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(B.8.7.GB)
Please read the Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to lethal accidents, malfunctions, brake failure and damage to other parts.
Contents:
Page 1: - Contents
- Manufacturers Declaration
Manufacturers Declaration
This product is intended for installation in a machine or system, based on the machine directive 98/37/EC.
It is forbidden to start use of the product until the machine or system into which it should be built is operating in accordance with the EC
directives.
The product corresponds to the low voltage directive 73/23/EEC.
The product corresponds to the elevator directive 95/16/EC
The customer is responsible for compliance with the EMC directive 89/336/EEC.
Please Observe:
According to German notation, decimal points in this document are represented with a comma (e.g. 0,5 instead of 0.5).
05/04/2007/TK/K/AM/GC/RJ
Page 1 of 13
(B.8.7.GB)
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
Danger!
Danger of death! Do not touch voltage-carrying
cables and components.
Device Conditions
Warning!
Before product installation and initial operation,
please read the Installation and Operational
Instructions carefully and observe the Safety
Regulations. Incorrect operation can cause injury or
damage.
The electromagnetic brakes have been developed in
accordance with the latest technology regulations
and are, at the point of delivery, operationally safe.
Warning:
Without a conformity inspection, this product is not suitable for
use in areas where there is a high danger of explosion. This
statement is based on the directive 94/9/EC (ATEX directive).
The brakes are only designed for dry running. The braking
torque is lost if the friction surfaces come into contact with
oil, grease, water or similar substances.
Please Observe!
Protection Class I
This protection can only be guaranteed if the basic insulation is
intact and if all conductive parts are connected to the PE
conductor. Should the basic insulation fail, the contact voltage
cannot remain (VDE 0580).
Appointed Use
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!
Warning!
At temperatures of around or under freezing point, condensation
can strongly reduce the torque. During longer downtimes, the
friction linings can stick to the friction surfaces.
The user is responsible for taking appropriate countermeasures.
05/04/2007/TK/K/AM/GC/RJ
Page 2 of 13
(B.8.7.GB)
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
User-implemented Protective Measures:
Liability
Guarantee
Machine directive
Conformity Markings
73/23/EEC
89/336/EEC
EMC directive
95/16/EC
Elevator directive
EN 81-1
Identification
mayr components are clearly marked and described on the
Type tag:
BGV C1
mayr
Manufacturer
Article number
EN60204
Serial number
License number
Double brake
ABV 760/1
Single brake
ABV 761/1
05/04/2007/TK/K/AM/GC/RJ
Page 3 of 13
(B.8.7.GB)
6.2
30
Option
single hand
release
6.1
Option
single hand
release
16
10
8.1
2
4
1.1
1
3
5.1
Brake
body 2
15
14
5
Cable length
standard
c. 600 mm
on sizes 4 - 200 and
c. 1000 mm
on sizes 300 - 1800
Brake
body 1
3
15
5
14
Air gap
Fig. 1
Fig. 2
6.4
6.5
6.3
6.4
Air gap
Fig. 3
(Single brake)
7.5
7.4
7.3
7.1
7.2
7.5
7.4
7.3
7.1
7.2
6.5
13
11
12
9
Fig. 4
Fig. 5
Fig. 6
05/04/2007/TK/K/AM/GC/RJ
Page 4 of 13
Guidelines!
Guidelines on important points.
(B.8.7.GB)
original parts)
O-ring
Type tag
7.
10
7.1 Microswitch
11
Flange plate
Rotor 1
12
Cap screw
5.1 Rotor 2
13
Noise damping
14
Thrust spring
15
Shoulder screw
16
Distance bolt
Technical Data
Nominal voltages:
Protection (electrical)
IP54
Protection (mechanical)
IP10
Duty Cycle:
100 %
Connection:
2 x 0,88 mm
Ambient temperature:
-20 C up to +40 C
Mass
[kg]
2x4
2x5
2x3
4500
2 x 23
2 x 1,4
2x8
2 x 16
2 x 32
2 x 64
2 x 100
2 x 200
2 x 300
2 x 500
2 x 800
2 x 1300
2 x 1800
2 x 10
2 x 19
2 x 40
2 x 77
2 x 120
2 x 235
2 x 360
2 x 600
2 x1000
2 x 1560
2 x 2150
2x6
2 x 12
2 x 26
2 x 43
2 x 80
2 x 157
2 x 225
2 x 380
2 x 600
2 x 980
2 x 1350
3500
2900
2500
2300
2000
1700
1500
1300
1150
1000
900
2 x 27
2 x 33
2 x 45
2 x 55
2 x 63
2 x 78
2 x 86
2 x 90
2 x 107
2 x 130
2 x 150
2 x 2,8
2 x 3,5
2 x 5,5
2 x 7,75
2 x 10,75
2 x 17
2 x 24
2 x 30
2 x 46
2 x 63
2 x 79
Switching times at
Hand release
nominal braking torque 100 %
force
per lever
at nominal
torque
Separation Connection Connection
c.
t2
t1 (AC)
t1 (DC)
[N]
[ms]
[ms]
[ms]
35
52
135
33
35
110
100
130
110
200
250
300
300 ***
320 ***
350 ***
70
94
120
174
234
270
308
444
581
589
850
196
398
518
477
488
968
1087
1023
1231
1464
1920
39
99
118
107
105
185
246
193
267
266
420
05/04/2007/TK/K/AM/GC/RJ
Page 5 of 13
100000
Function
The ROBA-stop-silenzio is designed as a double brake in which
two brake bodies working independently of one another ensure high
operational safety.
The braking torque in brake body 1 (3) is produced via the pressure
force of several thrust springs (14) using frictional locking between
the two rotor friction linings (5), the armature disk 1 (4) and the
flange plate (11) or machine wall.
The braking torque in brake body 2 (3) is produced via the pressure
force of several thrust springs (14) using frictional locking between
the two rotor friction linings (5.1), the armature disk 2 (4) and the
coil carrier 1 (2).
The brake is released electromagnetically.
1800
1300
800
500
300
200
100
64
10000
(B.8.7.GB)
32
16
Installation Conditions
8
1000
1
10
Switching frequency [1/h]
100
State of Delivery
Please check the state of delivery immediately!
mayr will take no responsibility for belatedly returned goods.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects immediately
to the manufacturer.
If the hub (1) is heated to make joining easier, the O-ring must
first be removed and then re-mounted after hub installation.
The max. joining temperature of 200 C must not be exceeded.
Application
Rotors (5 and 5.1) and brake surfaces must be oil- and greasefree. A suitable counter friction surface (steel or cast iron) must
be available. Sharp-edged interruptions on the friction surface
are to be avoided.
Recommended surface quality in the friction surface area:
Ra = 1.6 m.
In particular customer-side attachment surfaces made of
grey cast iron are to be rubbed down with fine sandpaper
(grain 400).
05/04/2007/TK/K/AM/GC/RJ
Page 6 of 13
(B.8.7.GB)
Table 2
Rotor
thickness
Size
2.
3.
4.
5.
6.
7.
8.
new condition
05/04/2007/TK/K/AM/GC/RJ
Page 7 of 13
Items 8 and
8.1
SW
[Nm]
Item 12
SW
[Nm]
3 x M4
3 x M5
3 x M6
3 x M6
3 x M8
3 x M8
3 x M10
3 x M12
6 x M12
6 x M16
8 x M16
8 x M16
7
8
10
10
13
13
16
18
18
24
24
24
3
5
10
13
30
36
71
123
123
250
250
300
3 x M4
3 x M5
3 x M6
3 x M6
3 x M8
6 x M8
6 x M10
6 x M12
6 x M16
6 x M16
8 x M16
8 x M20
3
4
5
5
6
6
8
10
14
14
14
17
3
5
10
15
36
36
71
123
200
300
300
470
2.
3.
2.
3.
(B.8.7.GB)
1.
2.
3.
In order to install the hand release, the brake must be
dismantled and de-energised.
On the sizes 4 to 300, the installation procedure is 4.
different on brake bodies 1 and 2 (see Fig. 7).
If the brake is installed in the wrong order, it
could fail.
On size 500, the installation procedure for brake
5.
bodies 1 and 2 (see Fig. 7a) is identical.
3.
4.
5.
6.
Screw the hand release rod (6.2) into the switch bracket (6.1)
and secure using Loctite 243.
Insert the raised head screws (6.3) through the slot bores of
the switch bracket (6.1).
Please Observe: On sizes 32, 64 and 100, a washer should
go between the screw head and the switch bracket (6.1).
Insert the raised head screws (6.3) with the switch bracket
(6.1) into the bores on the coil carrier (3).
Please ensure that the switch bracket (6.1) is in the correct
position. The switch bracket (6.1) with the screwed-in
hand release rod (6.2) must lie over brake body 1.
Push the thrust springs (6.4) armature disk-side onto the
raised head screws (6.3) and apply the hexagon nuts (6.5).
Tighten the hexagon nuts (6.5) evenly, until the specified
adjustment dimension Y (Fig. 7 and Table 3) is reached.
Y
6.5
6.4
6.1
6.
Screw the hand release rod (6.2) into the switch bracket (6.1)
and secure using Loctite 243.
Insert the thrust springs (6.4) onto the raised head screws
(6.3).
Insert the raised head screws (6.3) with the mounted thrust
springs (6.4) through the coil carrier (3) into the armature disk
(4) bores.
Push the switch bracket (6.1) onto both the raised head screws
(6.3) and apply the locking nuts (6.5).
Please Observe! On sizes 32, 64 and 100, a washer should
go between the switch bracket and the locking nut.
Please ensure correct position of the switch bracket (6.1).
The switch bracket (6.1) with the screwed-in hand release
rod (6.2) must lie over brake body 2.
Tighten the locking nuts evenly, until the specified adjustment
dimension Y has been reached.
3.
4.
6.4
6.5
6.4
6.5
Y
6.3
6.4
6.1
6.5
Brake
body 1
Brake
body 1
Brake
body 2
Brake
body 2
Fig. 7a (Size 500)
Table 3 (Adjustment Dimension and Hand Release adjusted at the mayr site of manufacture. As well as this, an
Force)
Additional Instruction Sheet B.8.7.H.GB is included in the brake
Size
Dimension "Y"
1,1 mm
35 N
1,5 mm
35 N
16
1,5 mm
110 N
32
1,5 mm
100 N
64
1,5 mm
130 N
100
1,5 mm
110 N
200
1,5 mm
200 N
300
1,5 mm
250 N
500
(1,5 mm)
300 N
05/04/2007/TK/K/AM/GC/RJ
Page 8 of 13
delivery.
Noise Damping
Important: Please Observe:
Replacement of damping elements is only permitted at the
mayr site of manufacture.
The noise damping has been set and adjusted manufacturerside. However, dependent on application or operating
conditions (torque adjustment, switching frequency, ambient
conditions, inherent operating system vibrations etc.), the
noise damping is subject to aging.
(B.8.7.GB)
1.
Bracket
6.7
Cap screw
2.
3.
4.
5.
6.
2.
3.
4.
5.
6.
7.
Screw in the bracket (6.6) with the cap screw (6.7) into the
switch bracket (6.1) vertical to the switch bracket (6.1) as
shown in Fig. 8, and secure with Loctite 243.
Please observe the tightening torque according to Table 4!
Screw the hand release rod (6.2) into the bracket (6.6) and
secure using Loctite 243.
Insert the raised head screws (6.3) through the slot bores of
the switch bracket (6.1).
Please Observe: On sizes 32, 64 and 100, a washer should
go between the screw head and the switch bracket (6.1).
Insert the raised head screws (6.3) with the switch bracket
(6.1) into the bores on the coil carrier (3).
Please ensure that the switch bracket (6.1) is in the
correct position. The switch bracket (6.1) with the
screwed-in hand release rod (6.2) must lie over brake
body 1 and the hand release rod (6.2) must face in the
direction of the machine wall.
Push the thrust springs (6.4) armature disk-side onto the
raised head screws (6.3) and apply the hexagon nuts (6.5).
Tighten the hexagon nuts (6.5) evenly, until the specified
adjustment dimension Y (Fig. 7 and Table 3) is reached.
7.
Screw in the bracket (6.6) with the cap screw (6.7) into the
switch bracket (6.1), vertical to the switch bracket (6.1) as
shown in Fig. 8, and secure using Loctite 243.
Please observe the tightening torques according to Table 4!
Screw the hand release rod (6.2) into the bracket (6.6) and
secure using Loctite 243.
Insert the thrust springs (6.4) onto the raised head screws
(6.3).
Insert the raised head screws (6.3) with the mounted thrust
springs (6.4) through the coil carriers (3) into the armature disk
bores (4).
Push the switch bracket (6.1) onto both the raised head
screws (6.3) and apply the locking nuts (6.5).
Please Observe! On sizes 32, 64 and 100, a washer should
go between the switch bracket and the locking nut.
Please ensure correct position of the switch bracket (6.1).
The switch bracket (6.1) with the screwed-in hand release
rod (6.2) must lie over brake body 2 and the hand release
rod (6.2) must face away from the machine wall.
Tighten the locking nuts evenly, until the specified adjustment
dimension Y has been reached.
Table 4
Size
10
16
24
32
24
64
48
100
48
200
83
6.2
6.2
6.7
6.7
Fig. 8
05/04/2007/TK/K/AM/GC/RJ
Page 9 of 13
6.6
6.6
6.1
6.1
Brake
body 2
Brake
body 1
(B.8.7.GB)
Guidelines
The ROBA-stop-silenzio brake can also be ordered as a
single brake.
In this case, the individual values for nominal braking
torque, electrical nominal power and mass apply.
1.
2.
Please Observe!
Single brakes do not meet the demands acc.
the EN81-1 standard or the
BGV C1 (previously VGB 70), DIN 56925 and
DIN 56921-11 for installation in elevators and
theatre stage technical systems.
3.
4.
Deviating Parts
5.
6.
Screw the hand release rod (6.2) into the switch bracket
(6.1) and secure with Loctite 243.
Insert the thrust springs (6.4) onto the raised head screws
(6.3).
Insert the raised head screws (6.3) with the mounted
thrust springs (6.4) through the coil carrier (3) into the
bores on the armature disk (4).
Push the switch bracket (6.1) onto both the raised head
screws (6.3) and apply the locking nuts (6.5).
Please Observe! On sizes 32, 64 and 100, a washer
should go between the switch bracket and the locking nut.
Please ensure correct position of the switch bracket
(6.1). The switch bracket (6.1) with the screwed-in
hand release rod (6.2) must lie over brake body 1.
Tighten the locking nuts evenly, until the specified
adjustment dimension Y has been reached.
Function
6.3
6.4
6.1
6.5
Fig. 9
6.4
6.5
Fig. 9a
05/04/2007/TK/K/AM/GC/RJ
Page 10 of 13
(B.8.7.GB)
Electrical Connection
AC-side switching
max.
230V~
2,5A
1/025.000.6
[U = 0,9U~]
Brckengleichrichter
Bridge rectifier
SDC
IN
OUT
Earthing Connection
The brake is designed for Protection Class I. This protection covers
not only the basis insulation but also the connection of all
conductive parts to the PE conductor on the fixed installation. If the
basis insulation fails, no contact voltage will remain. Please carry
out a standardized inspection of the PE conductor connections to
all contactable metal parts!
S1
Coil
F1
DC-side switching
max.
230V~
2,5A
Device Fuses
1/025.000.6
[U = 0,9U~]
Brckengleichrichter
Bridge rectifier
Switching Behaviour
SDC
IN
OUT
S1
Coil
F1
05/04/2007/TK/K/AM/GC/RJ
Page 11 of 13
(B.8.7.GB)
Please Observe!
The brake must be screwed onto the installation
device with tightening torque according to Table 2,
and the coil must be de-energised.
1. Join the hexagon head screw (7.3) with the hexagon nut (7.4) and
the spring washer (7.5), paint the first part of the thread with Loctite
243 and screw into the armature disk (4).
2. Screw the microswitch (7.1) assemblies with the cap screws (7.2)
to the partly-assembled brake bodies 1 and 2 (secure with Loctite
243).
Switch Adjustment
3. Turn the hexagon head screw (7.3) in the direction of the switch
(7.1) up to the switch tappet.
2
4. Connect the inspection or measurement device (diode inspection)
Input
1
to the NO contact black/blue.
Black connection
4
5. Insert the feeler gauge 0,1 mm (loose sensor plate) between the
NO Contact
switch tappet (7.1) and the hexagon head screw (7.3).
Blue connection
Connection when
6. Turn the hexagon head screw (7.3) in the direction of the switch
brake released
(7.1) up to the signal ON, and then turn it back to the signal
Function
OFF. Counter the hexagon head screw (7.3) with the hexagon
nut (7.4).
When the magnetic coil in the coil carrier (3) is energised, the
Signal "ON"
armature disk (4) is attracted to the coil carrier (3), a microswitch 7. Energise the brake
De-energise the brake
Signal "OFF"
(7.1) emits a signal and the brake is released.
If necessary, re-adjust and repeat the inspection.
Please Observe:
When the hand release (6) is being operated, a switching signal 8. Inspection with feeler gauge 0,15 mm
from the release monitoring (7) is not guaranteed.
Brake energised
Signal "ON",
Brake de-energised
Signal "ON"
9. Inspection with feeler gauge 0,10 mm
Table 5: Maximum Switch Performance
Brake energised
Signal "ON",
Brake de-energised
Signal "OFF"
AC-side switching
DC-side switching
10. Feeler gauge 0,3 mm between the armature disk (4) and
performance
performance
the coil carrier (3) in the area of the switch (7.1).
Resistance
Resistance
Voltage
Voltage
Energise the brake; the signal must be "ON".
load
load
[VAC]
[VDC]
[A/R Load]
[A/R Load]
11. Paint items 7.4 and 7.2 with safety lacquer.
NC Contact
Grey connection
Connection when
brake closed
125
250
up to 30
125
0,5
250
0,25
7.5
7.4
7.3
7.1
Items see
Brake 1
7.2
4
3
5
Fig. 10
05/04/2007/TK/K/AM/GC/RJ
Page 12 of 13
5.1
Brake 1
Brake 2
Chr. Mayr GmbH + Co. KG
Eichenstrae 1
D-87665 Mauerstetten
Germany
(B.8.7.GB)
Disposal
Products which have not been dismantled can be disposed of under the
Code No. 160214 (Mixed Materials) or Components under
Code No. 160216; or the objects can be disposed of by a certified
Inspection of the wear condition on the rotors 1 (5) and 2 (5.1) is waste disposal firm.
carried out by measuring the air gap a (Fig. 2 and Table 2).
At the latest after reaching the maximum air gap, the rotors are to Brake bodies made of steel girders with coil / cable and all other
steel components:
be replaced (Table 2).
Steel scrap
(Code No. 160117)
Before the rotors are replaced (Items 5 and 5.1):
Aluminium components:
Clean the brake, remove abraded particles
Non-ferrous metals
(Code No. 160118)
(use an industrial vacuum cleaner / wear a dust mask)
Measure the rotor thickness (new), the rotor thickness must Brake rotors (steel or aluminium girders with friction linings):
be in accordance with Table 2
Brake linings
(Code No. 160112)
(min. 1 x yearly)
(min. 1 x yearly
Warning!
On hoist drives, the drive brake must be
load-free, otherwise there is a danger of
load crashes!
Malfunctions / Breakdowns:
Malfunctions
Possible Causes
Solutions
Replace rotor
Interrupted coil
Replace brake
Switch DC-side
05/04/2007/TK/K/AM/GC/RJ
Page 13 of 13