Installation and Operating Instructions for ROBA-stop
Contents
1. As the rotor friction material 35 wears down the air gap a a2 increases By turning the graduated distance ring 31 the nominal air gap can be restored The adjustment has to be carried out at the latest when the maximum permissible working air gap according to Table 2 is achieved Re adjustment 1 Remove a plug from the threaded distance ring 31 Measure the air gap in a de energised condition with a feeler gauge before an adjustment The difference between the measured air gap and nominal air gap a1 a2 according to Table 2 must be re adjusted 2 Loosen the fixing screws 13 Release the locking screw 59 and lock washer 58 4 Turn the threaded distance ring 31 counter clockwise when looking at brake back side Turning the distance ring 31 by one graduation of the stamped scale corresponds to an air gap adjustment for the sizes 3 to 6 of 0 05 mm for the sizes 7 to 11 of 0 1 mm 5 Tighten the fixing screws 13 observe the tightening torques according to Table 1 6 Tighten the clamping screw 59 7 Check the air gap nominal air gap a1 a2 according to Table 2 must be available ca This adjustment can be repeated so often until the graduated distance ring 31 contacts the rod stop of the coil carrier 2 Fig 2 This contact avoids an unacceptable wear of the rotor 35 If a re adjustment is not possible any more the rotor 35 must be exchanged You can find data on the rotor thickness2. at least between armature disc 5 and coil carrier 2 Table 4 18 Rosas soo 4 3 6 7 2 e 1 Please contact the factory regarding the hand release sizes 10 and 11 Parts List hand release 2 22 10 Shoulder screw 16 Threaded bolt 17 Restoring bolt 18 Ball button 19 Return spring 10 21 Lock nut 22 Hand release bracket Inspection 19 hole Fig 4 17 18 11 2004 K KR Chr Mayr GmbH Co KG Tel 08341 804 241 EichenstraBe 1 Fax 08341 804 422 ma yr 87665 Mauerstetten http www mayr de Page 7 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 Electric connection Warning Electrical connection only in a voltage free condition The coil voltage is indicated on the Type tag additionally it is stamped on the brake The brakes are designed according to Euro voltage DIN IEC 38 DC current is necessary for the operation DC or AC current switchings are possible DC current switching however gains a faster engaging time engagement of the brake In case a faster disconnection time of the brake is desired a special ROBA switch fast acting rectifier is necessary In this case please contact our company Attention Cut off peaks may arise during switching off of electromagnetic units These can cause damage to the units and are therefore to be damped The connection times
3. in a new condition and thickness after a max wear in Table 2 Type 802 41 _ Type 800 41 _ Type 804 41 _ Table1 Fast acting Standard armature Fast acting silencing armature armature Bue Fig 2 Fixing screws 3x 3x 3x 3x 3x 3x 6x 6x 6x M4 M4 M5 M6 M6 M8 M8 M8 M12 tightening 3 3 10 10 10 40 torques Nm 18 11 2004 K KR Chr Mayr GmbH Co KG Tel 08341 804 241 EichenstraBe 1 Fax 08341 804 422 ma yr 87665 Mauerstetten http www mayr de Page 5 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 B 1110 1 GB Table 2 Dimension b Fig 2 mm 3 naps at the outer therefore measuring only in this no naps no naps range Max air gap mm Type 800 0 40 0 45 0 75 0 85 0 90 1 0 1 0 1 1 with nominal torque Type 802 0 35 0 40 0 70 EJ 75 arn 80 0 85 0 85 a 90 Rotor thickness in a new condition mm ss fz The max working air gap can be reduced with increasing working temperature Braking torque adjustment ROBA stop brakes are adjusted to the braking torque requested in the order in the factory The braking torque is reduced by turning the set screws 14 counter clockwise and increased by turning them clockwise All set screws 14 must be uniformly adjusted when the braking torque is adjusted Attention Type 802 41 _ Do not interchange set screws 14 with f
4. nuts 42 5 Connect the brake acc to the installation and operating instructions No B 1110 4 GB for ROBA stop brakes electric connection 6 Close the terminal box Observe the sealing 51 and sealing washers 53 Panel 44 mounted by choice with 1 Terminal 2 poles 2 Terminal 4 poles 47 3 Terminal 6 poles 4 Half wave rectifier 5 Bridge rectifier Cable of the brake coil fq Kabel der Bre le an B wie Fig 7 Maintenance ROBA stop brakes are virtually maintenance free Attachment The friction linings are robust and wear resistant ensuring a very 18 11 2004 K KR Chr Mayr GmbH Co KG Tel 08341 804 241 EichenstraBe 1 Fax 08341 804 422 ma yr 87665 Mauerstetten http www mayr de i Page 8 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 long brake service life However the gear hub 1 armature disc 5 as well as the rotor with friction linings 35 are subject to wear and must be checked at regular intervals and exchanged if necessary See for this the chapter Exchange of the wearing parts B 1110 1 GB Disposal Electronic components rectifier ROBA switch micro switch The not disassembled products can be supplied to the material utilization according to EAK 150106 mixed material or via the household waste code No 200301
5. 08341 804 241 EichenstraBe 1 Fax 08341 804 422 ma r 87665 Mauerstetten http www mayr de Page 1 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 B 1110 1 GB Safety regulations With these safety regulations no claim on completeness is raised Attention Hazardous conditions when contacting hot connections and components Only qualified and well trained specialists should work on the units to avoid any personal injury or damage to machinery Danger If the electromagnetic brake is used in an improper way If the electromagnetic brake has been modified or reconverted If the relevant standards of the safety or installation conditions are not observed Attention The installation and operating instructions must be read carefully and all safety regulations observed before installation and initial operation as danger to personnel and damage to machinery may be caused The electromagnetic brakes are developed and manufactured in conformance with the temporally known rules of the technology and they are basically considered as fail safe at the time of the delivery Attention Based on the guideline 94 9 EC ATEX guideline this product is not suitable for the application in potential explosive areas without evaluation of the conformity Observe O Only qualified and well trained specialists who are familia
6. Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 B 1110 1 GB Please read and observe this Operating Instruction carefully A possible malfunction or failure of the brake and any damage may be caused by not observing it Table of contents Page 1 Table of contents Manufacturer s declaration Page 2 Safety regulations Page 3 Safety regulations Page 4 Brake view Parts list Scope of delivery Function description Page 5 Assembly conditions Assembly Air gap adjustment Page 6 Table 2 Air gap adjustment Braking torque adjustment Brake inspection Exchange of the wearing parts Page 7 Assembly of the hand release Adjustment of the hand release Parts list hand release Page 8 Electric connection Assembly terminal box Page 9 Maintenance Disposal Breakdowns Manufacturer s declaration The product is to be seen as an option or component for installation into machines or equipment according to the machinery directive 98 37 EC The machinery product must not be put into service until the machinery or equipment into which it is to be incorporated has been declared in conformity with the provisions of the applicable EC directives The product corresponds to the low voltage directives 73 23 EEC The observance of the relevant EMC directive 89 336 EEC is to be guaranteed 18 11 2004 K KR Chr Mayr GmbH Co KG Tel
7. Pay attention that the helical springs 11 do not fall out The armature disc 5 can be different depending on the brake Type ee Fig 3 Therefore observe the mounting position Fig 3 18 11 2004 K KR Chr Mayr GmbH Co KG Tel 08341 804 241 EichenstraBe 1 Fax 08341 804 422 ma yr 87665 Mauerstetten http www mayr de Page 6 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 41 _ Sizes 3 11 B 1110 1 GB Assembly of the Hand release The hand release can be mounted to each Type of the positioning brake with the exception of the Type 804 41 _ Brake with fast acting silencing armature disc The brake must be dismantled and de energised for the assembly O Push the return spring 19 onto the restoring bolt 17 O Take out the plastic plugs from the bores on the back side of the coil carrier 2 O Push the restoring bolt 17 through the recesses in the armature disc 5 and through the bores in the coil carrier 2 O Bolt the hand release bracket 22 with the locking nuts 21 onto the restoring bolt 17 Fig 5 Fitting the hand release The restoring bolts 17 limit the stroke of the armature disc 5 in brake direction Figs 4 and 5 Attention The restoring bolts 17 may only be tightened by the locking nuts 21 so that the adjusting dimension X according to Table 4 and Fig 5 remains existing
8. ages immediately with the forwarder Recognizable faults incompleteness of the shipment immediately in the manufacturing company 18 11 2004 K KR Chr Mayr GmbH Co KG Tel 08341 804 241 Eichenstra e 1 Fax 08341 804 422 ma r 87665 Mauerstetten http www mayr de Page 4 of 9 Germany eMail info mayr de Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 Assembly conditions Before attachment of the brake the following points must be observed The eccentricity of the shaft end against the fixing hole P C D must not exceed 0 2 mm with sizes 3 6 or with larger brakes it must not exceed 0 4 mm O The positioning tolerance of the thread for the cap screws 13 must not exceed 0 2 mm O The deviation in the true running of the screw on surface to the shaft must not exceed the permissible true running tolerance according to DIN 42955 R Reference diameter is the pitch circle diameter for brake attachment Larger deviations can cause a reduction in torque a continuous wear of the rotor and overheating O The hub and shaft fits are to be selected to avoid any distortion of the hub splines observe the max joining temperature of 200 It can clamp the rotor on the hub impairing the brake function recommended hub shaft fit H7 k6 O The hub 1 is to be brought in such position that the toothing of the rotor 35 supports across the
9. ase demodulators or ROBA switch in the line side Therefore the installation and operating instructions must be read carefully the EMC directives are to be observed Conditions of the unit The catalogue values are reference values which can deviate in some cases When selecting the brake site of installation braking fluctuations permissible friction work behaviour during run in wear and ambient conditions are to be carefully checked and agreed with the unit manufacturer Observe O The mounting and connecting dimensions at the site of installation must match to the size of the brake O The brakes are designed for a relative switch on period of 100 O The brakes are designed for a dry running only Should oil grease water or similar materials come in contact with the friction surfaces the braking torque could be reduced O The braking torque depends on the corresponding running in condition of the brake O The metallic surface of the brake is protected against corrosion arranged by the factory Protection class The protection is not only based on the basis isolation but that all conductive components must be connected with the protective conductor PE of the fixed installation In case the basis isolation fails no contact voltage can remain existing VDE 0580 Protection electrical IP 54 Dust tight and protection against contact as well protection against splashing water from all directions A
10. ditional necessary safety measures against corrosion of the brake if they are used in extreme ambient conditions or in the open with direct atmospheric influences Measures against freezing from armature disc and rotor with high humidity and deep temperatures Following directives standards and guidelines have been used 98 37 EC Machinery directive 73 23 EEC Low voltage directive 89 336 EEC EMC directive DIN VDE 0580 Electromagnetic units and components general regulations Following standards are to be observed EN292 1 and 2 Security of machines DIN EN61000 6 4 Interference emission DIN EN61000 6 2 Interference resistance EN60204 Electrical equipment of machines 18 11 2004 K KR Chr Mayr GmbH Co KG EichenstraBe 1 87665 Mauerstetten Page 3 of 9 Germany Liability O The information notes and technical data indicated in the documentation were at the time of printing on the latest state Claims on brakes already supplied cannot be made valid from it 01 Liability for damages and breakdowns is not taken over with ignoring the installation and operating instructions improper use of the brakes arbitrary modification of the brakes inappropriate working at the brakes handling or operating errors Guarantee O The warranty conditions correspond to the sales and supply conditions of Chr Mayr GmbH Co KG O Defects are to be advised immediately after detection to may Test mark CE cor
11. entire surface O Rotors and braking surfaces must be free of oil and grease O There has to be a suitable counter friction surface for the rotor 35 made from steel or cast iron Sharp edged interruptions of the friction surface must be avoided Assembly O Mount the gear hub 1 onto the shaft and lock it axially Avoid damaging the toothing The gear hub 1 is to be mounted in such a way that the toothing of the rotor 35 remains completely engaged even when the friction linings 8 are worn down O Push the rotor 85 manually onto the gear hub 1 The rotor collar points to the brake Ensure that the splines slide easily No damage O Attach the brake using the included fixing screws 13 and lock it by means of the spring washers 28 Observe the screw tightening torques according to Table 1 Check the air gap a1 a2 Fig 2 nominal air gap a1 a2 according to Table 2 must be available The shoulder screws 10 Figs 1 and 4 prevent the individual parts from coming apart They do not impair the function of the brake and should not be removed during assembly B 1110 1 GB Air gap adjustment The working air gap between armature disc 5 and coil carrier 2 is adjusted to the nominal dimension a1 ag in the factory Fig 2 and Table 2 The size of the nominal air gap depends on the structural form of the armature disc 5 The third figure of the Type number informs on the fitted armature disc
12. indicated in the catalogue can be deteriorated by this damping A protection of the voltage supply according to the current values is to be provided The brakes are designed for a relative duty cycle of 100 Assembly terminal box Panel 44 mounted by choice with 1 Terminal 2 poles 2 Terminal 4 poles 3 Terminal 6 poles 4 Half wave rectifier 5 Bridge rectifier Parts list terminal box 37 Holding bracket 38 Cap screw M3 x 12 39 Terminal box lower part 40 O ring 41 Sealing plate 42 Hexagon nut M3 43 Cable gland 44 Panel 45 Countersunk screw M4 x 8 46 Terminal 47 Terminal marking 48 Cap screw M2 5 x 12 49 Cap screw M4 x 8 50 Terminal box cover 51 Sealing ring 52 Cap screw M4 x 30 53 Sealing washer B 1110 1 GB The components 37 to 43 of the parts list are pre assembled 1 a Screw rectifier into the terminal box lower part 39 or 1 b screw panel 44 into the terminal box lower part 39 with the countersunk screws 45 Mount the terminals with 2 4 or 6 poles 46 with caps screws onto the panel 44 Glue the terminal marking 47 onto the panel 44 Observe the position of the terminal marking acc to Fig 5 2 Cut the cable of the brake coil to the suitable length and strip it Lead the cable into the terminal box through the components 39 40 and 41 3 Screw the holding bracket 37 with cap screws 49 to the brake back side 4 Pull the brake coil tighten the hexagon
13. ixing Fast acting armature screws 13 by mistake In case the braking torque shall be essentially reduced the helical springs 11 must be removed Always two springs lying opposite should be taken out so that the armature 6 is uniformly loaded Friction lining side Brake inspection The full adjusted braking torque is only achieved after the run in process has been carried out The braking torque switching torque is the slipping torque acting on the shafting at a running speed of 1 m s referred to the mean friction radius acc to DIN VDE 0580 10 94 Table 3 mrp p p p E gesa Standard armature Set screws 6x 6x 6x 6x 12x 12x 12x 12x 16x M5 M6 M10 M10 M10 M14 M8 M10 M12 Number of brake springs else elizi liz iie Exchange of the wearing parts The rotor 35 armature disc 5 and gear hub 1 are wearing l Magnetic elem side parts Unscrew the brake remove the fixing screws 13 exchange the rotor 35 If there is extreme clearance in the toothing between rotor 35 and gear hub 1 pull off the gear hub 1 from the shaft and replace it Furthermore check the armature disc 5 as to plane parallelity and check the wear and exchange it if necessary Type 804 41_ Restore the nominal air gap via the distance ring 31 Fast acting The shoulder screws 10 as well as the hand release if silencing armature available must be removed for exchanging the armature disc 5
14. mbient temperature 20 C up to 40 C Attention The torque could be severely reduced in case of temperatures over or under the freezing point due to dewing The user must provide corresponding counter measures Thermal class F 155 The magnetic coil as well as the casting compound is designed for a max operating temperature of 155 Tel 08341 804 241 Fax 08341 804 422 http www mayr de eMail info mayr de mayr Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 _ 41 _ Sizes 3 11 B 1110 1 GB Safety Regulations With these safety regulations no claim on completeness is raised Necessary protective measures to be undertaken by the user Cover all moving parts to prevent personnel injury as squeezing and seizing and centrifuging out Cover dangerously hot magnetic parts to prevent contact Attach a conductive connection between magnetic part and electrical conductor PE of the fixed installation protection class I to prevent electrical shock and inspection conforming to standards of the unified protective connection to all contactable metallic components Protection against high inductive cut off peaks according to VDE 0580 2000 07 par 4 6 by fitting varistors spark quenching units or similar in order to prevent damage of coil insulations or the burn off of the switching contact this protection is included in mayr rectifiers Provide ad
15. r with the transport installation initial start up maintenance and operation of the units as well as with the relevant standards may carry out the corresponding works O Technical data and indications Type tag and documentation are to be kept absolutely O Correct supply connection according to Type tag O Supply connections must not be released and assembly maintenance or repair must not be made when the unit is energised O Electrical leads must not be under tension when connected O Check current carrying components regarding damage before installation Current carrying components must not be in contact with water O The braking torque does not exist any more if the friction lining and friction surface come into contact with oil or grease Intended use mayr brakes are determined for the use in machines and equipment and may only be used for the ordered and confirmed purpose The use beyond of the corresponding technical indications is considered as incorrect 18 11 2004 K KR Chr Mayr GmbH Co KG EichenstraBe 1 87665 Mauerstetten Page 2 of 9 Germany Notes to the electromagnetic compatibility EMC There are no emissions from the listed single ES components within the meaning of the EMC directive 89 336 EEC however increased interference levels can occur when working components are operated outside their specification limits as for example energising the brake in the line side with rectifiers ph
16. responding to the low voltage directive 73 23 EEC Marking mayr components are Clearly identified by means of the content of the Type tags Manufacturer mayr Designation Type Article No Series number Tel 08341 804 241 Fax 08341 804 422 http www mayr de eMail info mayr de mayr Antriebstechnik Installation and Operating Instructions for ROBA stop Positioning Brake Type 80 41 _ Sizes 3 11 B 1110 1 GB 28 m lt i seer eo 0 oo o 0055 oo eo 58 10 31 59 Fig 1 60 Parts List 1 Gear hub 2 Coil carrier complete with coil 9 and guide bushes 7 5 Armature disc 13 Fixing screw 14 Setscrew 28 Spring washer 31 Threaded distance ring E i ing 35 Rotor with friction linings 8 9 Coil 58 Lock washer 59 Locking screw 10 Shoulder screw 60 Spring washer 11 Helical spring Delivery range Delivery condition Functional description The braking torque is generated by the applied force of several The scope of supply or the delivery condition must helical springs 11 by means of a frictional locking between both immediately be checked after receipt of the shipment friction linings of the rotor 35 the armature disc 5 and may does not overtake any guarantee for faults machine wall complained subsequently The brake is released electromechanically or mechanically by Claim means of a hand release see page 6 Transportation dam
17. tetten http www mayr de Page 9 of 9 Germany eMail info mayr de Antriebstechnik
18. to the disposal The components of our Electromagnetic Brakes must separately be supplied to the utilisation due to the different material components Additionally the legal instructions are to be observed Code numbers can change with the kind of the separation metal plastic and cable Brake body made of steel with coil cable and all other steel components Scrap Code No 160117 Distance ring made of aluminium Non ferrous metal Code No 160118 Brake rotor steel or aluminium with friction lining Brake linings Code No 160112 Seals O rings V Seal Elastomere Terminal boxes PVC Plastic Code No 160119 Breakdowns Failures Possible reasons Solution Brake does not release False voltage measured at the rectifier Q Apply correct voltage Rectifier failed LJ Exchange rectifier Air gap too big rotor worn down LI Replace rotor Air gap too big metallic particles between LJ Clean the brake armature disc and coil carrier Coil interrupted LJ Exchange the brake Brake becomes too warm LJ Use fast acting rectifier Motor does not brake Hand release is adjusted falsely LJ Adjust the distance correctly Hand release play possible with decreased Q Replace rotor torque or operation with fast acting rectifier LJ Brake is switched to AC side Q Switch to DC side Brake engages with delay 18 11 2004 K KR Chr Mayr GmbH Co KG EichenstraBe 1 Tel 08341 804 241 Fax 08341 804 422 mayr 87665 Mauers
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