Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 1 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
11
Guidelines on the Declaration of Conformity
A conformity evaluation has been carried out for the product in terms of the EU Low Voltage Directive 2014/35/EU and the
Electromagnetic Compatibility (EMC) Directive 2014/30/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.
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 product 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 product 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 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 according
to Directive 2014/34/EU.
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.
Guidelines on important points.
General Safety Guidelines
DANGER
Danger of death! Do not touch voltage-carrying
lines and components.
DANGER
Danger of burns when touching hot surfaces.
CAUTION
• Danger of device failures caused by shortcircuits and earth short-circuits at the
terminals
• Electronic devices cannot be guaranteed failsafe.
During the risk assessment required when designing the machine or
system, the dangers involved must be evaluated and removed by
taking appropriate protective measures.
To prevent injury or damage, only professionals and specialists
are allowed to work on the devices. They must be familiar with the
dimensioning, transport, installation, initial operation, maintenance
and disposal according to the relevant standards and regulations.
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.
General Safety Guidelines
Only carry out installation, maintenance and
repairs in a de-energised, disengaged
state and secure the system against inadvertent
switch-on.
11
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 2 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
22
Function
The ROBA®-brake-checker plus DC monitoring module
is intended for use with an input voltage of 24 VDC. The
monitoring module monitors the movement of the armature
disk and emits the determined switching condition via
control terminal (signal output).
Critical conditions (line breakages, wear, excess temperature) can be recognised and the respective signal can be emitted via control terminal (error output).
It is possible to select between fast and slow disconnection
via the input F/S on the control terminal.
Louder switching noises are generated on the brakes in
case of fast switch-off than in case of slow switch-off.
The movement detection feature of the armature disk is
based on the detection of electromagnetic changes in the
brake. If, due to unfavourable external influences, the secured detection cannot be ensured, it is possible that the
signal and error outputs do not correspond to the expected
state (plausibility).
Dimensions (mm)
CAUTION
The ROBA®-brake-checker with integrated
DC-side disconnection is not suitable for
being the only safety disconnection in
applications!
66
48.4
61
89.4
5.6
31.5
19.3
36.5
22.8
6
42.3
20
96
Ø3
Ø3.5
20
Application
ROBA®-brake-checker plus DC monitoring modules are
used to supply permitted ROBA®-stop safety brakes.
Motion monitoring of the armature disk for released ROBAstop® safety brakes is possible.
Monitoring module ROBA®-brake-checker DC
• Consumer operation with overexcitation and/or power
reduction
• Controlled output voltage (on reduction)
• Automatic reduction to holding voltage U
H
• Fast or slow disconnection
• Armature disk motion recognition (release and drop-out
recognition)
• Preventative function monitoring (wear recognition and
error recognition, functional reserve)
• Continuous drop-out recognition
• Maximum output current I
RMS
= 5 A
• Maximum overexcitation current IO = 16 A
• Safe monitoring of the switching times (optional)
The use of the ROBA®-brake-checker in combination with brakes of other manufacturers is not intended and
expressly not approved by mayr® power transmission.
In these cases, operation is at your own risk, the guarantee and service and support provided by mayr®
power transmission no longer apply.
22
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 3 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
33
Technical Data
Input voltage
Power terminal
SELV/PELV ripple
content ≤ 5%
UI[VDC]
24
(18 - 30)
Output voltage ± 5%
U
O
[VDC] 0.99 × U
I
U
H
[VDC] 4, 6, 8, 12, 16, 20, 24
Output current
at ≤ 45 °C I
RMS
[A] 5
at max. 70 °C I
RMS
[A] 2.5
Device fuses 1.2 * IO, fast acting or circuit breaker 6 A; characteristic Z/A
Protection IP20 terminals
Control terminal
Nominal cross-section 0.14 - 1.5 mm2 (AWG 26 -16),
max. tightening torque for screws: 0.5 - 0.6 Nm
Power terminal
Nominal cross-section 0.2 - 1.5 mm2 (AWG 22 -14),
max. tightening torque for screws: 0.4 Nm
Ambient temperature [°C] -25 to +70
Storage temperature [°C] -40 to +105
Conformity markings
Protection IP20
Installation conditions
The installation position can be user-defined.
Please ensure sufficient heat dissipation and air convection!
Do not install near to sources of intense heat!
Preventative function monitoring
Through the monitoring of different parameters, the ROBA®-brake-checker recognises safety critical operating conditions of the
brake in advance, as well as acute faults (e.g. line breakage). Safety critical operating conditions are determined as they occur
and are notified to the user as a warning before the brake can no longer be operated.
Possible causes for the warning:
• Increasing wear
• Rising coil temperature
• Falling supply voltage
• Line voltage drop on feed lines to the brake
Type Input voltage
±5 %
Output voltage
±5 %
Article number
[VDC] UO [VDC] UH [VDC]
028.600.2
24 0,99 × U
I
4 8262586
24 0,99 × U
I
12 8267308
24 0,99 × U
I
16 8267387
33
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 4 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
44
Electrical Connection
Power terminal
1 Supply voltage +24 VDC
2 Supply voltage 0 VDC
3 Output voltage +
4 Output voltage –
5 Contact 1 (External fast switch off)
6 Contact 2 (External fast switch off)
Electrical Connection
Control terminal
11 IN Mode (Input) IN
12 Reset (Input) RST
13 Start (input) START
14 Fast/slow (Input) F/S
15 Error (output) max. 100 mA ERR
16 Signal (output) max. 100 mA OUT
PLC
IN
OUT
+
-
24VDC
1 2 3 4
5 6
11
12 13 14
15 16
PLC
IN
OUT
+
-
24VDC
123
4
5
6
1
1
121314151
6
4
5
6
Wiring Example Wiring Example
(external fast switch off)
ROBA®-brake-checker
plus DC
Type 028.600.2
ROBA®-brake-checker
plus DC
Type 028.600.2
Equivalent circuit diagram
INT interference
suppression diode
INT switch
EXT switch
EXT switch
44
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 5 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
55
Inputs
Outputs
F/S 14
0 VDC (low) Slow switch off (SLOW)
24 VDC (high) 1)Fast switch off (FAST)
START 13
0 VDC (low) Brake is not energised
24 VDC (high) Brake is energised
IN 11
0 VDC (low) Armature disk condition recognition activated
24 VDC (high) Armature disk condition recognition deactivated
RST 12
0 VDC (low) Deactivated On activating the reset procedure, the ROBA®-brakechecker
restarts, and as a result, all pending signals (ERROR) are
deleted.
24 VDC (high) Activated
tB = 200 ms (Boot time)
tC = 400 ms (Calibration time)
tR = 600 ms (Reset time)
tP = 10 < 100 ms (Pulse time
must be less than 100
ms, greater than 10 ms)
(Output)
t
t
U
OUT
U
I
ERR
RST
t
R
t
B
t
C
t
P
OUT 16
0 VDC (low)
Brake is not energised, movement of the armature disk for closing
the brake.
24 VDC (high)
Brake energised, movement of the armature disk for opening the
brake.
ERR
15
24 VDC (high) No errors
0 VDC (low)
Brake does not open or close, line interruption, false detection
Warning
1)
Preventative function monitoring (Wear recognition and error
recognition)
1) Rectangular signal 10 Hz
All inputs without assignment (not connected) have the condition 0 VDC (low)
55
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 6 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
66
Voltage reduction mechanism
After a brake-specific overexcitation time period, the intelligent automatic voltage mechanism mode adjusts to the preset holding voltage. Manual adjustment of the overexcitation
time is not necessary.
Continuous drop-out recognition
The continuous drop-out recognition can detect the following situation and signal it via the outputs:
Brake is energised --> Undesired movement of the armature
disk for closing the brake (drop-out of the armature disk).
Changes of the output signals:
Control terminal 16: OUT (24 VDC) --> 0 VDC
Control terminal 15: ERR (24 VDC) --> 0 VDC
Possible Causes
• Excessive temperature
• Marginal dimensioning
• Mechanical influences
Release monitoring
The release monitoring recognises the movement of the armature disk for opening the brake after switch-on as well
as the movement of the armature disk for closing the brake
after switch-off.
The release monitoring can be deactivated for certain applications in order to prevent errors.
Possible applications:
• Parallel operation of several brakes
• Damped brakes
• Unspecific brakes
Switch-OFF
Fast switch-off
If short engagement times are desired, fast switching should
be used (FAST).
Here, the ROBA®-brake-checker monitoring module limits
the switch-off voltage to approx. 60 VDC.
DC-side disconnection is signalized by the red light-emitting
diode flashing at the moment of switch-off.
Optional (customer-side) External fast switch off
An electrical and secure disconnection of the brake can
be guaranteed by the use of an external switch (see wiring
example).
Slow switch-off
If longer engagement times or quieter switching noises
are desired, slow switching should be used (SLOW) (factory
setting).
Switch-ON
Brake switch-on occurs with a connected supply voltage
(control and power terminal) by closing start (Input) on the
signal side using the voltage 24 VDC or a 24 VDC control
signal applied there. A green light-emitting diode emits a
signal when the device is switched on. After the changeover
from overexcitation voltage to holding voltage, the diode
continues to illuminate at reduced brightness.
Functional Guidelines
Start process
During each individual start process, all outputs (signal,
error, warning) are reset.
The outputs must be assessed for the plausibility of signal
conditions, signal changes and their correct temporal
sequence.
Inching Mode
During inching mode (fast sequence of switching on and
off), no reliable detection is possible.
After the end of inching mode, restart the monitoring
function:
• De-energise the brake
• Switch on (energise) the brake again
Repeated switch-on (energisation) before the brake is closed
generates a fault when the maximum current is reached.
66
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 7 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
77
Time Delays
Delays may occur during the detection and processing of
various brake conditions, input and output signals.
Switch-on delay
Normal operation
≤ 4 ms
Malfunction ≤ 4 ms
Delay time ≤ 4 ms
Signal delay ≤ 20 ms
MTTF 160 years at 60 °C
250 years at 40 °C
Duration of use 20 years
The basis of the MTTF calculation forms (if available) the
information of the component manufacturer supplemented
by the information from the Siemens standard SN 29500.
For the calculation, a simplified Parts-Count procedure has
been used (EN ISO 13849-1)
Reliability Nominal Values
• Avoid antennae effects: Keep the supply
cables as short as possible; do not form
rings or loops with the cables!
• Mount good earth connections onto the
metal body of the brake.
• Lay control cables (total length <30 m)
separately from power cables or from
strongly pulsating supply cables!
• A voltage drop can occur when operating
using long lines.
Check the holding voltage on the
respective brake.
EMC-compatible Installation
0 50 100 150 200 250 300 350 400 450 500 550 600
0
50
100
150
200
250
For brakes, which do not require overexcitation, the holding
voltage may be lower than the nominal voltage, e.g. on
power reduction to reduce the coil temperature.
Cycle frequency
In order to prevent thermal overload, an upper cycle limit
must be observed for especially high-performance brakes in
operation with fast switch-off.
Cycles/Minute
Braking performance P (24 VDC)
Device Fuses
Installation of a device fuse into the supply voltage line of the
ROBA®-brake-checker monitoring module.
Short-circuits or earth short-circuits can lead to ROBA®brake-checker monitoring module failures. After fuse
elements have reacted to a malfunction, the ROBA®-brakechecker monitoring module must be checked for functional
and operational safety (overexcitation voltage, switch-off
voltage, response delay time, holding voltage). The same
procedure is to be carried out after brake failure.
Intended Use
ROBA®-brake-checker products have been developed,
manufactured and tested as electronic equipment in
compliance with the DIN EN 50178 standard and in
accordance with the EU Low Voltage Directive. During
installation, operation and maintenance of the product, the
requirements for the standard must be observed. ROBA®brake-checker products are for use in machines, systems
and devices and must only be used in the situations for
which they are ordered and confirmed. The products are
designed for installation into electrical control cabinets and
terminal boxes. Using them for any other purpose is not
allowed.
77
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 8 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
88
0
Time Diagram:
If the switching frequency is higher than 1
cycle per minute or if the overexcitation time
tO is longer than double the separation time t2,
please observe the following:
P ≤ P
N
The coil capacity P must not be larger than PN
or the nominal current I which flows through
the ROBA®-brake-checker monitoring module
must not be exceeded, otherwise the coil and
the ROBA®-brake-checker monitoring module
may fail due to thermal overload.
U
U
O
U
N
U
H
T
t
on
t
off
t
O
t
N
t
Calculations:
P [W] RMS coil capacity dependent on switching
frequency, overexcitation and duty cycle
P =
PO x tO + PN x t
N
T
PN [W] Coil nominal capacity (catalogue values, Type tag)
PO [W] Coil capacity on overexcitation
PO = (
U
O
)² x P
N
U
N
PH [W] Coil capacity at power reduction
PH = (
U
H
)² x P
N
U
N
tO [s] Overexcitation time
tH [s] Time of operation with reduction in capacity
t
N
[s] Time of operation with coil nominal voltage
t
off
[s] Time without voltage
t
on
[s] Time with voltage
T [s] Total time (tO + tN + t
off
)
U
O
[V] Overexcitation voltage
UH [V] Holding voltage
UN [V] Coil nominal voltage
I [V] RMS current dependent on switching frequency,
overexcitation time and duty cycle
I =
P x P
N
U
N
²
t
88
t
N
t
O
t
11
t
2
t
t
t
t
t
t
U
I
U
I
I
U
O
UHU
N
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 9 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
99
Functional sequence diagram
Start
(Input)
Switch-off
F/S (Input)
Output current
WarningFast switch-offSlow switch-off Error
Output volt-
age
Signal
(Output)
ERROR
(Output)
99
Installation and Operational Instructions for
ROBA®-brake-checker plus DC Type 028.600.2 (B.0286002.EN)
your reliable partner
02/10/2018 TF/GF
Page 10 of 10
Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
www.mayr.com, E-Mail: info@mayr.com
1010
Malfunctions / Breakdowns
Standards
Product standard
VDE 0160 / DIN EN 50178:1998-04
Electronic equipment for use in power installations
EMC inspections
EN 61000-6-2:2006-03 Interference immunity
EN 61000-6-4:2007-09 Interference emission
EN 61000-6-3:2011-09 Interference emission for living area
Insulation coordination
acc. VDE 0110 / EN 60664:2008-01
Degree of pollution 2
Rated insulation voltage 63 VDC
Reliability nominal values
SN 29500, T = 60 °C / failure rates, components
EN ISO 13849-1
Disposal
Electronic Components
Products which have not been disassembled can be disposed of under Code No. 160214 (mixed materials) or components under Code No.
160216 (Code No. acc. 200/532/EC), or can be disposed of by a certified disposal firm.
Malfunction Possible Causes Measure
Brake does not release
No supply voltage available Check voltage on input terminal
Brake line interrupted Check brake supply line (check passage)
Line voltage drop on long line Check the brake voltage
Air gap not okay Check and adjust air gap
No signal
Brake is not permitted Use released brake
Brake is worn
Open and clean the brake, check the air gap;
replace the brake if necessary
Incorrect input voltage polarity Check input voltage and rotate if necessary
Error (continuous
signal)
Brake release is not recognised
Check: Brake is not permitted
Incorrect monitoring module (brake nominal voltage)
Brake drop-out is not detected
Brake is not permitted
Check the function of the monitoring module
Break voltage drop Check network stability and reinstate it
Unit temperature over 90 °C
Check ambient temperature and, if necessary,
improve the cooling.
Warning
Coil temperature of the brake too high
Check effective coil power, ext. Temperature, friction
power
Wear Replace rotor
Supply voltage too low
Check and, if necessary, increase supply/output
voltage of the monitoring module; check line length
Clock frequency or PN (coil nominal
capacity) too high
Lower clock frequency or PN (coil nominal capacity)
Unit temperature over 85 °C
Check ambient temperature. Check clock frequency
and PN.
1010
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