(B.018102.EN) Guidelines on he Declaraion of Conformiy A conformiy evaluaion has been carried ou for he produc in erms of he EC Low Volage Direcive 2006/95/ EC and EMC Direcive 2004/108/EC. The Declaraion of Conformiy is laid ou in wriing in a separae documen and can be requesed if required. Guidelines on he EMC Direcive (2004/108/EC) The produc canno be operaed independenly according o he EMC direcive. Only afer inegraion of he produc ino an overall sysem can his be evaluaed in erms of he EMC. For elecronic equipmen, he evaluaion has been verified for he individual produc in laboraory condiions, bu no in he overall sysem. Guidelines on he Machinery Direcive (2006/42/EC) The produc is a componen for insallaion ino machines according o he machinery direcive 2006/42/EC. The produc can fulfil he specificaions for safey-relaed applicaions in coordinaion wih oher elemens. The ype and scope of he required measures resul from he machine risk analysis. The produc hen becomes a machine componen and he machine manufacurer assesses he conformiy of he safey device o he direcive. I is forbidden o sar use of he produc unil you have ensured ha he machine accords wih he regulaions saed in he direcive. Guidelines on he ATEX Direcive Wihou a conformiy evaluaion, his produc is no suiable for use in areas where here is a high danger of explosion. For applicaion of his produc in areas where here is a high danger of explosion, i mus be classified and marked according o direcive 94/9/EC. Safey and Guideline Signs General Safey Guidelines Danger Immediae and impending danger, which can lead o severe physical injuries or o deah. DANGER Danger of deah! Do no ouch volagecarrying lines and componens. CAUTION Danger of injury o personnel and damage o machines. Danger Danger of burns when ouching ho surfaces Guidelines on imporan poins. CAUTION Danger from devices caused by shorcircuis and earh shor-circuis a he erminals Elecronic devices canno be guaraneed Sandards EMC inspecions EN 61000-6-2:2006-03 EN 61000-6-4:2007-09 Insulaion coordinaion acc. VDE 0110 / EN 60664:2008-01 Polluion degree 2 Raed insulaion volage 63 VDC Inended use acc. EN 50178:1998-04 Inerference immuniy Inerference emission During he risk assessmen required when designing he machine or sysem, he dangers involved mus be evaluaed and removed by aking appropriae proecive measures. To preven injury or damage, only professionals and specialiss are allowed o work on he devices. They mus be familiar wih he dimensioning, ranspor, insallaion, iniial operaion, mainenance and disposal according o he relevan sandards and regulaions. Before produc insallaion and iniial operaion, please read he Insallaion and Operaional Insrucions carefully and observe he Safey Regulaions. Incorrec operaion can cause injury or damage. Page 1 of 10
ON (B.028102.EN) Applicaion ROBA -brake-checker monioring modules are used o operae DC consumers. Moion monioring of he armaure disk for released ROBAsop safey brakes is possible. Consumer operaion wih overexciaion and/or power reducion Conrolled oupu volage (on reducion) Simple adjusmen of holding volage and overexciaion ime via a DIP swich Fas or slow swich off Armaure disk condiion recogniion (release and drop-ou recogniion) Wear recogniion and error recogniion Wide inpu volage range Maximum oupu curren I RMS = 10 A / 5 A Maximum overexciaion curren I O = 20 A / 10 A Auomaic reducion of he holding volage Elecrical isolaion of performance erminal and conrol erminal Dimensions (mm) 54 Ø4.5 5 9 CAUTION Funcion The ROBA -brake-checker wih inegraed DC-side disconnecion is no suiable for being he only safey disconnecion in applicaions! 5.6 4.5 64 54 30 17.5 Accessories: Mouning bracke se for 35 mm rail acc. EN 60715: Aricle No. 1802911 The ROBA -brake-checker monioring module is inended for use wih an inpu volage of 24 or 48 VDC. The module moniors he movemen of he armaure disk and emis he deermined swiching condiion via conrol erminal 3 (signal oupu). Criical condiions (line breakages, wear) can be recognised and he respecive signal can be emied via conrol erminal 7 (error oupu). Afer a brake-specific overexciaion ime period, he inegraed auomaic volage mechanism mode adjuss o he pre-se reducion volage. The auomaic volage mechanism mode can be swiched off using a DIP swich. 69 1 2 3 4 5 6 7 8 15 20 73.6 In case of swiched-off auomaic volage mechanism mode, he overexciaion ime can be adjused manually o 150 ms, 450 ms, 1 s, 1.5 s, and 2 s using he DIP swich. I is possible o selec beween fas and slow swich-off via he inpu S/L on he conrol erminal. Louder swiching noises are generaed on he brakes in case of fas swich-off han in case of slow swich-off. Page 2 of 10
(B.018102.EN) Technical Daa 24 VDC Type 2/028.100.2 48 VDC Type 4/028.100.2 Inpu volage Power Terminal SELV/PELV, U I [VDC] 18-30 42-54 Inpu volage Conrol erminal U I [VDC] 24 (19-28) Oupu volage ± 5 % U O [VDC] Inpu volage U I [VDC] 6, 8, 12, 16 12, 16, 24, 32 Oupu curren Device fuses Proecion Power Terminal Conrol erminals a 45 C I [A] 10 5.0 a max. 70 C I [A] 5 2.5 1.2 I O, fas acing Proecion IP65 componens, IP20 erminals Power erminals 4 mm 2 (AWG 20-12) max. ighening orque for screws: 0.5 Nm Nominal cross-secion 1.5 mm 2 (AWG 30-14), max. ighening orque for screws: 0.5 Nm Ambien emperaure [ C] -30 o +70 Sorage emperaure [ C] -40 o +105 Conformiy markings Insallaion condiions The insallaion posiion can be user-defined. Please ensure sufficien hea dissipaion and air convecion! Do no insall near o sources of inense hea! Only for varian 24 VDC (Type 2/028.100.2) The olerances from he signal erminals and power erminals differ in heir upper volage limi values. Whils he supply volage on he power erminal and herefore on he load can have a maximum volage of 30 VDC, only a maximum supply volage of 28 VDC may be applied o he signal erminal. Under hese prerequisies, boh erminals can be operaed wih one supply volage (see connecion example). Page 3 of 10
(B.028102.EN) Elecrical Connecion Power Terminal 1 Supply volage +24 VDC / +48 VDC 2 Oupu volage + 3 Oupu volage 4 Supply volage 0 VDC Elecrical Connecion Conrol erminal (elecrically insulaed) 1 Supply volage 0 VDC 2 Swich-off fas/slow (inpu) 3 Signal (oupu) 4 24 VDC (auxiliary volage for bridging) 5 Supply volage +24 VDC 6 Sar (inpu) 7 (oupu) max. 300 ma 48/24 VDC 24 VDC SPS Signal 24 VDC SPS Signal 1 3 5 7 1 3 5 7 2 4 6 1 2 3 4 1 2 3 4 5 6 7 8 2 4 6 1 2 3 4 1 2 3 4 5 6 7 8 Wiring example (wihou elecrical isolaion) S/L 2 Sar 6 S/L Sar Inpus 0 VDC (low) slow swich off 24 VDC (high) 1) fas swich off Wiring example (wih elecrical isolaion) 0 VDC (low) Brake is no energised 24 VDC (high) Brake is energised S/L Sar Signal 3 Operaion 7 0 VDC (low) 24 VDC (high) 24 VDC (high) no errors 0 VDC (low) Oupus Brake is no energised, movemen of he armaure disk for closing he brake. Brake energised, movemen of he armaure disk for opening he brake. - line breaks - Brake is no opened - Incorrec deecion Warning 2) Wear limi reached or brake oo ho 1) 24 VDC conrol signal or conrol erminal 4 (auxiliary volage for bridging) 2) Recangular signal 10 Hz / 24 Vpp For he operaion of he ROBA -brake-checker monioring module, he overexciaion ime and he swich-off mode mus be adjused afer connecion of he brake and he supply lines. These seings should be implemened in a de-energised sae a he DIP swich. An adjusmen change in energised sae is no adoped unil he end of he subsequen brake cycle (swich-off). Always observe he valid seings on he DIP swich of he ROBA -brake-checker monioring module. In case of an invalid or incorrec seing, he ROBA -brake-checker monioring module does no funcion. Page 4 of 10
(B.018102.EN) Swich-ON Brake swich-on occurs wih a conneced supply volage (conrol and power erminal) by closing of sar (Inpu) on he signal side using he volage 24 VDC (auxiliary volage for bridging) or a 24 VDC conrol signal applied here. A green ligh-emiing diode emis a signal when he device is swiched on. Afer he changeover from overexciaion volage o holding volage, he diode coninues o illuminae a reduced brighness. Holding volage The holding volage can be adjused via he DIP swich. The swiches may only be swiched in de-energised sae and may only be adjused as depiced. The se holding volage value should equal 3 imes he drop-ou volage of he safey brake. Swich-OFF If shor swiching imes are required, please swich DC-side and via he conrol inpu (bridge beween conrol erminal 2 and 4) Here, he ROBA -brake-checker monioring module limis he swich-off volage o approx. 60V. DC-side disconnecion is signalized by he red ligh-emiing diode flashing a he momen of swich-off. If a longer brake engagemen ime or a quieer swiching noise is required, please swich freewheeling (manufacurer-side seing). DIP swich 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Holding volage [VDC] 24 48 6 12 8 16 12 24 16 32 no power reducion Manufacurer-side seing Device Fuses Insallaion of a device proecion fuse ino he mains fuse of he ROBA -brake-checker monioring module. Shor-circuis or earh shor-circuis can lead o ROBA - brake-checker monioring module failures. Afer fuse elemens have reaced o a malfuncion, he ROBA -brakechecker monioring module mus be checked for funcional and operaional safey (overexciaion volage, swich-off volage, response delay ime, holding volage). The same procedure is o be carried ou afer coil failure. Adjusmens DIP swich The 8 posiions DIP swich mouned ono he device is spli up ino several differen funcional areas: If he brakes are operaed in power reducion mode, hen addiional imes mus be observed in order o ensure reducion of he curren. Design 24 VDC Minimum recommended reducion imes prior o swich-off [ms] Reduced volage [VDC] 16 12 8 6 Curren range < 5 A 100 120 140 150 > 5 A 200 250 300 350 Design 48 VDC Minimum recommended reducion imes prior o swich-off [ms] Reduced volage [VDC] 32 24 16 12 Curren range < 5 A 150 170 200 250 > 5 A 300 340 400 500 1 2 3 4 5 6 7 8 Release monioring Volage reducion mechanism Overexciaion ime Holding volage Page 5 of 10
(B.028102.EN) Overexciaion Increased wear and herefore an enlarged air gap as well as coil hea-up lenghen he separaion ime 2 of he brake. Therefore, when dimensioning he overexciaion ime O, please selec a leas double he separaion ime 2 on each brake size (caalogue values). The overexciaion ime O can be adjused via he DIP swich o 150 ms, 450 ms, 1 s, 1.5 s and 2 s ± 1 %. The DIP swiches may only be swiched in de-energised sae and may only be adjused as depiced. The volage reducion mechanism (DIP swich 7) mus be de-acived. Release monioring The inelligen release monioring can be deacivaed for cerain applicaions in order o preven errors. Possible applicaions: Parallel operaion of several brakes Damped brakes Unspecific brakes The release monioring recognises he movemen of he armaure disk for opening he brake afer swich-on as well as he movemen of he armaure disk for closing he brake afer swich-off. DIP swich Release monioring DIP swich Overexciaion ime O [s] 8 8 ON OFF 4 5 6 0.15 Manufacurer-side seing 4 5 6 0.45 4 5 6 4 5 6 4 5 6 1.00 1.50 2.00 In order o ensure correc monioring, brakes <50 W may no be reduced below 12 VDC. Manufacurer-side seing Volage reducion mechanism Afer a brake-specific overexciaion ime period, he inelligen auomaic volage mechanism mode adjuss o he prese holding volage. Manual adjusmen of he overexciaion ime is no necessary. DIP swich 7 7 Overexciaion ime O [s] ON (auomaically) OFF (manual) Time delays During deecion and processing of differen brake condiions, inpu and oupu signal delays can occur. Swich-on delay Delay ime Signal delay Normal operaion Malfuncion 4 ms 4 ms 4 ms 20 ms Manufacurer-side seing Page 6 of 10
(B.018102.EN) Coil Capaciy The values for he maximum coil nominal capaciy saed in he Table are guideline values for a swiching frequency of maximum 1 cycle per minue and for keeping o he permied curren I. Design 24 VDC Holding Volage Coil volage Coil capaciy P N Operaion wih Type 2/028.100.2 overexciaion power reducion 45 C 75 C [VDC] [VDC] [W] 6 30 15 x 8 53 27 x x 6 12 120 60 x x 16 213 107 x x 24 480 240 x 8 53 27 x 8 12 120 60 x x 16 213 107 x x 24 480 240 x 12 120 60 x 12 16 213 107 x x 24 480 240 x 16 16 160 80 x 24 360 180 x Design 48 VDC Holding Volage Coil volage Coil capaciy P N Operaion wih Type 4/028.100.2 45 C 75 C overexciaion power reducion [VDC] [VDC] [W] 12 30 15 x 16 53 27 x x 12 24 120 60 x x 36 270 135 x x 48 480 240 x 16 53 27 x 16 24 120 60 x x 36 270 135 x x 48 480 240 x 24 120 60 x 24 36 270 135 x x 48 480 240 x 36 36 180 90 x 48 320 160 x Page 7 of 10
(B.028102.EN) Calculaions: If he swiching frequency is larger han 1 cycle per minue or if he overexciaion ime O is longer han double he separaion ime 2, please observe he following: P P N The coil capaciy P eff mus no be larger han P N or he raed curren I which flows hrough he ROBA -brake-checker Type 2/028.100.2 monioring module mus no be exceeded, oherwise he coil and he ROBA -brake-checker Type 2/028.100.2 monioring module may fail due o hermal overload. P [W] RMS coil capaciy dependen on swiching frequency, overexciaion and duy cycle P P = O x O + P N x N T P N [W] Coil nominal capaciy (caalogue values, Type ag) P O [W] Coil capaciy on overexciaion P O = ( U O )² x P N Cycle frequency In order o preven hermal overload, an upper cycle limi mus be observed for especially high-performance brakes in operaion wih fas swich-off. Braking performance P N (24 VDC) 500 450 400 350 300 250 200 150 100 0 5 10 15 20 25 30 35 40 45 50 55 60 Cycles/Minue For brakes, which do no require overexciaion, he holding volage may be lower han he nominal volage, e.g. on power reducion o reduce he coil emperaure. P O [W] Coil capaciy on reducion in capaciy Time Diagram: U U O O P H = ( on N T )² x P N O [s] Overexciaion ime H [s] Time of operaion wih reducion in capaciy N [s] Time of operaion wih coil nominal volage off [s] Time wihou volage on [s] Time wih volage T [s] Toal ime ( O + N + off ) U O [V] Overexciaion volage [V] Holding volage [V] Coil nominal volage I [V] RMS curren dependen on swiching frequency, overexciaion ime and duy cycle I = P x P N ² off EMC-compaible Insallaion Avoid anennae effec: Keep he supply cables as shor as possible; Do no form ring or bow shapes wih he cables. Moun good earh connecions ono he meal body of he brake. Lay conrol cables separaely from power cables or from srongly pulsaing cables. A volage drop can occur when operaing using long lines. Check he holding volage on he respecive brake. In case of operaion of he ROBA -brake-checker monioring module in living and small business areas, special precauions mus be aken in order o keep o he correc limi values for hese areas in line wih he complee sysem, (for example by insalling a Würh ferrie WE74271221). The device has been inspeced individually only for indusrial areas. 0 Page 8 of 10
(B.018102.EN) Malfuncions / Breakdowns Malfuncion Possible Causes Soluions Brake does no release No signal oupu release monioring (brake has audibly released) (Coninuous signal) Warning (Recangular signal) Overexciaion ime no reached No supply volage available Brake line inerruped Unpermied seing on he DIP swich Line volage drop on long line Sar signal missing Release monioring deacivaed Non-specified brake, brake worn, brake does no release, movemen of he armaure disk oo low Brake is no opened, brake will no be recognised Brake does no close, brake is no recognised Brake feed line inerruped Wear limi reached Supply volage oo low Coil emperaure of he brake oo high DIP swich for he volage reducion mechanism is acivaed Check volage a he supply and signal erminals Inspec he brake feed line (check feed-hrough) Check he DIP seing (valid seings) Deacivae release deecion (DIP), apply supply volage, Check oupu volage a he brake oupu (power erminals 2 + 3) (Mulimeer) Check he volage a he sar (inpu) Acivae release monioring (DIP seing) Check brake and replace if necessary, check error oupu Check he supply/oupu volage (power erminal) o he brake Check he supply/oupu volage (power erminal) o he brake Inspec he brake feed line (check feed-hrough) Check he brake and replace if necessary. Check or increase supply/oupu volage (power erminal) o he brake Check or increase supply/oupu volage (power erminal) o he brake Deacivae he DIP swich for volage reducion mechanism Page 9 of 10
(B.028102.EN) Funcional sequence diagram Slow swich-off Fas swich-off Warning Sar (Inpu) U I Swich-off Swich-off fas/ slow (inpu) U I Oupu curren I 2 O N 11 100% 80% Oupu volage U O Signal (Oupu) (Oupu) Page 10 of 10