Mayr ROBA-stop-S Quick start guide

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany 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
Page 6: - Design
- Function
- State of Delivery
- Installation Conditions
Page 7: - Brake Attachment
- Air Gap Inspection
Page 8: - Air Gap Re-adjustment
- Replacing the Rotor
- Tacho Attachment (Option)
- Electrical Connection and Wiring
Page 9: - Electrical Connection and Wiring
Page 10: - Electrical Connection and Wiring
Page 11: - Release Monitoring
Page 12: - Braking Torque Adjustment
Page 13: - Emergency Release
- Anti-condensation Heating (Option)
- Condensation
- Disposal
Page 14: - 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 safety brake) in terms of the EC Low
Voltage Directive 2006/95/EC. The declaration of conformity is set out in writing in a separate document and can be
requested if required.
Guidelines on the EMC Directive (2004/108/EC)
The product cannot be operated independently in terms of the EMC directive.
Due to their passive quality, brakes are also non-critical equipment according to the EMC.
Only after integration of the product into an overall system can it 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 Machinery Directive (2006/42/EC)
The product 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 connection 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-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany 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 risk assessment required 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, 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, released state and
secure the system against inadvertent switch-
on.
Guidelines for Electromagnetic Compatibility
(EMC)
In accordance with the EMC directive 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, 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.
 The magnetic coils are designed for a relative duty cycle of
100 %.
 The braking torque is dependent on the present run-in
condition of the brakes.
 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 zinc
phosphated manufacturer-side to form a basic corrosion
protection.
CAUTION The rotors may rust up and seize up in
corrosive ambient conditions and/or after long
periods of storage.
The user is responsible for taking appropriate
counter measures.

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany 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, condensation can strongly reduce the
torque, or the friction surfaces can freeze up.
The user is responsible for taking appropriate
counter measures.
Appointed 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 PE conductor on the fixed installation. If
the basic insulation fails, no contact voltage will remain. Please
carry out a standardized inspection of the PE conductor
connections to all contactable metal parts!
Insulation Material Class F (+155 °C)
The insulation components on the magnetic coils are
manufactured at least to insulation material class F (+155 °C).
Protection IP67
When installed, dust-proof and protected against contact as well
as against temporary submersion under water.
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 installation
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 dangerously high temperatures.
 Protective circuit: When using DC-side switching, the coil
must be protected by a suitable protective 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 operation current are
sufficient. Depending on the application, the switching
contact can also be protected by other protective circuits
(e.g. mayr ®-spark quenching unit, half-wave and bridge
rectifiers), although this may of course then alter the
switching times.
 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
CSA C22.2 No. 14-2010 Industrial Control Equipment
UL 508 (Edition 17) Industrial Control Equipment
Please Observe the Following Standards:
DIN EN ISO 12100-1 and 2 Machine safety
DIN EN ISO 14121-1 Risk assessment
DIN EN 61000-6-4 Noise emission
DIN EN 61000-6-2 Interference immunity
EN 60204 Electrical machine equipment

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany E-Mail: [e-mail]
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
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
CE according to the Low Voltage Directive 2006/95/EC
CSA/UL in terms of the Canadian and American standards
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®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany E-Mail: [e-mail]
Fig. 1 Fig. 2 Fig. 3
Parts List (Only use mayr original parts)
Item Name
1 Gear hub
2 Coil carrier assembly
3 Flange plate assembly
3.1 Stud screws
3.2 O-ring
3.3 O-ring
4 Rotor assembly
5 Armature disk assembly
6 Thrust spring
7 Cap screw
8 Washer
9 Thrust spring
10 Screw plug
11 Copper sealing ring
12 Screw plug
13 Copper sealing ring
14 Screw plug
15 Copper sealing ring
16 Sealing cover
17 Hexagon head screw
18 O-ring
19 Cap nut
20 Washer
21 Distance washer assembly
inc. cap screw
22 Microswitch assembly
23 Terminal box assembly
24 Heating assembly
25 Type tag
26 Cable screw connection
24
6
19
20
3.1
3
5
1
2
17
18
16
22
23
3.2
4
3.3
12
25
15
14
26
10
10
13
26
Fig. 4

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany E-Mail: [e-mail]
Design
ROBA-stop®-S brakes are spring applied, electromagnetic safety
brakes.
When installed, the ROBA-stop®-S brakes are completely closed
and therefore comply with Protection IP 67.
Standard equipment: - Microswitch for release monitoring
- Emergency hand release
- Condensate drain screw
- Air gap checks opening
- Tacho attachment possibility
Options: - Installed rectifier
- Microswitch for wear inspections
- Anti-condensation heating
Function
Spring applied function:
In de-energised condition, thrust springs (6) press against the
armature disk (5). The rotor (4) is held between the armature
disk (5) and the flange plate (3).
The shaft is braked via the gear hub (1).
Electromagnetic function:
Due to the magnetic force of the coil in the coil carrier (2), the
armature disk (5) is attracted against the spring force to the coil
carrier (2).
The brake is released and the shaft can rotate freely.
Safety brake function:
The ROBA-stop®-S brakes reliably and safely in the event of a
power switch-off, a power failure or an EMERGENCY STOP.
State of Delivery (Figs. 1 - 4)
The ROBA-stop®-S brake is pre-assembled and screwed
together with the flange plate (3).
The emergency release screws (7) are screwed into the
armature disk (5) and serve as a shipping brace.
The Technical Data is stated on the Type tag (25).
Please check state of delivery!
Installation Conditions
Before installing the ROBA-stop®-S brake, please observe the
following points:
 The eccentricity of the shaft end in relation to the mounting
pitch circle must not exceed 0,4 mm (Fig. 5).
Fig. 5
 The axial run out deviation of the screw-on surface to the
shaft must not exceed the permitted axial run out tolerance
according to DIN 42955.
Larger deviations can lead to a drop in torque, to continuous
slipping on the rotor and to overheating.
 The tolerances of the hub (8) and the shaft must be selected
so that the hub toothing (1) is not widened (please observe
the max. joining temperature of +200 °C). Widening of the
toothing leads to the rotor (4) jamming on the hub (8) and
therefore to brake malfunctions (recommended hub - shaft
tolerance H7/k6).
 The rotor and brake surfaces must be oil and grease-free.
 Please abstain from using cleaning agents containing
solvents, as they could affect the friction material.
max. 0,4 mm

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany E-Mail: [e-mail]
Brake Attachment
1. Loosen the cap nuts (19) and remove the washers (20).
2. Remove the flange plate (3) from the brake by lightly tapping
the stud screws (3.1) with a plastic hammer.
3. Screw the flange plate (3) onto the motor bearing shield or
onto the machine wall (sealing must be carried out customer-
side; if there are any questions concerning sealing, please
contact the manufacturers).
4. Mount the gear hub (1) onto the shaft, bring it into the correct
position (the length of the key should lie over the entire hub)
and secure it axially (e.g. using a locking ring).
5. Push the rotor (4) by hand onto the gear (1).
Check that the toothing moves easily.
Do not cause any damage!
The rotor (4) must be placed onto the hub (1)
so that the toothing remains engaged even
after wear on the friction linings (Fig. 6).
Fig. 6
6. Push the brake over the stud screws (3.1) and join it with the
flange plate (3).
Do not damage the O-rings (3.2 and 3.3)!
7. Screw on the brake using the cap nuts (19) and the washers
(20). Do not tilt!
Observe the tightening torque acc. Table 1!
Fig. 7
Table 1
Size 8 9 10
Tightening torque for
cap nuts (19) [Nm]
13 26 26
Nominal air gap [mm]
0,20 +0,25 0,25 +0,25 0,25 +0,25
Max. air gap [mm]
0,75 1,0 1,1
Min. air gap for
re-adjustment [mm]
0,65 0,8 0,8
8. Unscrew the screw plugs (10) inc. the copper sealing rings
(11).
9. Important!
Unscrew both emergency release screws (7) in
the armature disk (5).
Unscrew the screws, but do not remove them.
10.Screw the screw plugs (10) inc. the copper sealing rings (11)
back in. The emergency release screws (7) are spring
applied.
11.Check the air gap acc. section "Air Gap Inspection".
Air Gap Inspection (Figs. 8 and 9)
Due to wear on the friction linings, the air gap between the coil
carrier (2) and the armature disk (5) increases.
The wear condition of the rotor (4) can be monitored in regular
air gap inspections.
Air gap inspection on a de-energised brake.
Air gap inspection on a de-energised brake:
1. Unscrew the screw plug (12) inc. the copper sealing ring (13).
2. Check the air gap by means of a feeler gauge.
The air gap must lie between the nominal air gap and the
max. air gap. Once the max. air gap has been reached, the
air gap must be re-adjusted (see Table 1).
Fig. 8
Fig. 9
T
Air gap
inspection opening
A
i
r
g
a
p
Air gap
inspection opening
Feeler gauge

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU 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 14 Germany E-Mail: [e-mail]
Air Gap Re-adjustment (Figs. 3, 4, 9 and 10)
It is possible to re-adjust the air gap once by removing the
distance washers (Item 21, on Size 8: 6 pieces, on Sizes 9 and
10: 3 pieces) between the flange plate (3) and the coil carrier (2).
If the air gap exceeds the max. value (acc. Table 1) again and
the distance washers (21) have already been removed, the rotor
(4) must be replaced (see section "Replacing the Rotor" (4)).
Please observe the min. air gap for re-
adjustment acc. Table 1.
1. Unscrew the screw plugs (10) inc. the copper sealing rings
(11).
2. Screw in both emergency release screws (7) up to contact on
the coil carrier (2)
DANGER Caution with hoist drives!
Actuating the emergency release nullifies the
braking torque.
Load crashes must be prevented.
3. Loosen the cap nuts (19) inc. the washers (20).
4. Remove the brake from the flange plate (3).
Do not damage the O-rings (3.2 and 3.3)! Remove abraded
particles from the rotor - clean the brake (do not use grease
or oil).
5. Remove the distance washers (21) from the flange plate (3).
Fig. 10
6. Clean the brake interior!
7. Push the brake over the stud screws (3.1) and join it with the
flange plate (3).
Do not damage the O-rings (3.2 and 3.3)!
8. Screw on the brake using the cap nuts (19) or the washers
(20).
Please make sure that there is no tilting!
Observe the tightening torque acc. Table 1!
9. Important!
Unscrew both emergency release screws (7) in
the armature disk (5).
Unscrew the screws, but do not remove them.
10.Screw the screw plugs (10) inc. the copper sealing rings (11)
back in. The emergency release screws (7) are spring
applied.
11.Check the air gap.
Replacing the Rotor (4)
1. Follow the procedure as described in section "Air Gap Re-
adjustment", points 1 - 4.
2. Replace the rotor (4).
Check that the toothing moves easily.
The rotor (4) must be placed onto the hub so
that the toothing remains engaged even after
wear on the friction linings.
3. Screw the distance washers (21) onto the flange plate (3)
using the cap screws M6 x 8 DIN 84.
(The distance washers and the cap screws are part of the
delivery set: replacement rotor).
4. Attach the brake following the procedure as described in
section "Air Gap Re-adjustment", points 6 - 10.
5. Check the air gap acc. "Air Gap Inspection".
When ordering replacement rotors, please state the
following Article Numbers:
Size 8: 1924657
Size 9: 1924350
Size 10: 1924494
6. Check the release monitoring device
(see section "Release Monitoring") and re-adjust it if
necessary.
Tacho Attachment (Option)
For tacho generator attachment, the sealing cover (16) must be
removed.
Please make sure that there is appropriate sealing between the
tacho generator and the coil carrier (2).
Electrical Connection and Wiring
DC current is necessary for operation of the brake. The coil
voltage is indicated on the Type tag as well as on the brake body
and is designed according to the DIN IEC 60038 (±10 %
tolerance). Operation can take place with AC current using a
rectifier or another suitable DC power supply. The connection
possibilities can vary dependent on the brake equipment. Please
follow the exact connections according to the Wiring Diagram.
The manufacturer and the user must observe the applicable
directives and standards (e.g. DIN EN 60204-1 and DIN VDE
0580). Their observance must be guaranteed and double-
checked!
For brake release at max. air gap and with a
braking torque adjustment > 100 % of the
nominal value stated in the catalogue,
overexcitation is mandatory.
Flange plate (3)
Fixing screw
Distance ring (21)
Distance ring (21)

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 9 of 14 Germany E-Mail: [e-mail]
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 PE conductor on the fixed installation. If
the basic insulation fails, no contact voltage will remain. Please
carry out a standardized inspection of the PE conductor
connections to all contactable metal parts!
Device Fuses
To protect against damage from short circuits, please add
suitable device fuses to the mains cable.
Switching Behaviour
The operational behaviour of a brake is to a large extent
dependent on the switching mode used. Furthermore, the
switching times are influenced by the temperature and the air
gap between the armature disk and the coil carrier (dependent
on the wear condition of the linings).
Magnetic Field Build-up
When the voltage is switched on, a magnetic field is built up in
the brake coil, which attracts the armature disk to the coil carrier
and releases the brake.
Field Build-up with Normal Excitation
If the magnetic coil is energised with nominal voltage, the coil
voltage does not immediately reach its nominal value. The coil
inductivity causes the current to increase slowly as an
exponential function. Accordingly, the build-up of the magnetic
field takes place more slowly and the braking torque drop
(curve 1) is also delayed.
Field Build-up with Overexcitation
A quicker and safer drop in braking torque is achieved if the coil
is temporarily placed under a higher voltage than the nominal
voltage, as the current then increases more quickly. Once the
brake is released, it needs to be switched over to the nominal
voltage (curve 2). The relationship between overexcitation and
separation time t2is roughly indirectly proportional, meaning that
at doubled nominal voltage the separation time t2for release of
the brake is halved. The ROBA®-(multi)switch fast acting rectifier
and phase demodulator work on this principle.
Operation with overexcitation requires an inspection of :
- the required overexcitation time*
- as well as the RMS coil capacity** with a cycle frequency
higher than 1 cycle per minute.
* Overexcitation time tover
Increased wear, and therefore an increasing air gap as well as
coil heating lengthen the separation time t2for the brake. For this
reason, at least double the separation time t2at nominal voltage
must be selected as overexcitation time tover on each brake size.
The spring forces also influence the brake separation times t2:
Higher spring forces increase the separation times t2and lower
spring forces reduce the separation times t2.
 Spring force (braking torque adjustment) < 100 % (Tab. 2):
The overexcitation time tover is less than the doubled
separation time t2.
 Spring force (braking torque adjustment) = 100 %:
The overexcitation time tover equals the doubled separation
time t2.
 Spring force (braking torque adjustment) > 100 %:
The overexcitation time tover is higher than the doubled
separation time t2.
** RMS coil capacity PRMS
PRMS ≤
≤≤
≤Pnom
The coil capacity PRMS must not be larger than
Pnom. Otherwise the coil may fail due to thermal
overload.
Calculations:
PRMS [W] RMS coil capacity dependent on switching frequency,
overexcitation, reductions in capacity
and duty cycle
tot
holdholdoverover
RMS ttPtP
P×+× =
Pnom [W] Coil nominal capacity
(Catalogue information, Type tag)
Pover [W] Coil capacity on overexcitation
nom
2
nom
over
over P
U
U
P×








=
Phold [W] Coil capacity at reduced capacity
nom
2
nom
hold
hold P
U
U
P×








=
tover [s] Overexcitation time
thold [s] Time of operation with reduction in capacity
toff [s] De-energised time
ttot [s] Total time (tover + thold + toff)
Uover [V] Overexcitation voltage (bridge voltage)
Uhold [V] Holding voltage (one-way voltage)
Unom [V] Coil nominal voltage
Time Diagram:
1
t
1
t
2
2
IM
Braking torque path
M
nom
I
nom
Current path
0
U
over
U
nom
U
hold
t
tot
t
off
t
on
t
hold
t
over

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 10 of 14 Germany E-Mail: [e-mail]
Magnetic Field Removal
AC-side Switching
The power circuit is
interrupted before the rectifier.
The magnetic field slowly
reduces. This delays the rise
in braking torque.
When switching times are not
important, please switch AC-
side, as no protective
measures are necessary for
coil and switching contacts.
AC-side switching means low-noise switching; however, the
brake engagement time is longer (c. 6-10 times longer than with
DC-side switching). Use for non-critical brake times.
DC-side Switching
The power circuit is
interrupted between the
rectifier and the coil as well as
mains-side. The magnetic field
reduces extremely quickly.
This causes a quick rise in
braking torque.
When switching DC-side, high
voltage peaks are produced in
the coil, which lead to wear on
the contacts from sparks and
to destruction of the insulation.
DC-side switching means short brake engagement times (e.g.
for EMERGENCY STOP); however, louder switching noises.
Protective Circuit
When using DC-side switching, the coil must be protected by a
suitable protective 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 operation current are sufficient.
Depending on the application, the switching contact can also be
protected by other protective circuits (e.g. mayr ®-spark
quenching unit, half-wave and bridge rectifiers), although this
may of course then alter the switching times.
Connection Examples
The coil voltage and - if applicable - the voltage of the option
"Anti-condensation heating" are stated on the brake Type tag
(25). A Wiring Diagram is glued to the terminal box cover (23).
Min. conductor cross-section for coil connection: 1,5 mm2.
The anti-condensation heating is powered by alternating current.
Example of an electrical connection
 With terminal block
 With microswitch for release monitoring
 With anti-condensation heating
Terminal assignment:
1/2: Release monitoring
3/4: AC voltage supply (AC voltage)
for anti-condensation heating
5/6: DC voltage supply (DC voltage)
for brake coil
Fig. 11
Example of an electrical connection
 With mayr®rectifier
 With microswitch for release monitoring
 With anti-condensation heating
Terminal assignment:
1/2: AC voltage supply (AC voltage)
for brake coil
7/8: AC voltage supply (AC voltage)
for anti-condensation heating
9/10: Release monitoring
Fig. 12
For short engagement times, a switching
contact at "S1" is necessary, which means DC-
side switching.
1 2 3
4
5
6
1 2 3
4
5
6
Earthing
Varistor
Break coil
Anti-condensation
heating (AC)
Release monitoring
microswitch
1 2 3 4 5 6 7 8 9 10
Contacts
potantialfree
Netz
AC
S1 Sp1
1 2 3 4 5 6 7 8 9 10
Contacts
potentialfree
Netz
AC S1 Sp1
Brake coil
Anti-condensation heating
Release monitoring
microswitch
F1: External fuse
Coil
S1
F1
L
N
1
2
3
4
5
6
7
8
1 2 345 6 7
8
20/017.000.2
200 - 500V~
200 - 300V~
:
R
IN
OUT
U– = 0,45×U~
+
–
S
DC
ROBA -switch
I = 1,8A
max –
0,05-2sec
0 -10M Ω Ω
t:
R
R
F1: External fuse
Coil
S1
F1
L
N
1
2
3
4
5
6
7
8
1 2 345
6
7
8
20/017.000.2
200 - 500V~
200 - 300V~
:
R
IN
OUT
U– = 0,45×U~
+
–
S
DC
ROBA -switch
I = 1,8A
max –
0,05-2sec
0 -10M Ω Ω
t:
R
R

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 11 of 14 Germany E-Mail: [e-mail]
Release Monitoring (Fig. 13)
The release monitoring device emits a signal on brake release,
which means the switch is actuated at:
 energised coil (electromagnetic release)
 emergency release actuation
From the point at which the brake is energised, a time span of
three times the separation time must pass before the
microswitch signal on the release monitoring is evaluated.
The microswitch (22) is adjusted manufacturer-
side.
If re-adjustment is necessary (no signal change
for energised / de-energised condition, or on
actuating the emergency hand release), it can
be carried out directly from the terminal box
(23).
Microswitch Adjustment
The microswitch is located in the terminal box (23) under the
terminal block (rectifier).
Microswitch adjustment is carried out on a de-energised coil. The
air gap must correspond to the nominal air gap (see Table 1).
Procedural Method for Adjustment:
1. Check the air gap between the coil carrier (2) and the
armature disk (5). On increased nominal air gap (see Table
1), first determine and use the adjustment values for the
feeler gauge (dimension "X") according to the example listed
below.
2. Remove the terminal block (rectifier).
3. Loosen the fixing screws of the microswitch (22) holding
bracket slightly.
4. Change the microswitch position axially using a feeler gauge.
Here, please observe the following:
a) Feeler gauge "X" = 0,1 mm: Microswitch must not switch
(contact brown-blue opened).
b) Feeler gauge "X" = 0,15 mm: Microswitch must switch
(contact brown-blue closed).
5. Tighten the fixing screws of the microswitch (22) holding
bracket.
6. Attach the terminal block (rectifier).
Fig. 13
If the air gap between the coil carrier (2) and
the armature disk (5) is larger than the nominal
value due to rotor (4) wear, this increased value
must be taken into consideration when
adjusting the microswitch.
Example: Air gap = 0,75 mm
Determined air gap 0,75 mm
Nominal air gap (acc. Table 1)- 0,25 mm
Wear = 0,50 mm
Adjustment for
Switching: Not switching:
Wear 0,50 mm Wear 0,50 mm
Limit + 0,15 mm Limit +0,10 mm
Feeler gauge (X) = 0,65 mm Feeler gauge (X) 0,60 mm
Microswitch Specifications
Characteristic values for
measurement: 250 V~ / 3 A
Minimum switching capacity: 12 V, 10 mA DC-12
Recommended switching
capacity:
for maximum lifetime
and reliability
24 V, 10...50 mA
DC-12
DC-13 with free-wheeling
diode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)
Microswitches cannot be guaranteed fail-safe.
Therefore, please ensure appropriate access for
replacement or adjustment.
The switching contacts are designed so that they
can be used for both small switching capacities
and medium ones. However, after switching a medium
switching capacity, small switching capacities are no longer
reliably possible. In order to switch inductive, capacitative and
non-linear loads, please use the appropriate protective circuit to
protect against electric arcs and unpermitted loads!
X
"Y"
2
5
22
23
Feeler gauge
Detail "Y"
Rectifier
Nominal air gap
acc. Table 1

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 12 of 14 Germany E-Mail: [e-mail]
Braking Torque Adjustment (Fig. 14)
Braking torque adjustment is carried out via various thrust spring
(6) assembly variants in the coil carrier (2) acc. Table 2.
Procedural Method:
1. Unscrew the screw plugs (10) inc. the copper sealing rings
(11).
2. Screw in both emergency release screws (7) up to contact
on the coil carrier (2)
3. Loosen the cap nuts (19) inc. the washers (20).
4. Remove the brake from the flange plate (3).
Do not damage the O-rings (3.2 and 3.3)!
5. Remove the emergency release screws (7).
6. Remove the armature disk (5).
7. Remove abraded particles from the rotor and clean the
brake.
Do not use grease or oil.
8. Change the number of thrust springs (6) acc. Table 2.
The thrust springs must be distributed evenly in
the coil carrier (2). Always remove or insert two
springs located opposite each other to make
sure that the armature disk (5) is loaded evenly.
Only use mayr®thrust springs!
Table 2: Spring Configuration
Size
Nominal
torque 10
springs
[Nm]
8 springs
[Nm]
6 springs
[Nm]
4 springs
[Nm]
8 100 80 60 40
9 200 160 120 80
10 400 320 240 160
Torque tolerance: +40 % / -20 %
Further spring configurations or braking torques
on request.
9. Insert the armature disk (5).
Please make sure that the two pins for actuating the
microswitch situated next to each other protrude into the
terminal box.
10. Screw both emergency release screws (7) into the armature
disk (5) up to contact on the coil carrier (2).
If necessary, push the armature disk lightly onto the coil
carrier, so that the emergency release screws can be joined.
11. Push the brake over the stud screws (3.1) and join it with the
flange plate (3).
Do not damage the O-rings (3.2 and 3.3)!
12. Screw on the brake using the cap nuts (19) and the washers
(20).
Do not tilt!
Observe the tightening torque acc. Table 1!
13. Important!
Unscrew both emergency release screws (7) in
the armature disk (5).
Unscrew the screws, but do not remove them.
14. Screw the screw plugs (10) inc. the copper sealing rings
(11) back in. The emergency release screws (7) are spring
applied.
Fig. 14

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 13 of 14 Germany E-Mail: [e-mail]
Emergency Release (Fig. 15)
In case of malfunction or power failure, the brake remains
closed; it cannot be released electrically. Emergency release can
be carried out manually.
1. Unscrew the screw plugs (10) inc. the copper sealing rings
(11).
2. Screw both emergency release screws (7) into the armature
disk (5) until the load on the motor starts moving.
Interrupt the release procedure with individual stops (turning
back the emergency release screws), so that there is no
high load acceleration and brake heating occurrence.
DANGER Warning for hoist drives!
Actuating the emergency release nullifies the
braking torque.
Load crashes must be prevented.
3. After completing the release procedure, unscrew both
emergency release screws (7) in the armature disk (5).
However, do not remove the screws.
4. Screw the screw plugs (10) inc. the copper sealing rings
(11) back in. The emergency release screws (7) are spring
applied.
Fig. 15
Anti-Condensation Heating (Option)
The anti-condensation heating is used for preventing
condensation precipitate in the brake interior.
For connecting the anti-condensation heating (AC voltage), see
the Wiring Diagram.
Condensation (Fig. 16)
The condensation must be checked regularly via the screw plug
(14) with the copper sealing ring (15).
Fig. 16
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 disassembling process (metal, plastic and
cable).
Electronic Components
(Rectifier / ROBA-switch / Microswitch):
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.
Brake bodies made of steel pads with coil / cable
and all other steel components:
Steel scrap (Code No. 160117)
Aluminium components:
Non-ferrous metals (Code No. 160118)
Brake rotor (steel or aluminium pads with friction linings):
Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomers, terminal boxes (PVC):
Plastic (Code No. 160119)
9
8
7
11
10
Condensate
drain opening

Installation and Operational Instructions for
ROBA-stop®-S brake Type 856. _ _ _ . _
Sizes 8, 9 and 10 (B.8.3.GB)
03/11/2010 TK/KE/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0
Eichenstraße 1 Fax: 08341 / 804-421
D-87665 Mauerstetten http://www.mayr.de
Page 14 of 14 Germany E-Mail: [e-mail]
Malfunctions / Breakdowns:
Results of Malfunction Possible Causes Solutions
Brake does not release
 Abraded particles between the armature disk and
the coil carrier.
 Air gap too large
 Air gap too small (remove the distance washers
before reaching the max. air gap)
 Coil interruption
 Rectifier failure
 Incorrect voltage on rectifier
 Clean the brake
 Re-adjust the brake; replace the brake
 Insert distance washers between the coil
carrier and the flange plate
 Replace brake
 Replace rectifier
 Apply correct voltage
Brake does not brake  Emergency release screws are not loosened
 Grease or oil on the friction surfaces
 Loosen the emergency release screws
 Replace rotor
Release monitoring
does not emit a signal
 Abraded particles between the armature disk and
the coil carrier.
 Switching position misaligned
 Defective microswitch
 Clean the brake
 Adjust the switch again
 Replace the switch