Mayr ROBA-stop-M 250 Quick start guide

Spring applied, electromagnetic safety brake
BRE 250 ... BRE 400
Protection IP55 / IP66
(Mayr ROBA-stop®-M 250 ... 500)
Issue status 2019-10
Translation of the Original Operational
Instructions
© Copyright by mayr®–power transmission
All rights reserved.
Reprints and copies –even extracts –are only permitted with the consent of the manufacturer.
your reliable partner

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 2 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Design according to
Mayr –Size
Mayr –Type
Nord –Size
Protection
250
891.01_.0
BRE250
IP54
250
891.01_.1
BRE250
IP66
500
891.02_.0
BRE400
IP54
500
891.02_.1
BRE400
IP66
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: - Front page
Page 2: - Contents
Page 3: - Safety and Guideline Signs
- Guidelines on EU Directives
Page 4: - Safety Regulations
Page 5: - Safety Regulations
Page 6: - Safety Regulations
Page 7: - Brake Illustrations Size 250
Page 8: - Brake Illustrations Size 500
Page 9: - Parts List
Page 10: - Technical Data
Page 11: - Torque-Time Diagram
- Design
- Function
- Scope of Delivery / State of Delivery
Page 12: - Installation Conditions
- Installation
- Hand Release
Page 13: - Definition of the Braking Torques
- Braking Torque Adjustment
- Run-in Procedure
- Brake Inspection
Page 14: - Electrical Connection and Wiring
Page 15: - Permitted Brake Friction Work
Page 16: - Option: Microswitch for Brake Monitoring
- Release Monitoring
- Wear Monitoring
Page 17: - Air Gap Inspection
- Maintenance
Page 18: - Replacing the Rotors
- Information on the Components
- Cleaning the Brake
- Disposal
Page 19: - Malfunctions / Breakdowns
Page 20: - Malfunctions / Breakdowns

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 3 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
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.
Guidelines on the Declaration of Conformity
A conformity evaluation has been carried out for the product (electromagnetic safety brake) in terms of the EU Low Volt-
age Directive 2014/35/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.
Due to their passive state, brakes are also non-critical equipment according to the EMC.
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 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 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 EU Directive 2011/65/EU (RoHS II) with 2015/863/EU (RoHS III –from 22 July 2019)
These restrict the use of certain hazardous substances in electrical and electronic devices as well as in products / compo-
nents (category 11), the proper operation of which is dependent on electric currents and electromagnetic fields. Our elec-
tromagnetic products / components fulfil the requirements laid down in the RoHS Directive(s), taking into ac-
count the valid exceptions (according to Appendix III and IV RoHS (2011/65/EU) with delegated Directives (EU)
2018/739-741 from 01.03.2018 for Category 11 –until 21 July 2024) and comply with the RoHS.
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 accord-
ing 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 Restriction 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. In some products (ROBA-stop®, Sizes 2 –11, Type 8 - -.- - -.- /
ROBA-stop®-M, Sizes 2 –500, Type 891.- - -.- / ROBA-stop®-silenzio®, Sizes 4 –8, Type 896.- - -.- - / ROBA®-topstop®,
Sizes 100 –260, Type 899.- - -.- -), shoulder screws are installed which are made from a copper alloy containing up to
2.5 % by weight lead. Products made from copper and copper alloys do not fall within the area of applicability of Regula-
tion (EC) No. 1272/2008 of the European Parliament and Council Concerning the Classification, Labelling and Packaging
of Substances and Mixtures (CLP Regulation) and are therefore not subject to the classification and labelling obligations.
We would hereby like to point out that the proportion of lead used here is not prohibited according to the REACH Regula-
tion. It is merely necessary to declare the use of this substance.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 4 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
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 lines and compo-
nents.
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 condi-
tions are ignored.
During the risk assessment required when designing the ma-
chine or system, the dangers involved must be evaluated and re-
moved by taking appropriate protective measures.
To prevent injury or damage, only specialist personnel are
allowed to work on the components.
They must be familiar with the dimensioning, transport, installa-
tion, inspection of the brake equipment, initial operation, mainte-
nance and disposal according to the relevant standards and reg-
ulations.
Before product installation and initial operation,
please read the Installation and Operational In-
structions carefully and observe the Safety Reg-
ulations. Incorrect operation can cause injury or
damage. At the time these Installation and Oper-
ational Instructions go to print, the electromagnetic brakes ac-
cord with the known technical specifications and are operation-
ally safe at the time of delivery.
Technical data and specifications (Type tags and documen-
tation) 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 put-
ting 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 re-
pairs in a de-energised, disengaged state and
secure the system against inadvertent switch-
on.
Guidelines for Electromagnetic Compatibility
(EMC)
In accordance with the EMC directive 2014/30/EU, the individual
components produce no emissions. However, functional compo-
nents 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 val-
ues. 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 in-
tended application. When dimensioning the
brakes, please remember that installation situa-
tions, braking torque fluctuations, permitted friction work, bed-
ding-in condition / conditioning of the brake linings and wear as
well as general ambient conditions can all affect the given val-
ues. 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 in-
stallation.
Use of the brake in extreme environmental conditions or out-
doors, 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 current bedding-in
condition of the brake. Bedding in / conditioning of the friction
linings is necessary.
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 any other foreign bodies.
The surfaces of the outer components have been phos-
phated manufacturer-side to form a basic corrosion protec-
tion.
CAUTION
The rotors may rust up and seize up in corro-
sive ambient conditions and / or after longer
downtimes.
The user is responsible for taking appropriate
countermeasures.
Dimensioning
Attention!
When dimensioning the brake, please take into consideration
whether a load torque is present when selecting the protection.
Load torques reduce the deceleration torque available.
Load torques may increase the output speed:
during a possible processing time in the controls
during the brake downtime
When calculating the friction work, please observe that the brake
nominal torque is subject to a tolerance.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 5 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Climate Conditions
The electromagnetic brake is suitable for applications with an
ambient temperature of between -20 °C and +40 °C.
CAUTION
Reduction in braking torque possible
Condensation can form on the brake and cause
a loss in braking torque:
due to fast changes in temperature
at temperatures of around or under freez-
ing point
The user is responsible for taking appropriate
countermeasures (e.g. forced convection, heat-
ing, drain screw).
CAUTION
Brake malfunction possible
Condensation can form on the brake and cause
malfunctions:
at temperatures around or under freezing
point, the brake can freeze over and not
release any more.
The user is responsible for taking appropriate
countermeasures (e.g. forced convection, heat-
ing, drain screw).
The system function must be checked by the user after longer
downtimes.
At high temperatures and in high humidity or
with occurring dampness, the rotor can seize
up to the armature disk or the bearing shield /
the flange plate after longer downtimes.
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 compo-
nents. 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.
Grounding Connection
The brake is designed for Protection Class I. This protection co-
vers not only the basic insulation, but also the connection of all
conductive parts to the protective conductor (PE) on the fixed in-
stallation. If the basic insulation fails, no contact voltage will re-
main. Please carry out a standardised inspection of the protec-
tive conductor connections to all contactable metal parts!
Class of Insulation F (+155 °C)
The insulation components on the magnetic coils are manufac-
tured at least to class of insulation F (+155 °C).
Protection
IP54 (Type 891.0_ _.0):
Dust-proof and protected against contact as well as against wa-
ter spray from any direction.
When installed, under a fan cover provided by the customer,
Protection IP55 is valid: Dust-proof and protected against con-
tact as well as against jet water from a nozzle coming from any
direction.
IP66 (Type 891.0_ _.1):
When installed, dust-proof and protected against contact as well
as against strong jet water from a nozzle coming from any direc-
tion.
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 °C up to +40 °C.
Do not store in direct sunlight or UV light.
Do not store aggressive, corrosive substances (solvents / ac-
ids / lyes / salts / oils / etc.) near to the brakes.
For longer storage of more than 2 years, special measures are
required (please contact the manufacturer).
Storage acc. DIN EN 60721-3-1 (including the limitations / addi-
tions described above): 1K3; 1Z1; 1B1; 1C2; 1S3; 1M1
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 lin-
ings.
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 switching DC-side, the coil must
be protected using a suitable protection circuit in accordance
with VDE 0580, which is already integrated in mayr®-rectifi-
ers and Nord half-wave and bridge 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 ap-
plication, the switching contact can also be protected by
other protection circuits (e.g. 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 sur-
faces in high humidity and at low temperatures.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 6 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Standards, Directives and Regulations
Used and To Be Applied
DIN VDE 0580 Electromagnetic devices and compo-
nents, general specifications
2014/35/EU Low Voltage Directive
2011/65/EU RoHS II - Directive
2015/863/EU RoHS III- Directive
CSA C22.2 No. 14-2010 Industrial Control Equipment
UL 508 (Edition 17) Industrial Control Equipment
EN ISO 12100 Safety of machinery –General princi-
ples for design - Risk assessment and
risk reduction
DIN EN 61000-6-4 Interference emission
DIN EN 61000-6-2 Interference immunity
Liability
The information, guidelines and technical data in these docu-
ments were up to date at the time of printing. Demands on previ-
ously delivered brakes are not valid.
Liability for damage and operational malfunctions will not be
taken if:
- the Installation and Operational Instructions are ignored or ne-
glected.
- 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 condi-
tions.
Mistakes or deficiencies are to be reported to mayr®at
once!
CE Identification
in accordance with the Low Voltage Directive
2014/35/EU (only in case of voltages > 72 V) and /
or RoHS Directive 2011/65/EU with 2015/863/EU
Conformity Markings
in terms of the Canadian and American
approval
Identification
mayr®components are clearly marked and described on the Type tag:
Material number (Nord) Serial number Article number
Size/Type Voltage Power Braking torque DataMatrix code

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 7 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Brake Illustrations Size 250
Fig. 1 (Type 891.0_ _.0) Fig. 2 (Type 891.0_ _.0)
Fig. 3 (Type 891.0_ _.1) Fig. 4 (Type 891.0_ _.1)
Air gap “a”
Air gap inspection
opening
Air gap inspection
opening
Air gap “a”
Item 13 Release monitoring or
Item 14 Wear monitoring
(Options, independent on Type)

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 8 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Brake Illustrations Size 500
Fig. 5 (Type 891.0_ _.0) Fig. 6 (Type 891.0_ _.0)
337 Bild 7 (Type 891.0_ _.1) Bild 8 (Type 891.0_ _.1)
Fig. 9
Air gap “a”
Air gap inspection
opening
Air gap inspection
opening
Air gap “a”
Item 13 Release monitoring or
Item 14 Wear monitoring
(Options, independent on Type)

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 9 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Parts List (Only use mayr original parts)
Pcs.
Item
Name
Size 250
Size 500
1
Hub 1)
1
1
2
Coil carrier assembly (with magnetic coil)
1
1
3
Armature disk
1
1
4
Rotor
1
1
5
Thrust spring
acc. spring dimensioning
acc. spring dimensioning
6
Cap screw M10 x 110 DIN EN ISO 4762
3
6
7
Sealing plug 2) D16 / 12 x 1.5
1
-
Screw plug M16 x 1.5 (with O-ring)
-
1
8
Shoulder screw D18 x 44
2
2
9
Cone plug (only on Type 891.0_ _.0)
2
2
10
Type tag
1
1
11
Bonded seal (only on Type 891.0_ _.1)
3
6
12
O-ring (only on Type 891.0_ _.1)
1
1
13
Release monitoring (option, independent on Type)
1
1
14
Wear monitoring (option, independent on Type)
1
1
1) The hub (1) must be ordered separately.
2) An additional screw plug M16 x 1.5 (with O-ring) is installed on Size 250 and Type 891.0_ _.1
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.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 10 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Table 1: Technical Data
Size:
250
500
Type:
891.01_._
891.02_._
Nominal braking torque:
250 Nm
400 Nm
Braking torque tolerance (conditioned):
+40% / -20%
+40% / -20%
Braking torque tolerance (without conditioning):
+40% / -30%
+40% / -30%
Reference speed nref:
750 rpm
750 rpm
Max. speed nmax (brake engagement):
3600 rpm
3000 rpm
Permitted idle speed:
4700 rpm
3800 rpm
Nominal voltage UN :
see Type tag
see Type tag
Electrical power at nominal voltage PN:
see Type tag
see Type tag
Electrical connection, magnetic coil:
2 x 0.88 mm2
2 x 0.88 mm2
Mass with cap screw, without hand release and without hub:
25.9 kg
35.9 kg
Weight of hub / hand release assembly / hand release bar
0.98 kg / 1.27 kg / 1.28 kg
2.95 kg / 2.46 kg / 1.28 kg
Nominal air gap “a” +0.20/-0.05 (Figs. 2/4/6/8):
0.35 +0.1
-0.05 mm
0.40 +0.2 mm
Max. permitted air gap “a” after wear (Figs. 2/4/6/8) 1):
0.95 mm
1.0 mm
Minimal width of the counter friction surface:
14 mm
19 mm
Tightening torque Item 6:
45 Nm
45 Nm
Tightening torque Item 8:
18.5 Nm
18.5 Nm
Rotor thickness “new” (+0.08 mm):
17 mm
18.5 mm
Minimum rotor thickness:
16.4 mm
17.9 mm
Mass moment of inertia (hub + rotor):
71.8 x 10-4 kgm2
215 x 10-4 kgm2
Friction work Qr 0.1 (per 0.1 mm wear):
130 x 106J
170 x 106J
Friction work Qr ges. (max. possible friction work related to nominal air
gap):
780 x 106J
1700 x 106J
Duty cycle:
100%
100%
Protection (Type 891.0_ _.0):
IP 54 / IP552)
IP 54 / IP552)
Protection (Type 891.0_ _.1):
IP 66
IP 66
Ambient temperature:
-20 °C to +40 °C
-20 °C to +40 °C
1) Customer-side changes of the spring configuration have an effect on the maximum permitted air gap.
2) When installed, under a fan cover provided by the customer, Protection IP55 is valid.
The stated value Qr 0.1 is only a reference value for specific friction work values < 0.5 J/mm2and sliding speeds < 10 m/s.
Table 2: Changes in switching time t11 for different spring configurations
Size
Spring configuration
Braking torque
t11
250
8 x D21.5
250 Nm
100%
250
7 x D21.5
218 Nm
160%
250
6 x D21.5
187 Nm
220%
500
14 x D15 + 2 x D24.5
400 Nm
100%
500
11 x D15 + 2 x D24.5
350 Nm
137.5%

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 11 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Torque-Time Diagram
Key
MBr = Braking torque
ML= Load torque
t1= Connection time
t11 = Response delay on connection
t2= Separation time
t4= Slip time + t11
UN= Coil nominal voltage
Design
ROBA-stop®-M brakes are spring applied, electromagnetic safety
brakes, which apply a defined braking effect after the voltage is
switched off or after a voltage failure.
The brakes can optionally be retrofitted with a hand release (arti-
cle number 8265886 for Size 250 or article number 8265888 for
Size 500).
Function
The ROBA-stop®-M brake is a spring applied, electromagnetic
safety brake.
Spring applied function (brake):
In de-energised condition, thrust springs (5) press against the ar-
mature disk (3). The rotor (4) is held between the armature disk
(3) and the customer-side machine wall via frictional locking.
The braking torque is introduced into the drive line via the tooth-
ing of the rotor (4) and the hub (1).
Electromagnetic function (release):
Due to the magnetic force of the coil in the coil carrier (2), the ar-
mature disk (3) is attracted against the spring pressure to the coil
carrier (2). The brake is released and the brake rotor (4) with the
hub (1) can rotate freely.
Safety brake function:
The ROBA-stop®-M brake brakes reliably and safely in the event
of a power switch-off, a power failure or an EMERGENCY
STOP.
Scope of Delivery / State of Delivery
ROBA-stop®-M brakes are pre-assembled.
An optional release monitoring device / wear monitoring device is
installed and set manufacturer-side.
The hand release devices have already been mounted manufac-
turer-side for designs Type 891.0_1.1.
The hub (1) is not included in the standard scope of delivery and
must be ordered separately.
Included loose in delivery are:
- rotor (4)
- cap screws (6)
Additional parts for Type 891.0_ _.1:
- bonded seals (11)
- O-ring (12)
The brakes are set manufacturer-side to the braking torque stip-
ulated on order.
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 take no responsibility for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects immedi-
ately to the manufacturer.
MBr
0,1 x MBr
ML
t11
t1t2
t4
U
M
t
t
UN

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 12 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Installation Conditions
The eccentricity of the shaft end in relation to the mounting
pitch circle must not exceed 0.2 mm.
The positional tolerance of the threads for the cap screws (6)
must not exceed 0.2 mm.
The axial run-out deviation of the screw-on surface to the
shaft must not exceed the permitted axial run-out tolerance
of 0.1 mm for Size 250 and of 0.125 mm for Size 500, ac-
cording to DIN 42955. The reference diameter is the pitch
circle diameter for securement of the brakes.
Larger deviations can lead to a drop in torque, to continuous
grinding of the rotor (4) and to overheating.
The tolerances of the hub bore and the shaft must be se-
lected so that the hub toothing (1) is not widened. Widening
of the toothing leads to the rotor (4) jamming on the hub (1)
and therefore to brake malfunctions.
Recommended hub –shaft tolerance H7/k6.
The max. permitted joining temperature of 200 °C must not
be exceeded.
A suitable counter friction surface (flange surface) made of
steel or grey cast iron must be provided for the rotor (4).
Sharp-edged interruptions on the friction surfaces must be
avoided.
Surface quality in the friction area of the friction surface:
Ra 1.6 µm
When machining grey cast iron, please make
sure that the cast tips are removed.
The rotor (4) and brake surfaces must be oil and grease-
free.
The toothings of the hub (1) and the rotor (4) must not be
oiled or greased.
Friction value-increasing surface treatments are not permit-
ted.
Please abstain from using cleaning agents containing sol-
vents, as they could affect the friction material.
Protect the rotor from rusting up / seizing up against the
bearing shield / the flange plate (customer-side). We recom-
mend tried and tested anti-corrosion measures for the
mounting surface:
dry, oil-free phosphate layers
hard chromium and nitriding
Installation (Figs. 1 to 10)
1. Mount the hub (1) onto the shaft, bring it into the correct po-
sition (the length of the key should lie over the entire hub)
and secure it axially, e.g. using a locking ring.
2. Measure the rotor thickness of the new rotor (4).
The nominal dimension acc. Table 1 must be given.
3. Push the rotor (4) onto the hub (1) by hand (the rotor collar
should be facing away from the machine wall). The rotor
toothing must lie over the entire length of the hub (1).
Make sure that the toothing moves easily.
Do not cause any damage!
4. If necessary (dependent on Type), insert the O-ring (12) into
the axial groove of the coil carrier (2).
5. Push the rest of the brake over the hub (1) and the rotor col-
lar (4) (the fixing holes should align with the bores in the ma-
chine wall). The shoulder screws (8) prevent the individual
components from falling apart.
They do not affect the brake function and must not be re-
moved during installation.
6. Secure the brake with the cap screws (5) and mounted seals
(Item 11 / dependent on Type) onto the machine wall evenly
all around using a torque wrench and a tightening torque
of 45 Nm.
7. Check the air gap, see page 16.
8. Establish the electrical connection of the brake.
Hand Release
The brakes are suitable for the optional attachment of a hand re-
lease device.
The hand release including separate Installa-
tion Instructions can be ordered at the manu-
facturer’s stating the article or serial number of
the respective brake.
In order to install the hand release, the brake
must be removed from the machine wall and
de-energised!
The hand release devices have already been mounted manufac-
turer-side for designs Type 891.0_1.1.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 13 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Definition of the Braking Torques
Static braking torque
Effectively averaged, fully developed torque for slipping brake
with smallest speed values.
Guideline value: n = 3 [rpm]
Dynamic braking torque
Effectively averaged, fully developed torque in a braking proce-
dure from the output speed up to standstill.
For correct evaluation, a sufficient slip time is
required (sliding speed between 1 m/s and
10 m/s).
The permitted friction work and speed values
must not be exceeded.
Braking Torque Adjustment
The ROBA-stop®-M brakes are set manufacturer-side to the
braking torque stipulated on order.
The set torque is stated on the motor Type tag.
Run-in procedure / Conditioning of the friction
lining pairing
The stated brake nominal torques are valid for a run-in / condi-
tioned state of the friction lining pairing in standard climate condi-
tions.
When in new condition and without conditioning of the friction
pairing, the braking torque tolerance may be +40 % / -30 %
Conditioning is necessary:
in new condition
during the operation of the system
EMERGENCY STOP only after brake run-in procedure
Please carry out conditioning of the friction lining pairing
through dynamic braking procedures of the system.
Recommendation:
Approx. Please carry out approx. 5 dynamic braking procedures
at 50 % of the permitted speed nmax
at 25 % of the permitted friction work Qr zul.
Please observe the following under deviating run-in condi-
tions:
do not use higher speed and/or friction work values
at lower friction work values, increase the number of dy-
namic braking actions to achieve similar total friction works.
A generally valid definition of the parameters
required for the conditioning is not possible due
to the different application possibilities.
The frequency of the friction lining pairing con-
ditioning and the torque inspection must be de-
termined by the user depending on the appli-
cation.
If regular conditioning is not possible:
Dimension with a correspondingly higher safety.
Recommendation: Si ≥ 2.0
Attention! The dynamic dimensioning must be taken into account
separately
EMERGENCY STOP only after brake run-in
procedure
Brake Inspection (before brake initial operation)
Braking torque inspection:
Please compare the requested braking torque with the
torque stated on the Type tag (10).
Inspect the air gaps:
Air gap “a” (brake de-energised):
The nominal air gap acc. Table 1 must be given.
Release function inspection:
by energising the brake.
The braking torque is not achieved until after the run-in proce-
dure has been carried out. See section “Definition of the Braking
Torques”.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 14 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Electrical Connection and Wiring
DC current is necessary for operation of the brake. The coil nom-
inal 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 alternating voltage us-
ing a rectifier or another suitable DC power supply. The connec-
tion possibilities can vary dependent on the brake equipment.
Please follow the exact connections according to the Wiring Dia-
gram. The manufacturer and the user must observe the applica-
ble regulations and standards (e.g. DIN EN 60204-1 and DIN
VDE 0580). Their observance must be guaranteed and double-
checked!
Grounding Connection
The brake is designed for Protection Class I. This protection co-
vers therefore not only the basic insulation, but also the connec-
tion of all conductive parts to the protective conductor (PE) on
the fixed installation. If the basic insulation fails, no contact volt-
age will remain. Please carry out a standardised inspection of
the protective conductor connections to all contactable metal
parts!
Device Fuses
To protect against damage from short circuits, please add suita-
ble device fuses to the mains cable.
Switching Behaviour
The reliable operational behaviour of a brake is to a large extent
dependent on the switching mode used. Furthermore, the switch-
ing times are influenced by the temperature and the air gap be-
tween the armature disk and the coil carrier (dependent on the
wear condition of the linings).
Influencing the switching time
The same switching time can be used for rectifiers manufactured
by Getriebebau Nord and for those manufactured by mayr® (see
Table 2 and section “Protection circuit”).
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
current does not immediately reach its nominal value. The coil in-
ductivity 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 drop in braking torque is achieved if the coil is tempo-
rarily placed under a higher voltage than the nominal voltage, as
the current then increases more quickly. Once the brake is re-
leased, it needs to be switched over to the nominal voltage
(curve 2). The ROBA®-(multi)switch fast acting rectifier and
phase demodulator work on this principle.
Current path Braking torque path
Magnetic Field Removal
AC-side switching The power circuit is inter-
rupted in front of the rectifier.
The magnetic field slowly re-
duces. 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 (approx. 6-10 times longer than
with DC-side disconnection), use for non-critical braking times.
DC-side switching The power circuit is inter-
rupted between the rectifier
and the coil as well as mains-
side. The magnetic field re-
duces extremely quickly. This
causes a quick rise in braking
torque.
When switching DC-side, high
voltage peaks are produced in
the coil, which can lead to
wear on the switching con-
tacts from sparks and to de-
struction of the insulation.
DC-side switching means short brake engagement times (e.g.
for EMERGENCY STOP operation); however, louder switching
noises.
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®-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 volt-
age 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 quench-
ing unit, half-wave and bridge rectifiers), although this may of
course then alter the switching times.
Coil
F1: external fuse
Coil
F1: external fuse

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 15 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Permitted Brake Friction Work
The permitted friction work values dependent on the switching frequency shown in the characteristic curve must not be exceeded, not even
in EMERGENCY STOP operation.
The following diagrams show the permitted friction work values Qr referring to the respective switching frequency for the various brake sizes
and rated speeds (Table 1).
For 60 Hz operation, the max. permitted friction
work values must be reduced to 70 %.
Friction power diagram for RSM 250 –BRE 250
Friction power diagram for RSM 500 –BRE 400
Permitted friction work at other speeds (customer specific)
The permitted friction work at specific customer speeds can also be calculated using linear interpolation between the maximum speed and
reference speed.
Qn= Permitted friction work at customer speed
Qn ref = Permitted friction work from friction power diagram for reference speed
Qn max = Permitted friction work from friction power diagram for maximum speed
n = Actual customer speed
nref = Reference speed (see Table 1)
nmax = Maximum speed (see Table 1)
Qn = Qn ref - (Qn ref - Qn max)
(nmax - nref)× (n - nref)
Switching frequency
[1/h]
Permitted friction work [J]
Reference speed nref
Maximum speed nmax
Switching frequency
[1/h]
Permitted friction work [J]
Reference speed nref
Maximum speed nmax

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 16 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Optional microswitch for brake monitoring
(Items 13/14 / Figs. 3 and 7)
If you require a release monitoring device or a
wear monitoring device, please state this ex-
plicitly when ordering your brake.
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 powers and
medium ones. However, after switching a medium switching
power, small switching powers are no longer reliably possible.
In order to switch inductive, capacitive and non-linear loads,
please use the appropriate protection circuit to protect against
electric arcs and unpermitted loads!
Microswitch Specification
Characteristic values for
measurement:
250 V~ / 3 A
Minimum switching power:
12 V, 10 mA DC-12
Recommended switching
power:
for maximum lifetime
and reliability
24 V, 10...50 mA
DC-12
DC-13 with freewheeling di-
ode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)
If a replacement or new adjustment of a micro-
switch is required
by the customer, separate adjustment instruc-
tions stating the article or serial number of the
respective brake can be requested from the
manufacturer.
Release Monitoring (Item 13)
The brakes are supplied optionally with manufacturer-side in-
stalled and adjusted release monitoring device.
A microswitch emits a signal for every brake condition change:
“brake opened” or “brake closed”.
The customer is responsible for a signal evaluation of both
conditions.
From the point at which the brake is energised, a time span of
three times the separation time must pass before the micro-
switch signal on the release monitoring is evaluated.
Function
When the magnetic coil is energised in the coil carrier (2), the ar-
mature disk (3) is attracted to the coil carrier (2), the microswitch
emits a signal, the brake is released.
Wiring Diagram of the Microswitch for Release Moni-
toring
Customer-side Inspection after Attachment
Carry out a functional inspection before brake initial operation.
for connection as NO contact:
Brake de-energised: Inspection lamp must signal “OFF”.
Brake energised: Inspection lamp must signal “ON”.
for connection as NC contact:
Brake de-energised: Inspection lamp must signal “ON”.
Brake energised: Inspection lamp must signal “OFF”.
Wear Monitoring (Item 14)
The brakes are supplied optionally with manufacturer-side in-
stalled and adjusted wear monitoring device.
Function
Due to wear on the rotor (4), the air gap “a” between the coil car-
rier (2) and the armature disk (3) increases.
Once the limit air gap of 0.95 mm for Size 250 or 1.0 mm for
size 500 has been reached, the microswitch contact switches
over and emits a signal.
The rotor (4) must be replaced.
Customer-side changes of the spring configura-
tion have an effect on the maximum permitted
air gap.
The customer is responsible for a signal evaluation.
Wiring Diagram of the Microswitch for Wear Monitor-
ing
COM contact
Brown connection
NC contact
Black connection
Connection when
wear limit
has been reached
NO contact
Blue connection
Connection when
wear limit
has not yet been
reached
COM Contact
Brown connection
NC contact
Black connection
Connection when
brake closed
NO contact
Blue connection
Connection when
brake released

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 17 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Air Gap Inspection
The air gap can be inspected via a feeler gauge after removing
the sealing plug / screw plug (7). The feeler gauge must be in-
serted at least 40 mm deep (see Fig. 10), so that the distance
between the armature disk (3) and the coil carrier (2) can be
measured.
Fig. 10
Maintenance
The amount of wear on the rotor (4) must be examined during the
regular inspection intervals:
ROBA-stop®-M brakes are mainly maintenance-free.
The friction lining pairing is robust and wear-resistant. This en-
sures a particularly long service lifetime of the brake. The friction
lining is subject to functional wear in case of EMERGENCY
STOP and during regular conditioning of the friction lining pair-
ing.
In addition to this, further signs of wear may appear:
Dry-running wear due to the presence of residual friction in
the brake.
Increased wear (depending on speed) in the case of a verti-
cal or pivoting installation position for the motor axis, partic-
ularly to the lower friction lining.
If the rotor (4) does become worn due to the high total friction
work, and the function of the brake can no longer be guaranteed,
the brake can be re-set to its functional state by replacing the ro-
tor.
The quality of the counter friction surface must be checked.
The wear condition of the rotor (4) can be specified by:
Checking the air gap (see above).
Max. permitted air gap see Table 1.
Measuring the rotor thickness on the dismantled brake.
See Table 1 for the minimum rotor thickness.
We recommend the following regular inspection intervals:
Once a year
Inspection of the air gap “a”.
Twice a year or after 1000 operating hours
Inspection of the rotor thickness (wear).
Inspection of the toothing of the rotor (4) and hub (1) for
ease of movement, increased backlash, and damage.
Max. permitted torsional backlash of the rotors on the
hub 0.3°.
Inspection on an engaged brake and load-free output by
turning the motor shaft.
Inspection of the armature disk (3), the intermediate disk (10)
and the customer flange for plane parallelism and wear (ex-
cessive formation of scoring).
Clean the brake.
Replacing the rotors
After having reached the maximum air gap.
In safety-critical applications (without cyclical brake test) at
the latest after 6 years of operating the system
User-implemented determination
The frequency of the friction lining pairing conditioning and the
torque inspection must be determined by the user depending on
the application.
In order to maintain the brake torque in holding applications, the
friction lining pairing must be conditioned regularly. This must be
carried out in the form of dynamic braking procedures. After-
wards, the brake torque must be checked.
If regular brake conditioning in holding applications is not possi-
ble, a higher level of security must be used for dimensioning
(recommendation: Si = 2.0 => Please observe: The dynamic di-
mensioning must be taken into account separately).
Wear times are influenced by many factors and can vary substan-
tially. The required inspection and maintenance intervals must be
calculated individually according to the system manufacturer's
planning documentation.
Feeler gauge
min. 40 mm

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 18 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Replacing the Rotor (4)
Before replacing the rotor (4)
Clean the brake.
Please observe the section “Cleaning the
Brake”, see right column.
Measure the rotor thickness of the new rotor (4).
The nominal dimension acc. Table 1 must be given.
DANGER
The brake must be load-free. Please check that
it is load-free before de-installation. In order to
replace the rotor (4), the brake must be un-
screwed from the machine wall.
Replace the rotor by following the Brake Installation instruc-
tions backwards.
When armature disk (3) replacement is necessary, please pro-
ceed as follows:
1) Unscrew the shoulder screws (8) from the coil carrier (2) and
remove the armature disk (3).
Attention: The thrust springs (5) press against the armature
disk (3). In order to remove the shoulder screws (8), the ar-
mature disk (3) must be pressed against the coil carrier (2) to
avoid immediate relaxation of the thrust springs (5).
Observe the installation position of the armature disk (3), and
ensure that no thrust springs (5) fall out.
CAUTION
Danger of injury.
2) Lay the new armature disk (3) onto the coil carrier (2) or the
thrust springs (5) (observe installation position).
3) Press the armature disk (3) down against the spring force
and screw in the shoulder screws (8) up to their limits using
a tightening torque of 18.5 Nm.
For further assembly of the brake, please follow the Brake Instal-
lation instructions, followed by Brake Inspection and Run-in Pro-
cedure, see pages 12 and 13.
Information on the Components
The friction material contains different inorganic and organic
compounds, which are integrated into a system of hardened
binding agents and fibres.
Possible hazards:
No potential dangers have been recognised so far when the
brake is used according to its intended purpose. When grinding
in the brake linings (new condition) and also in case of EMER-
GENCY STOP braking actions, functional wear can occur (wear
on the friction linings); on open brake designs, fine dust can be
emitted.
Classification: Hazardous property
Attention: H-classification: H372
Protective measures and rules of behaviour:
Do not inhale dusts.
Vacuum the dusts at the point of origin
(tested suction devices, tested filters acc. DIN EN 60335-2-69 for
dust classes H; maintenance of the suction devices and filter re-
placement at regular intervals).
If local dust suction is not possible or is insufficient, the entire
work area must be ventilated using appropriate technology.
Additional information:
This friction lining (asbestos free) is not a dangerous product in
terms of the EU Directive
Cleaning the Brake
Do not clean the brake using compressed air,
brushes or similar devices!
Wear safety gloves / safety goggles.
Use a suction system or wet towels to clean off the brake
dust.
Do not inhale brake dust.
In case of dust formation, a dust mask FFP 2 is recom-
mended.
Disposal
Our electromagnetic brake components must be disposed of
separately as they consist of different materials. Please also ob-
serve the relevant authority regulations. Code numbers may vary
according to the disassembling process (metal, plastic and ca-
bles).
Electronic components
(Rectifier / 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.
Brake bodies made of steel with coil/cable and all other
steel components:
Steel scrap (Code No. 160117)
All aluminium components
Non-ferrous metals (Code No. 160118)
Steel or aluminium pads with friction linings:
Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomers:
Plastic (Code No. 160119)
Guidelines on the WEEE Directive 2012/19/EU
Avoidance of waste from electrical and electronic devices and
the reduction of such waste through recycling.
Our electromagnetic products (brakes, clutches) as well as the
components required to control them (rectifiers) are frequently
used in electrical and electronic devices within the appropriate
area of application of WEEE, independent of the applicable prod-
uct 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
(DIN 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 Di-
rective and not as parts or components are subject to registration
obligations.

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 19 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Malfunctions / Breakdowns
Malfunction
Result of Malfunction
Possible Causes
Solutions
The brake must always be dismantled in order
to remove damage and malfunctions.
Damaged parts must be replaced in order to
solve the respective problem.
The brake must be cleaned before re-installa-
tion.
The brake does not
release completely;
permanent grinding of
the rotor
The axial flexibility of
the rotor is limited;
rotor is jammed axially
Incorrect tolerance constellation
on the shaft-hub connection
Check tolerances
Tolerance errors
on the key connection
Broken hub due to installation
error when mounting
Suitable mounting method
Poor shaft quality
Check the shaft quality
Poor key
dimensioning
Carry out a key calculation
Contamination of the hub or rotor
toothing
due to abraded or worn particles
Check the hub and rotor toothing; maintain suitable
maintenance intervals
Wear, damage,
deformation or breakage
of the hub and rotor toothing
Wiring error on the
brake
Incorrect voltage,
no DC voltage
Check voltage,
observe the wiring guidelines
Defective electrical wiring
Check electrical wiring
Defective coil, coil is electrically or
thermally overloaded
Check coil capacity;
check insulation resistance
Air gap too small in re-
leased condition
Due to installation
Air gap inspection
Penetration of foreign bodies into
the brake, in particular
magnetisable particles
Check the brake interior for dirt and clean it
Excessive component tempera-
tures;
temperature expansion
Temperature inspection
Increased friction
work; brake grinds
Excessively long en-
gagement times
Load accelerates the drive line
during the brake engagement
time
Check for correct wiring, switching times and di-
mensioning
Drop in braking torque
Excessive wear on the rotor
Wear inspection; replace the rotor
Motor starts up against
closed brake
Excessive brake attraction times
Check for correct wiring, switching times; check di-
mensioning; check motor controls
Component breakage
Operating conditions
Oscillations, vibrations, overload,
unpermittedly high speeds
Check operating conditions and dimensioning
Ambient influences,
temperature, fluids,
media, corrosion
Friction linings sticking, settling or
swelling; changes in friction lining
friction behaviour
Check protection against environmental influences
Deviations,
adjustment dimensions,
screw tightening
torques
Brake securement,
hand release, actuation lever,
screws
Check the guidelines and values according to the
information in the Installation and Operational In-
structions

Installation and Operational Instructions for BRE250 and BRE400
ROBA-stop®-M brake Type 891.0_ _._
Sizes 250 and 500 (E070 09 203 001 4 EN)
31/10/2019 TK/MW Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: [phone], Fax: [phone]
Page 20 of 20 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Malfunctions / Breakdowns
Malfunction
Result of Malfunction
Possible Causes
Solutions
The brake must always be dismantled in order
to remove damage and malfunctions.
Damaged parts must be replaced in order to
solve the respective problem.
The brake must be cleaned before re-installa-
tion.
Slipping;
permanent grinding of
the brake under load;
increase in friction
work
Too low
Braking torque
Brake run-in procedure not carried
out
Carry out a run-in procedure
Do not carry out regular condition-
ing
Carry out conditioning of the friction pairing
Incorrect dimensioning
Check the required braking torque
Incorrect spring configuration
Check the spring configuration; have the brake
checked at the place of manufacture
Drop in braking torque
Excessive wear on the rotor
Wear inspection
Changes to the friction behaviour
on the friction lining due to the
maximum sliding speed being ex-
ceeded
Check for correct wiring, switching times and di-
mensioning
Changes
in braking torque
Unpermittedly high friction work,
squeaking, type and quality of the
counter friction surface
Check for correct wiring, switching times and di-
mensioning
Corrosion on the counter friction
surface
Check the brake for corrosion
Ambient influences, oil,
Water, cleaning media,
condensation formation
Check protection against environmental influences
Type and quality of the counter
friction surface
Check the counter friction surface
Extremely low
friction speeds
Check the dimensioning
Brake cannot be re-
leased
Excessive pull-in distance
due to unpermitted wear
Wear inspection; replace the rotor
No voltage connection
Check the voltage connection
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.