RINGSPANN DV 020 FEM User manual

Schaberweg 30-38
Phone [phone]
Fax [phone]
www.ringspann.com
[email protected]
61348 Bad Homburg
Germany
Installation and Operating Instructions for
Brake Caliper DV 020 FEM
E 09.772e

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 2
Important
Please read these instructions carefully before installing and operating the product. Your particular
attention is drawn to the notes on safety.
These installation and operating instructions are valid on condition that the product meets the
selection criteria for its proper use. Selection and design of the product is not the subject of these
installation and operating instructions.
Disregarding or misinterpreting these installation and operating instructions invalidates any product
liability or warranty by RINGSPANN; the same applies if the product is taken apart or changed.
These installation and operating instructions should be kept in a safe place and should accompany
the product if it is passed on to others –either on its own or as part of a machine –to make it
accessible to the user.
Safety Notice
•Installation and operation of this product should only be carried out by skilled personnel.
•Repairs may only be carried out by the manufacturer or accredited RINGSPANN agents.
•If a malfunction is indicated, the product or the machine into which it is installed should be stopped
immediately and either RINGSPANN or an accredited RINGSPANN agent should be informed.
•Switch off the power supply before commencing work on electrical components.
•Rotating machine elements must be protected by the purchaser to prevent accidental contact.
•Supplies abroad are subject to the safety laws prevailing in those countries.
This is a translation of the German original version!
In case of inconsistencies between the German and English version of this
installation and operating instruction, the German version shall prevail.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 3
Contents
1 General information
1.1 Safety information
1.2 Special safety information
2 Configuration, mode of operation and standards
2.1 Function
2.2 Identification
2.3 Standards, guidelines, protection class and certifications
3 Intended use
4 Impermissible use
5 Condition as delivered
6 Handling and storage
7 Technical requirements for safe operation
8 Installing the RINGSPANN brake
8.1 General instructions regarding assembly and installation
8.2 Installation instructions
8.3 Electrical connection of the brake caliper
8.4 Adjustment / readjustment of the friction block distance
8.5 Connecting the signal cable of the friction block (option)
9 Commissioning
10 Disassembling the brake
11 Maintenance
11.1 General maintenance
11.2 Permissible brake pad wear and replacement of the brake pads
11.3 Emergency release
12 Installing the inductive proximity switch (option)
13 EC-Declaration of Conformity
14 Electrical connection drawing 4457-000002
15 Drawing and parts list

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 4
1. General information
1.1 General safety instructions
Read these installation and operating instructions carefully before putting the brake into
operation. Consider these instructions as well as the drawings in the individual sections.
All work with and on the brake is to be carried out considering that "safety is top priority".
Switch the drive unit off before carrying out work on the brake.
Rotating parts (e.g. brake disc) must be secured by the operator against unintentional touching.
1.2 Special safety instructions
2. Configuration, mode of operation and standards
2.1 Function
The brake is a machine element with which accelerated masses can be safely slowed down. In
combination with a brake disc, you have a complete brake for the effective safeguarding of
machines and systems. Thanks to its universal design, it fulfils the following functions:
•As a holding brake, it prevents a stationary shaft from starting unintentionally.
•As a stopping brake, it brings a rotating shaft to a halt.
The brake force is generated by a spring (5) and the brake is released by means of an
electromagnet (1). If the friction blocks (2) are worn out, the holding or braking torque decreases
as the spring preload is reduced.
Max. Sound level during opening is 63 dB (measured according IEC 61672-2 “Fast”, with max.
clamping force).
2.2 Identification
These installation and operating instructions are valid for:
•the version DV 020 FEM, brake caliper attachment parallel to the brake disc.
•the DV 020 FEM with left-mounted electromagnet as shown in Fig. 2.1, for mounting on a 12.5
mm thick brake disc.
•the DV 020 FEM with right-mounted electromagnet.
•various types of brake-pads, and special brake pad materials.
•with manual spring force adjustment and special frame.
•the standard design, the cCSAus design and with proximity switch.
There is a type plate on the brake with a 16-digit part number. The exact design of the brake is
defined by this article number only.
As well as these instructions, please also consider the catalogue data for the brake at
www.ringspann.com and the drawings in the individual sections.
Life-threatening danger!
When assembling, operating and maintaining the brake it is to be ensured
that the entire drive train is secured against being switched on
unintentionally. Moving parts can cause severe injury. Rotating parts (e.g.
brake disc) must be secured by the operator against unintentional touching.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 5
Example: Identification:
Only for cCSAus type
2.3 Standards, guidelines, protection class and certifications
The following standards and guidelines have been applied:
2014/35/EU Low-Voltage Directive
DIN EN 61000-6-2 EMC –Immunity to interference for industrial areas
DIN EN 61000-6-4 EMC –Emission standard for industrial areas (with RFI filter 3515-
090001-000000)
CSA C22.2 No. 14-13 Industrial Control Equipment (cCSAus Design)
UL 508 Industrial Control Equipment (cCSAus Design)
Electrical protection class: IP65
Mechanical protection class: IP10
3. Intended use
The brake has been designed for use as a holding and stopping brake.
Use for any other purpose will be deemed improper. Ringspann is not liable for any damage
resulting from this; the user alone bears the risk.
4. Impermissible use
The brake must not be operated with a voltage higher than the value specified on the type label.
In addition, unauthorized structural changes to the brake are not permitted. Ringspann shall not
be liable for any damage resulting from this; the user alone bears the risk of such damage.
The standard UL 508 and CSA 22.2 No 14-13 is valid for ambient temperatures from 0°C to
+40°C. Technically, lower or higher ambient temperatures are permissible. Consultation with
Ringspann required.
5. Condition as delivered
When delivered, the brake has a clamping gap of approx. 8.0 mm between the friction blocks.
When the electromagnet is actuated, the brake opens to the preset clamping gap of 13.3 mm =
brake disc thickness 12.5 mm and an air gap of 0.4 mm on both sides between the brake disc
and the friction blocks.
In the sense of the Low-Voltage Directive 2014/35/EU.
cCSAus-Design:
Complies with Canadian and US American standard, Enclosure type 3R

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 6
6. Handling and storage
The brake weighs between 14 kg and 18 kg, depending on the version.
The brake is delivered preserved and can be stored in a closed, dry place for 12 months. Make
sure that no condensation occurs. Humid storage rooms are unsuitable. If the brake is stored for
a longer period than 12 months, as well as after each transport, the brake must be applied once
to prevent the seals and wipers from sticking together.
7. Technical requirements for save operation
Fastening the brake to stable and low-vibration machine parts will ensure quiet braking without
squeak.
8. Installing the RINGSPANN brake
8.1 General instructions regarding assembly and installation
Before installing the brake, the brake disc must be cleaned with alcohol (e.g. spirit (ethanol) or
isopropyl alcohol) or with water-based tenside solutions (soapy water or the like).
If cleaning the brake disc with a diluent, acetone or brake cleaning agent, it must be ensured that
these agents and no residues of these agents come into direct contact with the friction blocks.
This must be ensured for pure holding brakes in particular, since no dynamic braking takes place
that would remove any diluent residues from the brake disc.
Important!
Residues from oil and anti-rust agent considerably reduce the coefficient of friction
and thus also the braking and holding torque!
8.2 Installation instructions
The standard brake calliper is attached to the machine part with two M12 - 8.8 screws.
(The screws are not included in the scope of delivery)
Caution! Danger of injury!
When the brake caliper is released, the spring (5) is pretensioned. In the event that
the electromagnet is not constantly supplied with the correct power supply, parts of
the brake can suddenly move relative to each other!
Before assembly, check whether the mounting surface is level and the radial run-out between the
brake disc and mounting surface is within a tolerance of 0.3 mm.
Check that the permissible parallelism of 0.2 mm between the brake disc and the mounting
surface is not exceeded.
Check the axial movement of the brake disc. The axial movement shall not exceed ± 0,3 mm.
The maximum permissible lateral run-out of the brake disc is 0.1 mm. A greater lateral run-out
can cause the brake unit to rattle and shake.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 7
Fig. 8.1
The connecting plate for the brake as well as the brake disc must be checked for dimensional
accuracy. For this purpose, the connection dimensions shown on the catalogue data sheet or
installation drawing are to be checked. The standard distance between the connecting plate and
the centre of the brake disc is 73 mm.
During installation, it is essential to ensure that brake pads are centred and in full contact with the
brake disc (the midlines of the brake lever must point to the midpoint of the brake disc.).
Preparation for installation
Before mounting on the 12.5 mm thick brake disc, the brake must be released (opened). This is
possible:
•with the aid of the electromagnet (1), provided that it is already connected to a power source
(see Section 8.3).
•mechanically, by screwing on the "emergency release nut" (8), which you can find on the right
lever (see chapter 15). To do this, pull off the rubber cap (9) at the back of the electromagnet
and screw the "emergency release nut" onto the thread of the plunger.
Important!
Check whether the brake disc can rotate freely.
Important!
If the brake is released by screwing on the "Emergency release nut" (8), the
"Emergency release nut" must be removed after installation of the brake for a
functioning brake!
8.3 Electrical connection of the brake caliper

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 8
Caution! Danger of damage!
Before connecting the brake caliper to the power supply, check that your power
supply corresponds to the specifications for rated voltage and mains frequency on
the nameplate. In case of deviations, never connect the brake caliper, as otherwise
the electronics and the electromagnet of the brake caliper will be destroyed.
The customer must provide suitable surge protection to prevent voltage peaks
reaching the electronics.
Nominal voltage: 230..240 V AC, 50/60 Hz, single-phase.
Line protection : 6 A, protection has to be ensured by the user!
Outer diameter of the supply cable: 5 -10 mm (cCSAus); plug type (standard): 6-8mm.
Supply cable : 0,5-1,0 mm² (AWG 21- 18), fine wire, only copper cables are allowed.
When switched on, currents of up to 3 A occur for 0,7s. After that the current is about 0,6 A.
The brake caliper is actuated by switching the supply voltage on and off. On the electronics there
is a free-wheeling diode which suppresses a switch-off overvoltage when the supply voltage is
switched off. An autotransformer may be used for voltage reduction if its power rating is at least
0.3 kVA.The cable shall be selected according to the Canadian Electrical Code, part 1 or National
Electrical Code (NEC).
Pass the cable through the cable gland and connect the wires L, N, PE according to figure 8.2 or
8.3. The connections L and N can be swapped. Tightening torque of the connector screw is 6 lb-
in. See also chapter 14 “Electrical connection drawing 4457-000002”.
Fig. 8.2 (cCSAus) Fig. 8.3
8.4 Adjustment / readjustment of the friction block distance
The friction block distance is adjusted after mounting the brake caliper by adjusting / readjusting
with the adjusting screw (3). The distance between the friction blocks and the brake disc on both
sides should be approx. 0.4 mm when new. If the friction blocks wear out, brake force must be
adjusted. When reaching a dimension of "X" = 44 mm (see chapter 15) at the latest, brake force
adjustment and adjustment of the friction blocks must be carried out.
Attention!
Before commissioning, the air gap must be set to 0.4 mm on both sides!
The brake must be manually released with the "emergency release nut" (8) prior to adjustment
work. To do this, pull off the rubber cap (9) at the back of the electromagnet and screw the
"emergency release nut" onto the thread of the plunger.
Proceed as follows:
L N
1 = N
2 = PE
3 = L
4 = not connected

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 9
•Loosen the two lock nuts for the adjustment work and turn the two set screws (3) M12x60
DIN 913 in the lever approx. 2 turns counterclockwise.
•Turn the screw (6) into the lever until it touches the tip of the plunger. Now adjust a small
clearance of 0.2 to 0.4 mm on both sides between the friction blocks and the brake disc
by turning the screw (6) further, whereby the friction blocks must not grind. It is advisable
to press a friction block against the brake disc and adjust the required total clearance by
means of a feeler gauge on the opposite friction block.
Tip!
The adjustable minimum clearance depends on the lateral run-out of the brake disc.
The lower the clearance, the greater the wear reserve before the brake caliper has
to be adjusted.
Depending on the position of the brake caliper and the brake disc axle, the laterally mounted
electromagnet can generate a tilting torque, which causes an uneven air gap between the two
friction blocks and the brake disc. In extreme cases, a friction block can even come into contact
with the brake disc and the entire clearance is set at the opposite friction block.
The result would be a constant rubbing of this friction block during operation. The air gap can be
evenly adjusted by means of the set screws (3). Determine which friction block has the larger air
gap. Turn the set screw on the lever clockwise and adjust an even air gap of 0.2 - 0.4 mm on
both sides.
Important:
It must be ensured that the friction blocks (2) do not rub against the brake disc when
the brake caliper is open.
Important:
If the brake is released by screwing on the "Emergency release nut" pos. 8, the
hexagon nut must be removed for a functioning brake after installation of the brake!
If the power supply of the brake is switched off, the full braking torque (holding torque) is
available.
8.5 Connecting the signal cable of the friction block (option)
Connect the signal cable to a 24V control voltage, e. g. via a signal lamp. If the maximum
permissible friction lining abrasion limit is reached, contact to the neutral conductor is made and
the signal lamp lights up.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 10
9. Commissioning
Only full-face contact of the two friction blocks (2) on the brake disc as well as a rapid heating of
the friction linings to approx. 200°C will ensure an optimal braking effect. It is therefore necessary
to brake several times and for a short duration when the brake disc is rotating. This process is
finished when the friction surface shows a contact pattern of at least 70 to 80%.
Important!
If the brakes are used as holding brakes, then the braking torques indicated in the
catalogue will not be reached. Reductions of up to 50% of the braking torque are
possible.
10. Disassembling the brake
Life-threatening danger!
When disassembling the brake it is to be ensured that the entire drive train is
secured against being switched on unintentionally. Rotating parts can cause
severe injury. Rotating parts (e.g. brake disc) must be secured by the operator
against unintentional touching.
Important!
Make sure that no electrical voltage is applied to the brake caliper.
Remove the rubber cap (9) and screw on the hexagon nut (8) until an air gap between brake pad
and brake disc is adjusted and the brake disc can be turned freely.
Remove the two screws M12 - 8.8 which serve to fix the brake. The brake caliper can now be
removed from the mounting surfaces.
11. Maintenance
11.1 General maintenance
The brake caliper must be serviced at intervals of 4 to 12 weeks, depending on the application.
The following points must be checked during maintenance:
•Check the friction blocks for wear.
•Check that the friction blocks do not rub against the brake disc when the brake caliper is
released, or that there is an even air gap of approx. 0.4 mm on both sides.
•Check the screw connection of the brake caliper to the machine part and the screw
connection of the friction blocks for tight screw connection.
•Check the screw connection and the tight fit of the inductive proximity switch (optional).
•Check the screw connection of the electromagnet to the brake caliper lever.
•Check both brake caliper levers for easy moving.
•Clean the bearing and sliding points.
•Check the electrical wiring and connections.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 11
Important!
The friction linings (2) must not come into contact with lubricant!
11.2 Permissible friction lining wear and replacement of the friction blocks
Life-threatening danger!
Friction blocks may only be changed when the system or the work machine is
stationary!
Important!
When new, the friction lining has a thickness of 12.5 mm. After 4.5 mm of wear or
a residual lining thickness of 8 mm, the friction blocks must always be replaced in
pairs. Only original RINGSPANN friction blocks may be used.
Important!
Before replacing the friction blocks, make sure that the mass held by the brake is
secured against movement, as the brake must be released (opened) to change the
friction blocks.
Important!
Make sure that no electrical voltage is applied to the brake caliper.
Release the brake by switching on the supply voltage. Secure the open position with the
"Emergency release nut" (8). Turn the screw (6) back until the friction blocks can be changed
easily and secure the screw again with the lock nut. After changing the friction block, you must
readjust the braking torque and clearance as described in chapter 8.4.
Important:
If the brake is released by screwing on the "Emergency release nut" (8), the
hexagon nut must be removed for a functioning brake after installation of the
brake!
Finally, the new friction linings must be applied by braking briefly several times so that the brake
can achieve the required braking torque (see chapter 9).
11.3 Emergency release
Open the brake caliper manually by screwing on the ”Emergency release nut” (8) on the plunger
until you can move the friction blocks on the brake disc.
12. Installing the inductive sensor (option)
Life-threatening danger!
The inductive sensor may only be changed when the system or the work machine
is stationary!
The inductive encoders M12x1 length 65 mm are supplied separately. In the version with sensor
monitoring, a fixture for the inductive sensors is mounted on the brake lever or can be ordered as
an accessory.
Switching function: PNP (closer) Switching distance: 6 mm flush-mountable

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 12
Operating voltage: 10....30 V DC Operating current: 0...200 mA
No load current: < or = 10 mA Connection: V1-plug
Voltage drop: < or = 2 V Polarity reversal-resistant: yes
Signal indicator: LED Temp. range: -25 to +70°C
Protection level: IP 67
Fig. 12.1 Circuit diagram, PNP technology
Operating sequence for mounting or necessary replacement of the inductive sensor Brake closed
(actuated):
•Mount the inductive sensor to the brake when the brake is powerless.
•Slide the inductive sensor into the lower slot of the sensor fixture until a distance of
approx. 1 mm is reached between the inductive sensor and the collar of the sleeve (7).
•Connect the inductive sensor. Move the inductive sensor in the slotted hole from left to
right until the LED of the inductive sensor lights up.
•Secure this position with the lock nut.
•Test the correct function by operating the brake several times. When the brake is closed,
the LED of the inductive sensor must light up.
Sequence of operation for mounting or replacing the inductive sensor for the "Brake open"
operating state (ventilated):
•Actuate the electromagnet and secure the open position with the "emergency release nut"
(8).
•Mount the inductive sensor to the brake when the brake is powerless.
•Slide the inductive encoder into the upper slot of the sensor fixture until there is a distance
of approx. 1 mm between the inductive sensor and the collar of the sleeve (7).
•Connect the inductive sensors. Move the inductive sensor in the slotted hole from the right
to the left until the LED of the inductive encoder lights up.
•Secure this position with the lock nut.
•Remove the "emergency lock nut" (8) after installation of the inductive encoder.
•Test the correct function by operating the brake several times. When the brake is open,
the LED of the inductive sensor must light up.

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 13
13. EC-Declaration of Conformity
Note regarding EMC Directive 2014/30/EU
The brake is an uncritical equipment according to the EMC-Directive because of its passive
operation. The brake can not be operated independently. After integration into a complete
system, the brake can be evaluated according to EMC-Directive. To comply with DIN EN 61000-
6-4, the mounting of a RFI filter (3515-090001-000000) is required as a general rule.
Note regarding EC-Machinery Directive 2006/42/EC
The product is a component for installation in a machine according to the EC-Machinery Directive
2006/42/EC. Together with other components, the product can meet safety-related applications.
The necessary measures will emerge from the risk analysis of the machine. Built-in, the brake is
part of the machine and the machine manufacturer assesses the conformity of the safety device
on the Machinery Directive. The commissioning of the brake is only permitted if the machine
fulfills the Machine Directive.
Note regarding REACH Directive No. 1907/2006
The brake is considered as a “product” and not as a “substance”, and as such are not subjucted
to registration. EC-Declaration of Conformity
We hereby declare that the following products are developed, designed and manufactured by our
own responsibility in accordance with the Low-Voltage Directive.
RINGSPANN GmbH
Schaberweg 30-38
D-61348 Bad Homburg
Product: Electromagnetic released disk brake
Designation: DV020FEM
Sizes: 020
Types: 4457-2015xx-xxxxxx
Following standards and directives have been applied and complied with:
2014/35/EU Low-Voltage Directive
DIN EN 61000-6-2 EMC –Immunity to interference in industrial areas
DIN EN 61000-6-4 EMC –Emission standard for industrial areas (with RFI filter 3515-
090001-000000)
2011/65/EU RoHS Directive
2019/2006 REACH
CSA C22.2 No. 14-13 Industrial Control Equipment (cCSAus Design)
UL 508 Industrial Control Equipment (cCSAus Design)
The commissioning of the brake is only permitted when the machine complies with the EC-
Machinery Directive 2006/42 / EC.
ppa. Ernst Fritzemeier
RINGSPANN GmbH
Schaberweg 30-38
D-61348 Bad Homburg
Bad Homburg, 26.04.2020

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 14
14. Electrical Connection Drawing 4457-000002

Installation and Operating Instructions for
Brake Caliper DV 020 FEM,
spring activated –electromagnetic released
E 09.772e
Issue: 08.09.2021
Version: 2
drawn:MAYA
checked: EISF
Pages: 15
Page: 15
15. Drawing and parts list
Brake DV 020 FEM Standard with proximity switch (Specials see appendix).
Part
Designation
Quantity
1
Electromagnet DV20FEM
1
2
Friction block
1 Set
3
Set screw M12x60 DIN 913
2
4
Electronic box
1
5
Spring
1
6
Set screw M20x60
1
7
Sleeve D 020FEM
1
8
Nut M12
3
9
Rubber cap
1
10
Swivel piece
2
11
Proximity switch with fixture
optional
12
Electronic board
1
13
Plug or Cable gland (cCSAus Design)
1