Power Transmission Installation and Operating Instructions for Brake
Contents
1. accredited RINGSPANN agents e f 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 e Switch off the power supply before commencing work on electrical components e Rotating machine elements must be protected by the purchaser to prevent accidental contact e Supplies abroad are subject to the safety laws prevailing in those countries Installation and Operating Instructions for Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su __ Pages 10 Contents 1 General information 2 Configuration and function 3 Drawing and parts list 4 Condition on delivery 5 Installing the RINGSPANN brake caliper 5 1 Installation 5 2 Compressed air connection 5 3 Running in procedure 6 Maintenance 6 1 General maintenance 6 2 Permissible brake pad wear and brake pads exchange 7 Disassembly replacement of worn parts in the brake chamber 7 1 Drawing brake chamber 7 2 Disassembly assembly and replacement of worn parts in the brake chamber Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su__ Pages 10 1 General information These installation and operating instructions apply to e the DV 020 PFK brake calliper mounted parallel2. brake caliper is not under air pressure before replacing the brake pads 7 Disassembly replacement of worn parts in the brake chamber The brake chamber is defective if the push rod Pos 12 Fig 7 1 does not move when compressed air is applied and released or when air escapes from the brake chamber The brake chamber should be overhauled by the manufacturer If this is not possible the procedure described in Section 7 2 should be followed Danger to life and limb When disassembling the brake it is essential to ensure that the entire drive train is secured against inadvertent activation Rotating components can cause severe injuries Therefore rotating components e g brake discs must be secured against accidental contact To prevent injuries to personnel secure the brake with the aid of an assembly locking device Installation and Operating Instructions for Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su __ Pages 10 Page 10 7 1 Drawing brake chamber Type 5 Parts list valid for standard brake chamber 3514 032102 000000 7 2 Disassembly assembly and replacement of worn parts in the brake chamber e Remove the entire brake calliper from the machine component by loosening the screws If this cannot be done the brake pads must be removed so that the brake chamber can be removed e Remove the brake chamber from the
3. brake disc Maximum permissible lateral brake disc wobble is 0 2 mm Greater wobble may cause rattling and shaking of the brake unit Caution When mounting the brake caliper the brake chamber can not be filled with compressed air Installation and Operating Instructions for Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su__ Pages 10 The brake caliper is mounted to the machine component with using 2 M12 bolts with frame construction V or 1 M 20 bolts with frame construction H the strength class 8 8 Caution During installation ensure that the brake pads are centred and in full contact with the surface of the brake disc The gap between the brake pads and the brake disc should always be approx 0 5 mm on each side Please observe maximum the wear limit 5 2 Compressed air connection A flexible hose connection is required Please use hoses with a diameter of 6 mm Hose pressure must be at least 7 bar preferably 12 bar with a temperature range of approx 20 C to 80 C Air hoses are connected to the brake chamber with a G 1 4 fitting Whitworth Rohrgewinde DIN ISO 228 1 The caliper must first be mounted onto the brake disc before air pressure is introduced Compressed air must be filtered to remove all dirt pipe chips rust and condensation Purified air must then be enriched with a fine oil mist injected by a standard c
4. universal plug 4 7 Te possible with frame 4457 103 178 3504 000070 000000 Part number for 1 pad Part number for 1 set 2 pieces brake pads 4 Condition on delivery The brake caliper is delivered with a clamping gap of approx 13 5 mm between brake pads brake disc thickness of 12 5 and a gap of 0 5 mm between the disc and each brake pad 5 Installing the RINGSPANN brake calliper Before installing the brake the brake disc must be cleaned with alcohol e g ethyl or isopropyl alcohol or a water based surfactant solution soapy water etc and then rubbed dry with a clean cloth When cleaning the brake disc with a thinner acetone or a brake cleaning agent it is important to ensure that neither these cleaners nor any cleaner residues come in contact with the brake pads This is especially important in the case of brakes used only as parking brakes as no dynamic braking operations take place during which thinner residues would be rubbed off the brake disc Caution Oil and rust proofing agent residues reduced friction coefficient and thus diminish transmissible braking torque substantially 5 1 Installation The brake caliper should be mounted to stabile vibration free machine components in order to ensure noise free non screech 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 arm must point to the midpoint of the
5. RINGSPANN Power Transmission Installation and Operating Instructions for Brake Caliper DH 020 PFK and DV 020 PFK E 09 619e RINGSPANN GmbH Schaberweg 30 34 Telephone 49 6172 275 0 www ringspann com 61348 Bad Homburg Telefax 49 6172 275 275 mailbox ringspann com Germany Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su __ Pages 10 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 e Installation and operation of this product should only be carried out by skilled personnel e Repairs may only be carried out by the manufacturer or
6. caliper lever arm e Remove the flange bolts Pos 19 Fig 7 1 and nuts e Remove the retracting spring Pos 13 Fig 7 1 the pus rod Pos 12 Fig 7 1 and the diaphragm Pos 11 Fig 7 1 e Before reassembling the unit clean all parts and the inside walls of the brake chamber halves e Replace worn parts e g the diaphragm Ensure that round edge of the diaphragm fits precisely into the circular grooves of the brake chamber halves e Assemble the components as shown in Fig 7 1 e Tighten the flange bolts M6x30 DIN EN ISO 4014 8 8 Pos 19 Fig 7 1 crosswise in equal increments to block tightening torque 10 Nm
7. e brake disc when the brake is released 6 Maintenance Maintenance should be performed on the brake caliper at intervals of 4 to 12 weeks depending upon the frequency and duration of operation 6 1 General maintenance e Check both brake levers for easily of movement e Clean all bearings and glide points e Lubricate all bearing and glide points Check for fixed bolt screw connections e Brake caliper to machine component e Brake chamber to caliper lever arm e brake pad on the swivel part e Brake chamber flange connection Check the following for proper seal leaks e Hose connection and connection to the brake chamber Leaks can be detected quickly and easily using commonly used leak searcher Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su__ Pages 10 6 2 Permissible brake pad wear and brake pads exchange Brake pad material must have a thickness of at least 6 mm from the top surface of the brake ad to the top surface of the steel mounting plate see Fig 3 1 in Section 3 Brake pads or brake linings Pos 3 must always be replaced in pairs For unscrewing and screwing on fixed spanners or ring spanners with SW 13 are needed Caution Secure the brake for disassembly Caution Brake pads are basically always replace in pairs Caution Ensure that the
8. ommercially available air preparation unit The quantity of oil added depends on the nominal air flow rate in l min and is specified by the manufacturer of the air preparation unit The following types of oil are recommended for air preparation units Suitable types of oil Viscosity at 20 C mm s Avia Avilub RSL 3 34 BP Energol HLP 40 27 ESSO Spinesso 34 23 Shell Tellus Ol C 10 22 Mobil VAC HLP 9 25 2 Maximum air consumption per braking operations is approx 120 cm 5 3 Running in procedure Optimum braking effect is achieved only when both brake pads 3 are in full contact with the brake disc and the brake pads have attained a temperature of approx 200 C A repeated short braking with low compressed air 1 2 bar at a rotating disc is therefore necessary Caution If the brakes are used as parking brakes the braking torques specified are not met Reductions up to 50 of the braking torques are possible Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su__ Pages 10 Caution Check to ensure that the brake disc rotates freely Caution If the brake pads cannot be run in the torques listed in our Publication 46 cannot be achieved Reductions of up to 50 are possible Caution gt gt gt It is important to ensure that the brake pads do not rub against th
9. r LL connection 2 ian Fy No Cross section A B Position of wave spring washer 11 Position of the wave spring washer Residual brake pad thickness min 6 mm air gap 0 5mm _ Fig 3 1 Parts list Pari Frame to DV 020 PFK Frame to DH 020 PFK Frame to DV 20 for symmetric air gap Standard brake pad 2 2472 005013 A00112 Brake pad from BK 5300 v 50m s 2 2472 005013 A00103 Brake pad from BK 6905 2 2472 005013 A00117 Brake pad from PTFE Telfon 2 2472 00501 3 A00105 Brake pad from BK 8006 with alarm cable 1 2472 005013 A00113 2 2 Brake pad from BK 4773 2472 005013 A00102 Lever 2475 190001 000000 Lever for brake chamber 2475 190002 000000 Lever with thread for encoder mounting 2475 190008 000000 Retracting spring to DV 20 Grooved pin special 1151 00001 1 000000 Hexagon head screw M5x16 DIN EN ISO 4017 po 5019 005006 000000 2449 110001 000000 Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su __ Pages 10 Quantity 9 Hexagon nut M6 DIN EN ISO 4032 5101 005301 000000 140 Swivel part 2476 081001 000000 5124 021001 000000 12 Hexagon head screw M8x12 be DIN EN ISO 4017 5019 008003 000000 13 Hexagon nut self locking m 5113 012001 000000 15 Proximity switch for
10. to the brake disc frame construction V e the DH 020 PFK brake calliper mounted at a right angle to the brake disc frame construction H for installation on a brake disc with a thickness of 12 5 mm the versions with enhanced corrosion protection e various types of brake pads e g with wear alarm cable increased glide speed double friction surface or other special brake pad materials An identification plate with a 16 digit part number is affixed to the calliper The precise design of the brake calliper is defined by this part number only Please consult the drawings in each section when using this instructions 2 Configuration and function The brake calliper is used as a stopping control and parking brake Braking force is generated by compressed air The brake is released opened by spring force Rotating parts must be secured by the user against inadvertent contact e g brake disc Danger to life and limb It is essential to secure the entire drive train against inadvertent starts during brake installation and maintenance Rotating components can cause severe injuries Therefore rotating components e g brake disc must be secured by the operator to prevent accidental contact Installation and Operating Instructions for Brake Caliper DV DH 020 PFK E 09 619 e pneumatically activated spring released Issue 06 06 2013 Checked Su __ Pages 10 3 Drawing and parts list ay 0 4 ji Compressed ai
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