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

- Manufacturer’s 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

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 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 Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 1 of 8 Germany eMail: info@mayr.de
Installation and Operating Instructions for
ROBA®-diskstop® Type 894.001.1 Size 8
Safety Regulations
With this 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!

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.

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.
29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG
Eichenstraße 1
D-87665 Mauerstetten
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(B.8.4.GB)
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.
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 running-
in condition of the brake

The metallic surface of the brake is protected against
corrosion arranged by the factory.
Protection class I
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 (mechanical) IP 00:
No protection against contact, foreign matters and water.
Protection (electrical) IP 54:
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.
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 Liability

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.

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®.

Following directives, standards and guidelines

Test mark
have been used:
CE corresponding to the low voltage directive 73/23/EEC.
98/37/EC 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
regulations of the Type tags.

Following standards are to be observed:

Manufacturer
EN292-1 and 2 Security of machines
DIN EN61000-6-4 Interference emission mayr®
DIN EN61000-6-2 Interference resistance
EN60204 Electrical equipment of machines Designation/Type
Article No.
Series number

29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 3 of 8 Germany eMail: info@mayr.de
Installation and Operating Instructions for
ROBA®-diskstop® Type 894.001.1 Size 8 (B.8.4.GB)

220 MA = 68 Nm
26
16 9
27 25
4/5
1
3 2

(coordination dimension)
with outer diameter "Y"
11/12 6

brake disk centre

8

of the brake disk

Distance "X" of
locked with
16 7 Loctite 243

locked with
Loctite 243
MA = 9,9 Nm 18
Fig. 1 11/12 for disk 20 -0,05

10
Fig. 2 +0,05
22/30 17 13 SW 36
0,5 -0,1
29
15 ∅ 40 76,4
M24
MA = 400 Nm
28 (stroke hand release 2,2 mm)
M12 MA = 117 Nm
14
13,5 ±1
19,5

25

Table 1: Dimensions for Brake disc

22/23
22/23 Outer Distance Width
distance to the disk

diameter dimension
24 Ø "Y" "X"
[mm] [mm] [mm]
21 mayr
∅ 6,2

600 309
20 19
700 360
800 411 20 -0,05
Fig. 3 21 20 MA = 83 Nm
900 462
1000 513

Parts List
®
Only mayr original parts are to be used

1 coil carrier compl. with coil 16 silencing damping (assembly)

2 armature disk 17 terminal box (assembly)
3 brake calibre (assembly) 18 release monitoring (assembly)
4 lining carrier (assembly) 19 hexagon head cap screw M12x20 DIN 933
5 adjusting washer (if necessary) 20 cover
6 cap screw M6x10 DIN 912 21 thrust spring D34,5 x 71,5
7 countersunk screw M6x12 DIN 7991 22 hexagon head cap screw M6x20 DIN 933-A2
8 hand release (assembly) 23 hexagon nut M6 DIN 934-A2
8.1 hand release lever 24 type tag
9 cap screw M10x90 DIN 912 25 slide bearing (only for alu terminal box)
10 thrust spring D12,3 x 37,6 26 straight pin SO (only for alu terminal box)
11 thrust spring D11,5 x 25,9 27 thrust spring (to be arranged by customer)
12 set screw M14x22 DIN 913 28 cover sheet
13 guide bolt I 29 cap screw M4x45 DIN 84-MS
14 guide bolt II 30 hexagon nut BM6 DIN 439- 04
15 hexagon head cap screw M12x130 DIN 931

29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
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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
9
8.1
4/5
1
3 2
6 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)

Wiring diagram plastic terminal box Wiring diagram alu terminal box

mayr ® NC contact
grey
mayr ® NC contact
grey
input input
black NO contact black NO contact
blue blue
yellow
green
black

black
grey

grey
blue

blue

coil coil

1 2 3 4 5 PE 1 2 3 4 5 6

29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
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Installation and Operating Instructions for
ROBA®-diskstop® Type 894.001.1 Size 8
Delivery range / Delivery condition:
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.
Assembly conditions (Figs.1-3)
Before attachment of the brake following points must
be observed:
 Deviation of the concentric running of the brake disc:
max. 0,1 mm
 Surface quality brake disc (friction faces): Ra =1,6 µm
 Brake disc material: steel or grey cast iron
 Brake disc diameter: ∅ 600-1000 mm
 Brake disc width: 20 –0,05 mm
 Position of brake attachment: corresponding to brake disc
external ∅ (see Table 1 / page 4).
 Deformation or bearing play of the brake disc must not
influence the adjusted air gap.
 The guide bolt I (pos. 13) must stand 0,1mm vertically to the
brake disc.
 The distance 13,5 ± 1 mm (Fig. 3) between screw-on surface
and brake disc must be kept.
 Brake surfaces and friction linings must be free of oil.
 A suitable protective cover of the open brake must be
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.
29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG
Eichenstraße 1
D-87665 Mauerstetten
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(B.8.4.GB)
Assembly Bowden cable hand release (Figs. 1-4)
Hand release is pre-assembled at the factory.
Max. hand release force: 500 N
Release travel at the Bowden cable: approx.. 83 mm
 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.
 Design with plastic terminal box
 There is a bore each provided for the Bowden cable at the hand
release lever (pos. 8.1) and at the brake jaw.
 Push Bowden cable through the bore of a brake jaw (pos. 3 or 4)
and the thrust spring (restoring force 100 N, supply of the
customer pos. 27) and mount it at the
hand release lever (pos. 8.1).
Attention!
Do not operate brake without
thrust spring (pos. 27).
Risk of a load crash.
 Adjust Bowden cable in this way that the hand release (after
actuation) returns to contact again.
=> Performance check.
Adjustment of the brake force (at the factory) (Fig. 1)
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)
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! Design with alu terminal box:
Execute electrical connection only in a voltage free The brake is earthed using the earthing screw in the terminal box.
condition.
The coil voltage is indicated on the Type tag (pos. 24), additionally Design with plastic terminal box:
it is mentioned on the brake. The brake is earthed via the terminal PE provided in the
The brakes are designed according to Euro-voltage DIN IEC 38. terminal box.
DC current is necessary for the operation.
This one can be generated via Trafo-rectifier or bridge rectifier.
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! 1 U~ 2 3 4 5 U– 6
The bridge rectifier shown on Fig. 4 can be taken as switching
example and can be replaced by a power supply unit. F1
S1 S2
Switching-ON coil - brake
Switching-ON is either made on the AC current side with the
switch S3 and a bridge via the terminals 3 and 4 S3 S1 and S2 DC current switching
(in this case there are no switches S1 and S2) S3 AC current switching
or F1 external fuse
on the AC and DC current sides with the switches S1 and S2 AC AC mains supply
(in this case there is no switch S3). 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 Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
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Installation and Operating Instructions for
ROBA®-diskstop® Type 894.001.1 Size 8 (B.8.4.GB)

Noise damping (Pos. 16) (Fig. 1):
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 doesn’t 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.
The end of the drawing is achieved with 1,7 mm.
Exchange of the lining carrier (pos. 4) (Fig. 2):
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”

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

Release monitoring does not switch Brake does not release As mentioned above

Micro switch defective Exchange micro switch (at factory)

29/06/2005 TK/KR Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241

Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
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