _.0
Sizes 3 to 9 (B.5.2.EN)
26/08/2013 TK/RB/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 9 of 9 www.mayr.com, E-Mail: [email protected]
Malfunctions / Breakdowns
Malfunction
Possible Causes
Solutions
Braking torque too low
The permitted offsets V or V1 are exceeded
Align the brake
Brake does not brake
Incorrect voltage applied
Rectifier failure
Air gap too large
Grease and / or oil on the friction surfaces
Coil interrupted
Apply correct voltage
Replace rectifier
Re-adjust the air gap
De-grease the friction surfaces
Replace brake
Brake does not
disengage
Air gap too small or no air gap present
Re-adjust the air gap
mayr® will take no responsibility or guarantee for replacement parts and accessories which have not been delivered by
mayr®, or for damage resulting from the use of these products.