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Installation and Operating Instructions for

ROBA-diskstop Type 894.001.1


Size 8

(B.8.4.GB)

Please read the operating instruction carefully and observe it in any case!
A possible malfunction or failure of the brake and possible damages can be caused by not observing it.

Table of contents:
Page 1:

- Table of contents
- Manufacturers declaration

Page 2:

- Safety regulations

Page 3:

- Safety regulations

Page 4:

- Brake views (design alu terminal box)


- Parts list
- Table 1: Dimensions for brake disc

Page 5:

- Brake view (design plastic terminal box)


- Wiring diagram (design plastic terminal box)
- Wiring diagram (design alu terminal box)

Page 6:

- Delivery range / delivery condition


- Assembly conditions
- Brake assembly
- Assembly Bowden cable hand release
- Adjustment of the brake force
- Brake inspection
- Release monitoring

Page 7:

- Electric connection
- ON/OFF switching of the brake
- Earthing
- Protection

Page 8:

- Noise damping
- Maintenance
- Exchange of the lining carrier
- Breakdowns

Manufacturers 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 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 EMV-guideline 89/336/EEC is to be guaranteed.

29/06/2005 TK/KR

Page 1 of 8

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8

(B.8.4.GB)

Safety Regulations
With this safety regulations no claim on completeness is raised!
Attention!
Hazardous conditions when contacting hot
connections and components.

Notes to the electromagnetic compatibility (EMV)


There are no emissions from the listed single
components within the meaning of the EMV-guideline
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,
phase demodulators or ROBA-switch in the line side.
Therefore, the installation and operating instructions
must be read carefully the EMV-guidelines are to be
observed.

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.

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!


The mounting and connecting dimensions at the site of


installation must match to the size of the brake.

The brakes are designed for a relative switch on period


of 60 %.

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.

The braking torque depends on the corresponding runningin condition of the brake

The metallic surface of the brake is protected against


corrosion arranged by the factory.

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!


Only qualified and well trained specialists who are familiar


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.

Technical data and indications (Type tag and


documentation) are to be kept absolutely.

Correct supply connection according to Type tag.

Supply connections must not be released and assembly,


maintenance or repair must not be made when the unit is
energized.

Electrical leads must not be under tension when


connected.

Check current carrying components regarding damage


before installation. Current carrying components must not
be in contact with water.

Protection (mechanical) IP 00:

The braking torque does not exist any more, if the friction
lining and friction surface come into contact with oil or
grease.

Protection (electrical) IP 54:

Protection class I

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.

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).

No protection against contact, foreign matters and water.

Dust-tight and protection against contact as well protection against


splashing water from all directions.

Ambient 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 C)


The magnetic coil as well as the casting compound is designed for
a max. operating temperature of 155 C.

29/06/2005 TK/KR

Page 2 of 8

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8

(B.8.4.GB)

Safety Regulations
With this 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 additional 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

Liability


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.

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


The warranty conditions correspond to the sales and supply


conditions of Chr. Mayr GmbH + Co. KG.

Defects are to be advised immediately after detection to


mayr.

Test mark
CE corresponding to the low voltage directive 73/23/EEC.

Machinery directive

73/23/EEC

Low-voltage directive

89/336/EEC

EMV-guideline

Marking

DIN VDE 0580

Electromagnetic units and components, general

mayr-components are clearly identified by means of the content


of the Type tags.

regulations

Following standards are to be observed:


EN292-1 and 2

Manufacturer

Security of machines

mayr

DIN EN61000-6-4 Interference emission


DIN EN61000-6-2 Interference resistance
EN60204

Designation/Type

Electrical equipment of machines

Article No.
Series number

29/06/2005 TK/KR

Page 3 of 8

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8
220

(B.8.4.GB)

MA = 68 Nm

16

26

27

25

4/5
1
Distance "X" of
brake disk centre
with outer diameter "Y"
of the brake disk
(coordination dimension)

3
11/12
16

locked with
Loctite 243

locked with
Loctite 243
MA = 9,9 Nm

18

11/12

Fig. 1

for disk 20 -0,05

10
Fig. 2

15

M12

0,5
SW 36

25

22/23

6,2

mayr

20

19
21

Fig. 3

20

29

76,4
(stroke hand release 2,2 mm)

Table 1: Dimensions for Brake disc

distance to the disk

22/23
24
21

28

MA = 400 Nm

M24

MA = 117 Nm

19,5

14

17 13

13,5 1

22/30

40

+0,05
-0,1

MA = 83 Nm

Outer
diameter
"Y"
[mm]

Distance
dimension
"X"
[mm]

600
700
800
900
1000

309
360
411
462
513

Width

[mm]

20 -0,05

Parts List

Only mayr original parts are to be used


1
2
3
4
5
6
7
8
8.1
9
10
11
12
13
14
15

coil carrier compl. with coil


armature disk
brake calibre (assembly)
lining carrier (assembly)
adjusting washer (if necessary)
cap screw
M6x10
countersunk screw
M6x12
hand release (assembly)
hand release lever
cap screw
M10x90
thrust spring
D12,3 x 37,6
thrust spring
D11,5 x 25,9
set screw
M14x22
guide bolt I
guide bolt II
hexagon head cap screw
M12x130

29/06/2005 TK/KR

Page 4 of 8

DIN 912
DIN 7991

DIN 912

DIN 913

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

silencing damping (assembly)


terminal box (assembly)
release monitoring (assembly)
hexagon head cap screw
M12x20
cover
thrust spring
D34,5 x 71,5
hexagon head cap screw
M6x20
hexagon nut
M6
type tag
slide bearing (only for alu terminal box)
straight pin SO (only for alu terminal box)
thrust spring (to be arranged by customer)
cover sheet
cap screw
M4x45
hexagon nut
BM6

DIN 931

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

DIN 933

DIN 933-A2
DIN 934-A2

DIN 84-MS
DIN 439- 04

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8

(B.8.4.GB)

Design plastic terminal box


MA = 68 Nm

17

8.1

4/5
1
3

8
locked with
Loctite 243

locked with
Loctite 243
MA = 9,9 Nm
for disk 20 -0,05

+0,05

0,5 -0,1
75,95

(stroke hand release 2,2 mm)

input
black

29/06/2005 TK/KR

Page 5 of 8

green
yellow

blue

grey

5 PE

NC contact
grey

input
black

NO contact
blue

black

coil

mayr

coil

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

NO contact
blue

blue

NC contact
grey

grey

mayr

Wiring diagram alu terminal box

black

Wiring diagram plastic terminal box

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8

(B.8.4.GB)

Delivery range / Delivery condition:

Assembly Bowden cable hand release (Figs. 1-4)

The scope of supply or the delivery condition must


immediately be checked after receipt of the shipment.
mayr does not overtake any guarantee for faults
complained subsequently.
Claim:
 Transportation damages immediately with the forwarder.
 Recognizable faults / incompleteness of the shipment
immediately in the manufacturing company.

Hand release is pre-assembled at the factory.


Max. hand release force:
500 N
Release travel at the Bowden cable: approx.. 83 mm

Assembly conditions (Figs.1-3)

Design with alu terminal box

 Put both slide bearings (pos. 25) into the bores of the
hand release (pos. 8) from the interior.
 Push straight pin (pos. 26) into both slide bearings and mount
Bowden cable with thrust spring (restoring force 100 N,
supply of customer pos. 27) at the hand release.

Before attachment of the brake following points must


 Design with plastic terminal box
be observed:
 Deviation of the concentric running of the brake disc:
 There is a bore each provided for the Bowden cable at the hand
max. 0,1 mm
release lever (pos. 8.1) and at the brake jaw.
 Surface quality brake disc (friction faces): Ra =1,6 m
 Push Bowden cable through the bore of a brake jaw (pos. 3 or 4)
 Brake disc material: steel or grey cast iron
and the thrust spring (restoring force 100 N, supply of the
customer pos. 27) and mount it at the
 Brake disc diameter: 600-1000 mm
hand release lever (pos. 8.1).
 Brake disc width: 20 0,05 mm
 Position of brake attachment: corresponding to brake disc
external (see Table 1 / page 4).
Attention!
Do not operate brake without
 Deformation or bearing play of the brake disc must not
thrust spring (pos. 27).
influence the adjusted air gap.
Risk of a load crash.
 The guide bolt I (pos. 13) must stand 0,1mm vertically to the
brake disc.
 Adjust Bowden cable in this way that the hand release (after
 The distance 13,5 1 mm (Fig. 3) between screw-on surface
actuation) returns to contact again.
and brake disc must be kept.
=> Performance check.
 Brake surfaces and friction linings must be free of oil.
 A suitable protective cover of the open brake must be
Adjustment of the brake force (at the factory) (Fig. 1)
provided.

Brake assembly (Figs. 1-3)


Brake is pre-assembled at the factory.
1. Screw on guide bolt I (pos. 13) at machine wall.
(tightening torque 400 Nm, locking with Loctite 243).
2. Push guide bolt II (pos. 14) (brake back side) into brake
calibre (pos. 3).
3. Release brake electrically or mechanically with an auxiliary
device.
4. Push released brake over guide bolt I (pos. 13) and slew it
over brake disc.
5. Push cover (pos. 20) with thrust spring (pos. 21)
over hexagon head cap screw (pos.15).
6. Push hexagon head cap screw with cover and thrust spring
into guide bolt II (pos. 14) and screw brake at machine wall
(tightening torque 117 Nm).
7. Check the axial well running of the guide!
8. Attach cover (pos. 20) and thrust spring (pos. 21)
with hexagon head cap screw (pos.19) at guide bolt I
(pos. 13) (tightening torque 83 Nm).
9. Make brake to engage at that place where the brake disc
(due to the true running tolerance) is the nearest to the
machine wall (release).
10. Adjust gap (min. 0,1mm) between hexagon head cap screw
(pos. 22) and machine wall via hexagon head cap screw
(pos. 22) and lock it with a hexagon nut (pos. 23/30).
11. Release brake and turn brake disc. In this case the brake
disc must not slip.
12. Attach cover depending on mounting position.

The spring force (brake force) of the brake is adjusted to


max. 4500 225 N (without influence of the silence damping).
A reduction of the set brake force to min. 3670 N is possible by
uniformly turning all 4 set screws (pos. 12) to the left side.
Indication:
When adjusting the braking torque it has to be observed that all
brakes being located at the drive are adjusted uniformly!

Attention:
Do not mix it up with noise damping (pos. 16)!

Brake inspection
The full adjusted brake torque is only achieved after the run-in
process has been carried out.
The brake 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).

Release monitoring (Pos. 18) (Fig. 2):


Execute performance test before initial operation of the brake
The ROBA-diskstop is supplied with release monitoring adjusted at
the factory (air gap 0,25 0,3 mm).
A micro switch signals the change of the condition of the brake (brake
opened or brake closed).
The signal is evaluated at the customer (see wiring diagram page 5).
From the time when the brake is energised a period of three times the
separation time must be passed, before the micro switch signal of the
release monitoring system is evaluated.
Minimum switch capacity: 0,12 VA ( > 12 V; > 10 mA)

29/06/2005 TK/KR

Page 6 of 8

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8

(B.8.4.GB)

Electrical connection

Earthing

Warning!
Execute electrical connection only in a voltage free
condition.

Design with alu terminal box:

The coil voltage is indicated on the Type tag (pos. 24), additionally
it is mentioned on the brake.
The brakes are designed according to Euro-voltage DIN IEC 38.
DC current is necessary for the operation.
This one can be generated via Trafo-rectifier or bridge rectifier.

The brake is earthed using the earthing screw in the terminal box.
Design with plastic terminal box:
The brake is earthed via the terminal PE provided in the
terminal box.

Protection class of the brake


Protection class I

ON/OFF switching of the brake


Important!
The operating performance of the brake depends on the used kind
of wiring. Therefore the following kind of wirings must be observed.

Switching example (Fig. 4)


Note!
The bridge rectifier shown on Fig. 4 can be taken as switching
example and can be replaced by a power supply unit.

U~

S1

S2
coil - brake

S3

S1 and S2 DC current switching


S3 AC current switching
F1 external fuse
AC mains supply
AC
Fig. 4 (Example: bridge rectifier)

Switching-OFF
On the AC current side with the switch S3 and a bridge over the
terminals 3 and 4.
Observe!
 Application for standard operation of the elevator.


Silent switching, but longer engaging time of the brake


(approx. 6-8 times longer than with switching-OFF on the DC
current side).

Switching-OFF
On the DC current side with the switches S1 and S2
Observe!
 Noisy switching but short engaging time of the brake.


Application for emergency-stop operation!

Important!
In case of switching-OFF on the DC current side the coil must be
protected against transient overvoltages by means of a suitable
protective wiring according to VDE 0580.

Miniature Fuse F1
A miniature fuse for protection against short circuits must be
provided in the supply mains by the customer.
The brake is designed for a relative switch-ON period of 60 % .

29/06/2005 TK/KR

Page 7 of 8

F1

Switching-ON
Switching-ON is either made on the AC current side with the
switch S3 and a bridge via the terminals 3 and 4
(in this case there are no switches S1 and S2)
or
on the AC and DC current sides with the switches S1 and S2
(in this case there is no switch S3).

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de

Installation and Operating Instructions for


ROBA-diskstop Type 894.001.1
Size 8
Noise damping (Pos. 16) (Fig. 1):

(B.8.4.GB)

Exchange of the lining carrier (pos. 4) (Fig. 2):

Important note:
The noise damping used here has been adjusted at the factory.
However, the noise damping used in this case is incumbent on
a certain ageing depending on the application or working
conditions (torque adjustment, switching frequency, ambient
conditions, natural oscillation of the operational plant etc.) and
must be readjusted, or replaced routinely in case of too loud
switching noises.
Only qualified and authorized well trained specialists are
allowed to do this and it should only be done in the factory.

Maintenance
The ROBA-diskstop nearly doesnt require any maintenance. The
friction lining pairing is robust and wear resistant and hereby a very
long service life of the brake is obtained. At certain intervals the
brake linings must be checked and when they have reached the
max. permissible degree of wear the brake pad (pos. 4) must be
exchanged.

Attention:
Brake must be released!
1. Dismantle brake in the opposite way than mentioned under
Brake assembly.
2. Remove brake calibre (pos. 3) by unscrewing the cap screws
(pos. 9).
3. Remove brake lining carrier (pos. 4) (and, if necessary adjusting
washers pos. 5) at calibre brake and armature disc sides by
unscrewing the cap screws (pos. 6) and countersunk screws
(pos. 7).
Attention: Adjusting washers (if available) must be included
again when the new lining carriers are assembled!
4. Screw on new lining carriers (pos. 4) (and if necessary adjusting
washers pos. 5), brake calibre and armature disc sides by the aid
of cap screws (pos. 6) and countersunk screws (pos. 7) (secure it
with Loctite 243 MA = 9,9 Nm).
5. Attach brake calibre (pos. 3) by the aid of cap screws (pos. 9)
(MA = 68 Nm).
Assemble brake according to the chapter Brake assembly

The end of the drawing is achieved with 1,7 mm.

Breakdowns:
Failures

Possible reasons

Remove

Brake does not release

False voltage measured at the rectifier

Apply correct voltage

Rectifier failed

Exchange rectifier

Air gap too big (rotor worn down)

Exchange lining carrier

Coil interrupted

Exchange brake

Brake does not release

As mentioned above

Micro switch defective

Exchange micro switch (at factory)

Release monitoring does not switch

29/06/2005 TK/KR

Page 8 of 8

Chr. Mayr GmbH + Co. KG


Eichenstrae 1
D-87665 Mauerstetten
Germany

Tel.: 08341 / 804-241


Fax: 08341 / 804-422
http://www.mayr.de
eMail: info@mayr.de