INTORQ BFK455 Operating Instructions Manual
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setting the standard
INTORQ BFK455
Electromagnetically released spring-applied brake
Operating Instructions
www.intorq.com
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This documentation applies to ...
BFK455 -28 - dou bl e -disk version
BFK455-001.iso/dms BFK455-020.iso/dms
Product key
Product key INTORQ B FK
Legend for the INTORQ BFK455 product key
Product group Brakes
Product type Spring-applied brake
Type 455
Size 28
Not coded: supply voltage, hub bore, options
-
2
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Identification
Package label Example
Manufacturer Bar code
Type (see product key) Type No.
Name Quantity per box
Rated voltage Rated torque Packing date
Rated power Hub diameter
Additional information CE designation
Nameplate Example
Manufacturer
Type (see product key) CE designation
Rated voltage Rated power Hub diameter
Type No. Rated torque Production date
BFK455-101.iso/dms
BFK455-002.iso/dms
Notes
The brake is marked with the following labels, which have to be observed:
for holding voltage for air gap setting
Document history
Material number Version Description
33000803 1.0 05/2011 TD09 First edition
33000803 1.1 05/2012 TD09 Change in telephone and fax number
Front and back page new
Addition of the EC type test number
Supplemented by chapter ”Project planning notes”
Supplemented by chapter ”Wear of spring-applied brakes”
33002468 2.0 03/2013 TD09 Amended by new chapter on hand-release installation
Tables of dimensions and operating times were changed
Amendment of the spare parts list and the spare parts order
33002468 3.0 05/2013 TD09 Limitation of the adjustability
Note on the suppressor circuit added to the ”Electrical
installation” chapter
Values for characteristic torque 2x2065 Nm added to
”Dimensions” table
0Fig.0Tab. 0
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Contentsi
1 Preface and general information 6.......................................
1.1 About these Operating Instructions 6...................................
1.2 Terminology used 6.................................................
1.3 Conventions used 6.................................................
1.4 Abbreviations used 7................................................
1.5 Notes used 8......................................................
1.6 Scope of supply 9..................................................
1.7 Disposal 9........................................................
1.8 Drive systems 9....................................................
1.9 Legal regulations 10.................................................
2 Safety instructions 11...................................................
2.1 General safety information 11..........................................
2.2 Application as directed 12............................................
3Technicaldata 13.......................................................
3.1 Product description 13...............................................
3.2 Rated data 16......................................................
3.3 Rated data (selection data) 17.........................................
3.4 Friction work / operating frequency 19..................................
3.5 Emission 20.......................................................
4 Mechanical installation 21................................................
4.1 Important notes 21..................................................
4.2 Necessary tools 21..................................................
4.3 Mounting 21.......................................................
4.4 Installation 22......................................................
4.5 Manual release 28..................................................
4.6 Assembly of the cover ring 34..........................................
5 Electrical installation 35.................................................
5.1 Electrical connection 35..............................................
5.2 Bridge/half-wave rectifiers ( opti on ) 36...................................
5.3 Electrical connection 38..............................................
6 Commissioning and operation 39..........................................
6.1 Important notes 39..................................................
6.2 Function checks before commissioning 39................................
6.3 Commissioning 40...................................................
6.4 During operation 41.................................................
4
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Contentsi
7 Maintenance/repair 42..................................................
7.1 Wear of spring-applied brakes 42.......................................
7.2 Inspections 43......................................................
7.3 Maintenance operations 44............................................
7.4 Spare-parts list 46..................................................
7.5 Spare parts order 47................................................
8 Troubleshooting and fault elimination 48...................................
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Preface and general information1
1 Prefaceand generalinformatio n
1.1 About these Operating Instructions
| These Operating Instructions will help you to work safely on and with the
spring-applied brake with electromagnetic release. They contain safety instructions
that must be followed.
| All persons working on or with the electromagnetically released spring-applied brakes
must have the Operating Instructions available and observe the information and notes
relevant for them.
| The Operating Instructions must always be in a complete and perfectly readable
condition.
1.2 Terminology used
1.3 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
Spelling of numbers Decimal separator Point The decimal point is always used.
Symbols
Term In the following text used for
Spring-applied brake Spring-applied brake with electromagnetic release
Drive system Drive systems with spring-applied brakes and other drive
components
For example: 1234.56
Page reference Reference to another page with additional information
For example: 16 = see page 16
Document reference Reference to another documentation with additional
information
For example: Operating instructions
Wildcard Wildcard for options, selections
For example: BFK458- = BFK458-10
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Preface and general information1
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1.4 Abbreviations used
Abbreviation Unit Name
I A Current
I
H
I
L
I
N
M
A
M
K
n
max
P
H
P
L
P
N
Q J Heat/energy
Q
E
Q
R
Q
Smax
R
N
S
h
S
hue
S
hmax
s
L
s
LN
s
Lmin
s
Lmax
t
1
t
2
t
11
t
11
t
12
t
ue
U V Voltage
U
H
U
L
U
N
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A Holding current at 20 °C and holding voltage
A Release current at 20 °C and release voltage
A Rated current at 20 °C and rated voltage
Nm Tightening torque of the fixing screws
Nm Rated torque of brake, rated value at a relative speed of 100 rpm
rpm Maximum speed during the slipping time t3
W Coil power during holding, through normal excitation and 20 °C
W Coil power during release, through normal excitation and 20 °C
W Rated coil power at rated voltage and 20 °C
J Max. permissible friction work per switching cycle, thermal rating of
the brake
J Braking energy, friction work
J Max. permissible friction work during cyclic switching, depending on
the operating frequency
Ohm Rated coil resistance at 20 °C
1/h Operating frequency, the number of repeated operations per unit
time
1/h Transitional operating frequency, thermal rating of the brake
1/h Maximum permissible operating frequency, depending on the
friction work per operation
mm Air gap, movement of armature plate by switching the brake
mm Rated air gap
mm Minimum air gap
mm Maximum air gap
ms Engagement time, the total of the reaction delay and torque rise
time t
1=t11+t12
ms Disengagement time, time from switching the stator until the torque
has reduced to 0.1 M
K
ms Slipping time to standstill (after t11)
ms Delay time when connecting, time from disconnecting the
voltage until the torque begins to rise
ms Rise time of braking torque, time from beginning of rise of torque
until braking torque is reached
S Overexcitation time
VDC Holding voltage by change of voltage
VDC Release voltage by change of voltage
VDC Rated coil voltage for brakes which require automatic voltage
changing, the rated coil voltage U
voltage U
L
isthesameastherelease
rated
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Preface and general information1
1.5 Notes used
The following pictographs and signal words are used in this documentation to indicate dangers
and important information:
Safety instructions
Structure of safety instructions:
Danger!
Characterises the type and severity of danger
Note
Describes the danger
Possible consequences:
| List of possible consequences if the safety instructions are disregarded.
Protective measure:
| List of protective measures to avoid the danger.
Pictograph and signal word Meaning
Danger of personal injury through dangerous electrical voltage
Danger!
Danger!
Stop!
Application notes
Pictograph and signal word Meaning
Note!
Tip!
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Danger of personal injury through a general source of danger
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Danger of property damage
Reference to a possible danger that may result in property damage if the
corresponding measures are not taken.
Important note to ensure troublefree operation
Useful tip for simple handling
Reference to another documentation
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Preface and general information1
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1.6 Scope of supply
After receipt of the delivery, check immediately whether it corresponds to the accompanying
papers. INTORQ does not grant any warranty for deficiencies claimed subsequently.
| Claim visible transport damage immediately to the forwarder.
| Claim visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG.
1.7 Disposal
The spring-applied brake consists of different types of material.
| Recycle metals and plastics.
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| Ensure professional disposal of assembled PCBs according to applicable
environmental regulations.
1.8 Drive systems
Labelling
Drive systems and components are unambiguously designated by the indications on the
nameplate.
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D-31855 Aerzen
| The spring-applied INTORQ brakeis also delivered in single modules and individually
combined to its modular design. The data - package labels, nameplate, and type code
in particular - apply to one complete stator.
| If single modules are delivered, the labelling is missing.
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Preface and general information1
1.9 Legal regulations
Liability
| The information, data and notes in this documentation met the state of the art at the
time of printing. Claims referring to products which have already been supplied cannot
be derived from the information, illustrations and descriptions.
| We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorised modifications to the product
– improper working on and with the product
– operating faults
– disregarding the documentation
Warranty
| Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG.
| Warranty claims must be made to INTORQ immediately after detecting defects or
faults.
| The warranty is void in all cases where liability claims cannot be made.
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Safety instructions2
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2 Safetyinstructions
2.1 General safety information
| INTORQ components ...
– ... must only be applied as directed.
– ... must not be commissioned if they are noticeably damaged.
– ... must not be technically modified.
– ... must not be commissioned if they are mounted and connected incompletely.
– ... must not be operated without the required covers.
– ... can hold live as well as moving or rotary parts during operation according to their
degree of protection. Surfaces may be hot.
| For INTORQ components ...
– ... the documentation must always be kept at the installation site.
– ... only permitted accessories are allowed to be used.
– ... only original spare parts of the manufacturer are allowed to be used.
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| All specifications of the corresponding enclosed documentation must be observed.
This is vital for a safe and trouble-free operation and for achieving the specified product
features.
| Only qualified, skilled personnel are permitted to work on and with INTORQ
components.
In accordance with IEC 60364 or CENELEC HD 384, qualified, skilled personnel are
persons ...
– ... who are familiar with the installation, mounting, commissioning, and operation of
the product.
– ... who have the qualifications necessary for their occupation.
– ... who know and apply all regulations for the prevention of accidents, directives, and
laws relevant on site.
|Riskofburns!
– Surfaces may be hot during operation! Provide for protection against accidental
contact.
| Risk of injury due to a rotating shaft!
– Wait until the motor is at standstill before you start working on the motor.
| The friction lining and the friction surfaces must by no means have contact to oil or
grease since even small amounts reduce the brake torque considerably.
| The brake is designed for operation under the environmental conditions that apply to
IP54. Because of the numerous possibilities of using the brake, it is however necessary
to check the functionality of all mechanical components under the corresponding
operating conditions.
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Safety instructions2
2.2 Application as directed
| INTORQ components ...
– ... are intended for use in machinery and systems.
– ... must only be used for the purposes ordered and confirmed.
– ... must only be operated under the ambient conditions prescribed in these
Operating Instructions.
– ... must not be operated beyond their corresponding power limits.
Any other use shall be deemed inappropriate!
Possible applications of the INTORQ spring-applied brake
| Humidity: no restrictions
– In case of formation of condensed water and moisture: provide for appropriate
ventilation to ensure that all components will dry quickly.
| Ambient temperature:
-5 °C to +40 °C
| At high humidity and low temperature:
– Take measures to protect armature plate and rotor from freezing.
| Protect electrical connections against contact.
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Technical data3
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3Technicaldata
3.1 Product description
Versions
Basic module
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Fig. 1 Design of a BFK455 spring-applied brake
1.1 Stator 3 Complete rotor 6 Flange
1.2 Compression springs 4 Hub 8 Coil
2Armatureplate 5Shaft 13Coverring
3.1.1 General information
The spring-applied brake is designed for the conversion of mechanical work and kinetic energy
into heat. Due to the static brake torque, the brake can hold loads without speed difference.
Emergency braking is possible at high speed. The more friction work, the higher t he wear,
(operating speeds 16).
The BFK455 spring-applied brake is a double disc brake with four friction surfaces. The braking
torque is generated within two electrically and mechanically separated braking circuits by
means of several compression springs (1.2) with friction locking. The braking circuits are
released electromagnetically. Due to its division into two braking circuits, the brake is
especially suitable for applications in the fields of lift technology and stage machinery. The
brake is selected on the basis of the characteristic torque for one braking circuit. The second
braking circuit meets the requirement for redundancy.
The braking circuits are divided by two separate armature plates (2) with the respective
compression springs (1.2) assigned and electromagnetic coils (8). The separate connecting
cables for each stator and armature plate render it possible to switch each braking circuit
individually, 36.
BFK455-005.iso/dms
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Technical data3
The switching status of the spring-appliedbrake is monitored by one microswitch (16) for each
braking circuit. The associated switchgear rectifies the supply voltage (AC voltage) which is
reduced after a short time while the brake is in the released state. Thus the mean electrical
power of the brake is reduced.
The stator (1) is designed in temperature class F. The temperature limit of the coils (8) is
155 °C. The BFK455 spring-applied brake is designed for a maximum operating time of 60 %
with a reduction of the holding current.
Certificate
Type Characteristic torque [Nm] EC type-examination certificate
BFK455-28
2 x 1100, 2 x 1200
2 x 1700, 2 x 1800
2 x 2065
ABV 881/1
3.1.2 Braking
During braking, the rotor (3), which is axially movable on the hub (4), is pressed against
the friction surface - via the armature plates (2) - by means of the springs (1.2). The
asbestos-free friction linings ensure a high braking torque with low wear. The braking
torque is transmitted between hub (4) and rotor (3) via the splines.
3.1.3 Brake release
In braked state, there is an air gap ”s
release the brake, the coil of the stator (1) is excited with the DC voltage provided. The
magnetic force generated attracts the armature plate (2) towards the stator (1) against the
spring force. The rotor (3) is then released and can rotate freely.
3.1.4 Release monitoring
The spring-applied brake is equipped with one microswitch (16) each per braking circuit
for monitoring the switching status. When the braking circuits are released, the
microswitches (16) change over. This means that the operation of the drive against the
applied brake can be excluded. The microswitches can be connected both as NO and NC
contacts.
” between the stator (1) and the armature plate (2). To
L
For checking the correct functioning of the microswitches, we recommend to check the
switching status (see Tab. 6) both when the brake is released and when the brake is
applied.
3.1.5 Encapsulated design (optional)
This design not only avoids the penetration of spray water and dust, but also the spreading
of abrasion particles outside the brake. This is achieved by:
| a cover seal over the armature plate and rotor.
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Technical data3
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3.1.6 Project planning notes
| The brakes are dimensioned in such a way that the given characteristic torques are
reached safely after a short run-in process.
| Due to the fluctuating properties of the organic friction linings used and the alternating
environmental conditions, deviations of the given braking torques may occur. These
must be considered by corresponding safety measures in the dimensioning process.
Especially with humidity and alternating temperatures, an increased breakaway torque
may occur after a long downtime.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.
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Technical data3
3.2 Rated data
3.2.1 Dimensions
BFK455-006.iso/dms
Type Character
BFK455-28
Type
BFK455-28 314 M16 6 x M16x210 6 x M16x220 25 22.5 206 265
istic
torque
[Nm] s
2 x 1100
2 x 1200
2 x 1700
2 x 1800
2 x 2065 0.6 0.2 17.8
Pitch circle
∅[mm] Thread [mm] [mm] [mm] [mm] MA[Nm] MA[Nm]
Tab. 1 Dimensions of the BFK455-28
LN
Air gap Perm. wear Rotor thickness Mass
+0.05
[mm] s
0.4
Fixing screws DIN 912 Minimum thread depth
without
flange
[mm] [mm] min. [mm] max. [mm] m[kg]
Lmax.
0.7 0.3 17.7
+1.0 mm
with flange without
flange
with flange without
18 46
flange
of complete
stator
Tightening torque
with flange
Stop!
| The minimum thread depth of the end shield must be observed in any case,
Tab. 1
| If the required thread depth is not observed, the fixing screws may run into
the thread root. As a result, the required preload force will no longer be built
up and the brake will no longer be fixed securely!
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