Mayr ROBA-stop 820.61 Series Quick start guide

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 1 of 8 Germany eMail: [email protected]
Please read these Installation Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to brake failure, resulting in damage to other parts.
Contents:
Page 1: - Contents
- Declaration of Conformity
Page 2: - Safety Regulations
Page 3: - Safety Regulations
Page 4: - Brake Illustrations
- Parts List
- State of Delivery
- Function
Page 5: - Installation Conditions
- Installation
- Air Gap Adjustment
- Braking Torque Adjustment
Page 6: - Brake Inspection
- Replacing Worn Parts
- Hand Release Installation
- Hand Release Adjustment
- Hand Release Parts List
Page 7: - Electrical Connection
- Terminal Box Installation
Page 8: - Maintenance
- Disposal
- Malfunctions / Breakdowns
Declaration of Conformity
A conformity evaluation for the applicable EU directives has been carried out for this product.
The conformity evaluation is set out in writing in a separate document and can be requested if required.
It is forbidden to start use of the product until the machine or system into which it should be built is operating in accordance with all
applicable EU directives.
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion.
This statement is based on the ATEX directive.
Please Observe!
According to German notation, decimal points in this document are represented with a comma (e.g. 0,5 instead of 0.5).

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 2 of 8 Germany eMail: [email protected]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Danger!
Danger of death! Do not touch
voltage-carrying cables and components.
To prevent injury or damage, only professionals and
specialists should work on the devices.
Danger!
This warning applies if:
 the electromagnetic brake is used incorrectly.
 the electromagnetic brake is modified.
 the relevant standards for safety and / or installation
conditions are ignored.
Warning!
Before product installation and initial
operation, read the Installation and
Operational Instructions carefully and
observe the Safety Regulations. Incorrect operation can
cause injury or damage. The electromagnetic brakes have
been developed in accordance with the latest technology
regulations and are, at the point of delivery, operationally
safe.
Please Observe!
 Only specialists who are trained in the transport,
installation, initial operation, maintenance and general
operation of these devices and who are aware of the
relevant standards should be allowed to carry out this work.
 Technical data and specifications (Type tags and
documentation) must be followed.
 The correct connection voltage must be connected
according to the Type tag.
 Never loosen electrical connections or carry out
installations, maintenance or repairs while the voltage
connection is energised!
 Cable connections must not be placed under mechanical
strain.
 Check electrical components for signs of damage before
putting them into operation. Never bring them into contact
with water or other fluids.
 The braking torque is lost if the friction lining and / or the
friction surface come into contact with oil or grease.
Appointed Use
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!
Guidelines for Electromagnetic Compatibility
(EMC)
In accordance with the EMC directives 89/336/EEC, the
individual components produce no emissions. However,
functional components e.g. rectifiers, phase demodulators,
ROBA®-switch devices or similar controls for mains-side
energisation of the brakes 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.
Device Conditions
Please Observe!
The catalogue values are standards, which
can, in certain cases, vary. When
dimensioning the brakes, please remember
that the installation situation, brake torque fluctuations,
permitted friction work, run-in behaviour and wear as well as
general ambient conditions can all affect the given values.
These values should therefore be carefully assessed, and
alignments made accordingly!
Please Observe!
 Mounting dimensions and connecting dimensions must be
adjusted according to the size of the brake at the place of
installation.
 The brakes are designed for a relative duty cycle of 100 %.
 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.
 The braking torque is dependent on the present run-in
condition of the brakes.
 Manufacturer-side corrosion protection of the metal surface
is provided.
Protection Class I
This protection can only be guaranteed if the basic insulation is
intact and if all conductive parts are connected to the PE
conductor. Should the basic insulation fail, the contact voltage
cannot remain (VDE 0580).
Protection IP 54:
Dust-proof and protected against contact as well as against
splashing water from all directions.
Ambient Temperature –20 °C up to +40 °C
Warning!
At temperatures of around or under freezing point, condensation
can strongly reduce the torque, or the rotors can freeze up. The
user is responsible for taking appropriate countermeasures.
Insulation Material Class F (+155 °C)
The magnetic coil and the casting compound are suitable for use
up to a maximum operating temperature of +155 °C.

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 3 of 8 Germany eMail: [email protected]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
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.
 Protect against electric shocks by installing a conductive
connection between the magnetic component and the PE
conductor on the permanent installation (Protection Class I)
and by carrying out a standardised inspection of the
continuous PE conductor connection to all contactable metal
parts.
 Protect against highly inductive switch-off peaks by installing
varistors, spark quenching units or similar devices according
to VDE 0580/2000-07, Paragraph 4.6, to prevent damage to
the coil insulation or switch contact consumption in extreme
conditions (this protection is contained in mayr® rectifiers).
 Install additional protective measures against corrosion if the
brake is subject to extreme ambient conditions or is installed
in open air conditions, unprotected from the weather.
 Take precautions against freeze-up of the friction surfaces in
high humidity and at low temperatures.
Regulations, Standards and Directives Used:
DIN VDE 0580 Electromagnetic devices and components,
general directives
2006/95/EC Low voltage directive
98/37/EC Machine directive
89/336/EEC EMC directive
Please Observe the Following Standards:
DIN EN ISO
12100-1 and 2 Machine safety
DIN EN 61000-6-4 Noise emission
DIN EN 61000-6-2 Interference immunity
EN 60204 Electrical machine equipment
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!
Conformity Markings
The product conforms to the CE according to the low voltage
directives 2006/95/EC.
Identification
mayr® components are clearly marked and described on the
Type tag:
Manufacturer
mayr®
Name / Type
Article number
Serial number

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 4 of 8 Germany eMail: [email protected]
Fig. 1
Parts List
1 Gear hub
2 Coil carrier assembly with coil (9) and guide bushings (7)
5 Armature disk
7 Guide bushing
8 Friction lining
9 Coil
10 Shoulder screw
11 Helical spring
State of Delivery
Please check the state of delivery immediately!
mayr®will take no responsibility for belatedly returned
goods.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects to the
manufacturer.
13 Fixing screw
14 Set screw
28 Spring ring
31 Threaded distance ring
35 Rotor with friction linings (8)
58 Lock washer
59 Clamping bolt
60 Spring ring
Function
The braking torque is produced by the pressure force of several
spring rings (11) via frictional locking between the rotor friction
linings (35), the armature disk (5) and the machine wall.
The brake is released electromagnetically or mechanically via a
hand release (see page 6).

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 5 of 8 Germany eMail: [email protected]
Installation Conditions
Before mounting the brake, please observe the following
points:
 The eccentricity of the shaft end against the mounting pitch
circle may not exceed 0,2 mm (on sizes 3 – 6),
or 0,4 mm on larger brakes.
 The positioning tolerance of the thread for the
cap screws (13) may not exceed 0,2 mm.
 The axial eccentricity deviation of the screw-on surface to
the shaft may not exceed the permitted axial eccentricity
tolerance according to DIN 42955 R.
The related diameter is the pitch circle diameter of the
brake attachment.
Larger deviations can lead to a drop in torque, to permanent
slipping on the rotor and to overheating.
 The tolerances of the hub and the shaft must be selected
so that the hub toothing is not widened (please observe the
maximum join temperature of 200 °C). Widening the
toothing leads to the rotor clamping on the hub and
therefore to brake malfunctions.
(Recommended hub - shaft tolerance H7/k6).
 The hub (1) must be positioned so that the
rotor toothing (35) carries holohedrally.
 The rotor and the brake surfaces must be free of oil and
grease.
 A suitable counter friction surface (steel or cast iron) must
be used. Sharp-edged interruptions on the friction surface
are to be avoided. Recommended surface quality in the
friction surface area: Ra = 1,6 µm.
Friction surfaces made of grey cast iron are to be
rubbed down with fine sandpaper (grain ≈400).
Installation
 Mount the gear hub (1) onto the shaft and secure it axially.
Please avoid damage to the toothing.
Mount the gear hub (1) so that the rotor (35) toothing stays
in complete contact even after the friction linings (8) have
become worn.
 Push the rotor (35) by hand onto the gear hub (1). The rotor
collar should be facing in the direction of the brake.
Make sure that the toothing moves easily.
Do not cause damage.
 Screw on the brake using the fixing screws included in
delivery (13), and secure using spring rings (28).
Check the nominal air gap „a“ according to Table 1. The
nominal air gap must be present.
Observe the screw tightening torques according to Table 1.
The shoulder screws (10) prevent the individual parts from
falling apart. They do not affect the brake function and
should not be removed during installation.
Table 1
ROBA-stop®
size 3 4 5 6 7 8 9 10 11
Screw tightening
torque (pos. 13)
[Nm]
3 3 6 8 8 10 10 10 40
Nominal air gap
“a” [mm]
0,20 0,20 0,25 0,25 0,35 0,35 0,40 0,40 0,50
Max. permitted
working air gap*
[mm]
0,30 0,30 0,40 0,45 0,50 0,50 0,50 0,50 0,70
* as the operating temperature increases, the max. air gap can decrease.
Air Gap Adjustment
The working air gap „a“ between the armature disk (5) and the
coil carrier (2) is set manufacturer-side to the nominal dimension,
see Fig. 2 and Table 1.
However, as the rotor (35) wears down, the air gap increases. By
turning the threaded distance ring, (31) it is possible to reset the
nominal air gap. Adjustment must take place at the latest when
the maximum permitted working air gap (acc. Table 1) has been
reached.
Adjustment
1. Take a screw plug out of the threaded distance ring (31).
Measure the air gap before adjustment in de-energised
conditions using a sensor gauge. The difference between
the measured air gap and the nominal air gap „a“ must be
readjusted according to Table 1.
2. Loosen the fixing screws (13).
3. Loosen the clamping bolt (59) and the lock washer (58).
4. Turn the threaded distance ring (31) anti-clockwise (facing
the rear side of the brakes). Turn the distance ring (31) one
graduation line on the imprinted scale. This equals an air
gap adjustment of 0,05 mm on sizes 3 to 6 and of 0,1 mm
on sizes 7 to 11.
5. Tighten the fixing screws (13) and observe the tightening
torques according to Table 1.
6. Tighten the clamping bolt (59).
7. Check the air gap. The nominal air gap „a“ according to
Table 1 must be present.
Re-adjustment can be repeated until the threaded distance ring
(31) lies against the coil carrier (2) collar, see Fig. 2. This contact
prevents unpermitted wear on the rotors (35). If no more re-
adjustment is possible, the rotor (35) must be replaced.
Fig. 2
Braking Torque Adjustment
ROBA-stop®brakes are set manufacturer-side to the braking
torque requested on order. By turning the set screws (14) to the
left, the braking torque is reduced. By turning them to the right,
the braking torque is increased.
During braking torque adjustment, all the set screws (14) must
be adjusted evenly.
Warning!
Do not confuse the set screws (14) with the fixing
screws (13)!
a
Collar

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 6 of 8 Germany eMail: [email protected]
Brake Inspection
Full braking torque is not reached until the run-in procedure has
been completed.
The braking torque (switching torque) is the torque acting on the
shaft train when the brakes slip at a sliding speed of 1 m/s in
relation to the mean friction radius (DIN VDE 0580/10.94).
Replacing Worn Parts
Parts which are subject to wear are the rotor (35), the armature
disk (5) and the gear hub (1). Screw off the brake (by removing
the fixing screws (13)) and replace the rotor (35). If there is
excessive backlash in the toothing between the rotor (35) and
the gear hub (1), please pull the gear hub from the shaft and
replace it.
Please also check the armature disk (5) for axial parallelism and
wear and replace if necessary.
Re-adjust the nominal air gap via the distance ring (31).
In order to replace the armature disk (5) the shoulder
screws (10) and, if present, the hand release must be removed.
Please make sure that the helical springs (11) do not fall out.
Hand Release Installation
The hand release can be installed onto every holding brake
Type. However, due to the high spring forces, mounting a
standard hand release onto sizes 9 – 11 is not possible (special
hand release available on request).
In order to install the hand release, the brake must be removed
and must be in a de-energised condition.
 Push the return spring (19) onto the restoring bolts (17).
 Take the plastic plugs out of the bores at the back of the
coil carrier (2).
 Put the restoring bolts (17) through the armature disk (5)
recesses and through the bores in the coil carrier (2).
 Screw the hand release bracket (22) using the locking
nuts (21) onto the restoring bolts (17).
Hand Release Adjustment
The restoring bolts (17) limit the armature disk (5) stroke in the
direction of the brake, see Figs. 3 and 4.
Warning:
The restoring bolts (17) may only be pulled over the
locking nuts (21) so far that at least the adjustment
dimension „X“ (acc. Table 2 and Fig,. 3) remains
between the armature disk (5) and the coil carrier.
Table 2
ROBA-stop®
size
Adjustment
dimension "X"
[mm]
31,0
41,1
51,2
61,6
71,4
81,5
Hand Release Parts List
10 Shoulder screws
16 Threaded bolts
17 Restoring bolts
18 Spherical button
19 Return spring
21 Locking nut
22 Hand release bracket
Fig. 3
Fig. 4
Inspection
hole

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 7 of 8 Germany eMail: [email protected]
Electrical Connection
Danger!
Only carry out electrical connection when the
device is de-energised!
The coil voltage is clearly shown on the type
tag and imprinted on the brake.
The brakes are designed according to the Euro – voltage
DIN IEC 38.
DC voltage is necessary for operation.
Switching can take place DC-side or AC-side.
However, DC-side switching produces a faster connection time
(brake engagement).
If a faster separation time is required, a special fast acting
rectifier is required.
In this case, please contact the manufacturers.
Warning!
When switching off electromagnetic devices, switch-off peaks
can occur. These can lead to destruction of the device, and
should therefore be damped.
This damping can have a negative effect on the connection
times.
Please provide a fuse for the voltage supply according to the
current values.
The brakes are designed for a relative duty cycle of 100 %.
Installation Terminal Box
Base plate (44) optionally assembled with:
1. 2-pole terminal
2. 4-pole terminal
3. 6-pole terminal
4. Half-wave rectifier
5. Bridge rectifier
Parts List Terminal Box
37 Holding bracket
38 Cap screw M3 x 12
39 Terminal box – lower part
40 O-ring
41 Sealing plate
42 Hexagon nut M3
43 Cable clamp
44 Base plate
45 Countersunk screw M4 x 8
46 Terminal
47 Terminal identification code
48 Cap screw M2.5 x 12
49 Cap screw M4 x 8
50 Terminal box - lid
51 Sealing ring
52 Cap screw M4 x 30
53 Sealing washer
Attachment
The parts 37 to 43 in the Parts List are partly assembled.
1. a) Screw the rectifier into the terminal box lower part (39) OR
1. b) Screw the base plate (44) into the terminal box lower
part (39) using the counter-sunk screws (45).
Attach the 2, 4 or 6-pole terminals (46) using cap screws
(48) onto the base plate (44).
Stick the terminal identification code (47) onto the base
plate (44) (observe the terminal identification code
according to Fig. 5).
2. Cut the brake cable coil to the correct length and insulate it.
Insert the cable via Parts 39, 40 and 41 into the terminal box.
3. Screw the holding bracket (37) using the cap screws (49) to
the brake rear side.
4. Re-tighten the brake coil cable, and tighten the
hexagon nuts (42).
5. Connect the brake according to the „Installation and
Operational Instructions B.1110.4.D for ROBA-stop®Brakes /
Electrical Connection".
6. Close the terminal box, observing the sealing ring (51) and the
sealing washers (53).
Fig. 5
Fig. 6
Brake coil cable
Base plate (44)
Optionally
assembled with:
1. 2-pole terminal
2. 4-pole terminal
3. 6-pole terminal
4. Half-wave rectifier
5. Bridge rectifier

Installation and Operational Instructions for
ROBA-stop®Holding Brake Type 820.61_._ (B.1110.6.GB)
08/02/2010 K/GC/RJ/GF Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 8 of 8 Germany eMail: [email protected]
Maintenance
ROBA-stop®brakes are mainly maintenance-free.
The friction linings are robust and wear-resistant. This ensures a
particularly long service lifetime.
However, the gear hub (1), the armature disk (5) and the rotor
with friction linings (35) are subject to functional wear. They must
therefore be regularly inspected and replaced if necessary.
To do this, see the section “Replacing Worn Parts”.
Disposal
Our electromagnetic brake components must be disposed of
separately as they consist of different materials. Please observe
the relevant authority regulations. Code numbers may vary
according to the dismantling process (metal, plastic and cable).
Electronic components
(Rectifier / ROBA®-switch / Microswitch):
Products which have not been dismantled can be disposed of
under the Code No. 160214 (Mixed Materials) or Components
under Code No. 160216; or the objects can be disposed of by a
certified waste disposal firm.
Brake bodies made of steel girders with coil / cable and all
other steel components:
Steel scrap (Code No. 160117)
Aluminium components:
Non-ferrous metals (Code No. 160118)
Brake rotors
(steel or aluminium girders with friction linings):
Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomere, terminal boxes (PVC):
Plastics (Code No. 160119)
Malfunctions / Breakdowns
Malfunction Possible Causes Solutions
Brake does not release  Incorrect voltage on rectifier
 Rectifier failure
 Air gap too large (worn rotor)
 Air gap too large (metal particles between
the armature disk and the coil carrier)
 Interrupted coil
 Overheated brake
 Apply correct voltage
 Replace rectifier
 Replace rotor
 Clean brake
 Replace brake
 Use fast acting rectifier
Motor does not brake  Hand release wrongly adjusted
 Hand release backlash; (possible at
decreased torque or operation with a fast
acting rectifier)
 Re-adjust distance
 Replace rotor
Delayed brake engagement  The brake is switched AC-side  Switch DC-side