INTORQ BFK458-06...25 Operating Instructions Manual

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INTORQ BFK458

Electromagnetically Released Spring-Applied Brake

Translation of the Original Operating Instructions

INTORQ | BA 14.0168 | 09/2015 2

Document history

Legal regulations

Liability

❚ The information, data and notes in these Operating Instructions met the state of the art at the time of

printing. Claims referring to drive systems which have already been supplied cannot be derived from this 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 work on or with the drive system

- operating errors

- disregarding the documentation

Material number Version Description

405520 1.0 08/1998 TD09 First edition for the series 405520 1.1 05/2000 TD09 Address revision

Changed values of brake torques, table 1 and table 3 Supplemented table 4, switching times

460730 2.0 11/2002 TD09 All chapters: Complete editorial revision

Changed company name Changed values of brake torques Changed drawings: Fig. 12, Fig. 13, Fig. 14, Fig.15 and Fig. 16

New: Chapter 7.4 "Spare parts list for double spring-operated brake" 13040626 2.1 02/2005 TD09 Changed company name to INTORQ 13284675 3.0 12/2008 TD09 Changed the tightening torques

Supplemented table 5

Revision of Chapter 3.5

Supplemented Chapters 7.1 and 7.2 13284675 3.1 01/2010 TD09 Changed the maintenance intervals for holding brake s with emergency

stop 13343893 4.0 07/2010 TD09 Changed values of the braking torques and rotation speeds

( table 3) 13343893 4.1 05/2012 TD09 Changed strength grade of the fixing screws 13343893 5.0 10/2013 TD09 Complete revision 13343893 6.0 09/2015 SC Restructured FM, harmonized connection diagrams, revised graphics

INTORQ | BA 14.0168 | 09/2015 3

Warranty

❚ Warranty claims must be made to INTORQ immediately after the defects or faults are detected. ❚ The warranty is void in all cases when liability claims cannot be made.

Spring-applied brakes of type BFK458-06...25

NOTICE

The warranty conditions can be found in the terms and conditions of INTORQ GmbH & Co. KG.

Design E Design N

Doubled design N

INTORQ | BA 14.0168 | 09/2015 4

Product key

Not coded: Supply voltage, hub bore, options

Checking the delivery

After receipt of the delivery, check immediately whether the items delivered match the accompanying papers. INTORQ does not accept any liability for deficiencies claimed subsequently.

❚ Claim visible transport damage immediately to the deliverer. ❚ Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.

INTORQ B FK -

Product group: Brake

Product type Spring-applied brake

Type: 458

Size: 06, 08, 10, 12, 14, 16, 18, 20, 25

Design/type: E - adjustable (brake torque can be reduced via adjuster nut) N - not adjustable L - not adjustable, LongLife design

NOTICE Labelling of drive systems and individual components

❚ Drive systems and components are unambiguously designated by the labelling on their

nameplates.

❚ The INTORQ spring-applied brake is also delivered in single modules which can then be put

together by the customer according to their requirements. The specifications – particularly the packaging label, nameplate and type code – apply to a complete stator .

❚ The labelling is not included when modules are delivered individually.

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Contents

1 General information ................................................................................................................................................7

1.1 Using these operating instructions.................................................................................................................7

1.2 Conventions in use.........................................................................................................................................7

1.3 Safety instructions and notices......................................................................................................................8

1.4 Terminology used........................................................................... .... .... ........................................................9

1.5 Abbreviations used.........................................................................................................................................9

2 Safety instructions ................................................................................................................................................11

2.1 General safety instructions...........................................................................................................................11

2.2 Disposal.......................................................................................................................................................11

3 Product description...............................................................................................................................................12

3.1 Application as directed.................................................................................................................................12

3.2 Layout..........................................................................................................................................................12

3.2.1 Basic module E ................................................................................................................................12

3.2.2 Basic module N ................................................................................................................................13

3.2.3 Basic module L ................................................................................................................................13

3.2.4 Basic module N, doubled design .....................................................................................................14

3.3 Optional configuration..................................................................................................................................15

3.3.1 Manual release (optional) ................................................................................................................15

3.3.2 Optional microswitch ........................................................................................................................15

3.3.3 Optional encapsulated design ..........................................................................................................15

3.3.4 Optional CCV ...................................................................................................................................15

4 Technical specifications.......................................................................................................................................16

4.1 Brake torque reduction.................................................................................................................................16

4.2 Rated data....................................................................................................................................................17

4.3 Switching times............................................................................................................................................22

4.4 Switching energy / switching frequency......................................................................... .... .... ......................24

4.5 Electromagnetic compatibility.......................................................................................................................25

4.6 Emissions.....................................................................................................................................................25

4.7 Manual release.............................................................................................................................................26

4.8 Labels on product.........................................................................................................................................27

5 Mechanical installation .........................................................................................................................................29

5.1 Tools............................................................................................................................................................30

5.2 Preparing the installation............................................................................ ..................................................30

5.3 Installing the hub onto the shaft...................................................................................................................31

5.4 Installing the brake.......................................................................................................................................32

5.5 Installing the friction plate (optional).............................................................................................................34

5.6 Mounting the flange......................................................................................................................................34

5.6.1 Mounting the flange without additional screws ................................................................................34

5.6.2 Installing the flange (variants: size 06) .............................................................................................35

5.6.3 Installing the flange (variants: sizes 18 – 20) ...................................................................................36

5.6.4 Installing the flange (variants: size 25) .............................................................................................37

5.7 Installing the double-rotor brake...................................................................................................................38

5.8 Cover ring assembly ....................................................................................................................................39

5.9 Installing the shaft seal.................................................................................................................................40

5.10 Installing the manual release (retrofitting) ...................................................................................................41

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6 Electrical installation.............................................................................................................................................42

6.1 Electrical connection.......................................................................... ..........................................................42

6.2 AC switching at the motor – extremely delayed engagement......................................................................43

6.3 DC switching at the motor – fast engagement.............................................................................................44

6.4 AC switching at mains – delayed engagement............................................................................................45

6.5 DC switching at mains – fast engagement...................................................................................................46

6.6 Technical specifications for the microswitch................................................................................................47

6.7 Bridge/half-wave rectifier (optional)..............................................................................................................47

6.7.1 Assignment: Bridge/half-wave rectifier – brake size ........................................................................48

6.7.2 Technical specifications ................................................................................. .... .... ..........................49

6.7.3 Reduced switch-off times .................................................................................................................49

6.7.4 Permissible current load at ambient temperature ............................................................................50

7 Commissioning and operation.............................................................................................................................51

7.1 Protect the electrical connections against any contact or touching..............................................................51

7.2 Function checks before commissioning.......................................................................................................52

7.2.1 Function check of brake without microswitch ...................................................................................52

7.2.2 Release / voltage check for brakes without microswitch ..................................................................52

7.2.3 Release / voltage check for brakes with microswitch .......................................................................52

7.2.4 Microswitch – checking for wear ......................................................................................................53

7.2.5 Test that the manual release functions ............................................................................................54

7.3 Commissioning.............................................................................................................................................55

7.4 Operation.....................................................................................................................................................55

7.4.1 Brake torque reduction .....................................................................................................................56

8 Maintenance and repair ........................................................................................................................................57

8.1 Wear of spring-applied brakes.....................................................................................................................57

8.2 Inspections...................................................................................................................................................58

8.2.1 Maintenance intervals ......................................................................................................................58

8.3 Maintenance.................................................................................................................................................58

8.3.1 Checking the component parts ........................................................................................................59

8.3.2 Check the rotor thickness .............................................. .... .... .... ......................................................59

8.3.3 Check the air gap ................................................................................................... ..........................59

8.3.4 Release / voltage .............................................................................................................................60

8.3.5 Adjusting the air gap ........................................................................................................................60

8.3.6 Replacing the rotor ............................................................. .... ..........................................................61

8.4 Spare-parts list.............................................................................................................................................62

9 Troubleshooting and fault elimination ................................................................................................................64

General information

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1 General information

1.1 Using these operating instructions

❚ These Operating Instructions will help you to work safely with the spring-applied brake with electromag-

netic release. They contain safety instructions that must be followed.

❚ All persons working on or with the electromagnetica lly released spring-applied brakes must have t he Op-

erating Instructions available and observe the information and n otes relevant for them.

❚ The Operating Instructions must always be in a complete and perfectly read able condition.

1.2 Conventions in use

This document uses the following styles to distinguish between different types of info rmation:

Spelling of numbers

Decimal separator Point The decimal point is always used. For exam-

ple: 1234.56

Symbols

Page reference Reference to another page with additional

information For example: 16 = refer to page 16

Wildcard Wildcard for options, selections

For example: BFK458- = BFK458-10

Note

Important notice about ensuring smooth operations or other key information.

General information

INTORQ | BA 14.0168 | 09/2015 8

1.3 Safety instructions and notices

The following icons and signal words are used in this document to indicate dangers and important safety information:

Safety instructions

Structure of safety instructions:

Danger level

SIGNAL WORD

Icon

Indicates the type of danger

Signal word

Characterizes 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

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Notice about a harmful situation with possible consequences: the product itself or surroun ding objects could be damaged.

General information

INTORQ | BA 14.0168 | 09/2015 9

1.4 Terminology used

1.5 Abbreviations used

Term In the following text used for

Spring-applied brake Electromagnetically Released Spring-Applied Brake Drive system Drive systems with spring-applied brakes and other drive components Cold Climate Version (CCV) Version of the sp ring-operated brake suited for particularly low temper-

atures

Letter symbol Unit Designation

I A Current I

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 fixing screws

Rated torque of the brake, rated value at a relative speed of rotatio n of 100 rpm

max

rpm Maximum occurring speed of rotation during the slipping time t

W Coil power during holding, after voltage change-over and 20 °C

W Coil power during release, before voltage change-over and 20 °C

W Rated coil power, at rated voltage and 20 °C

Q J Quantity of heat/energy Q

J Max. permissible friction energy for one-time switching, thermal parame ter of

the brake

J Braking energy, friction energy

Smax

J Max. permissible friction energy for cyclic switching, depending on the switch-

ing frequency

N/mm

Tensile strength

Ohms Rated coil resistance at 20 °C

µm Average surface roughness

1/h Operating frequency: the number of switching operations evenly spread over

the time unit

hue

1/h Transition switching frequency, thermal parameter of the brake

hmax

1/h Maximum permissible switching frequency, depending on the friction energy

per switching operation

mm Air gap: the lift of the armature plate while the brake is switched

mm Rated air gap

Lmin

mm Minimum air gap

General information

INTORQ | BA 14.0168 | 09/2015 10

Lmax

mm Maximum air gap

mm Air gap for manual release

ms Engagement time, sum of the delay time and braking torque - rise time

= t11 + t

ms Disengagement time, time from switching the stator until reaching 0.1 M

ms Slipping time, operation time of the brake (according to t11) until standstill

ms Delay du ring engagement (time from switching off the supply voltage to the

beginning of the torque rise)

ms Rise time of the braking torque, time from the start of torque rise until reach-

ing the braking torque

s Over-excitation time

UVVoltage U

V DC Holding voltage, after voltage change-over

V DC Release voltage, before voltage change-over

V DC Rated coil voltage; in the case of brakes requiring a voltage change-over,

equals U

Letter symbol Unit Designation

Safety instructions

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2 Safety instructions

2.1 General safety instructions

❚ Never operate INTORQ components when you notice they are damaged. ❚ Never make any technical changes to INTORQ components. ❚ Never operate INTORQ components when they are incompletely mounted or incompletely connected. ❚ Never operate INTORQ components without their required covers. ❚ Use only accessories that have been approved by INTORQ. ❚ Use only original spare parts from the manufacturer.

Keep in mind the following during operations: ❚ Depending on the degree of protection, INTORQ components may have both live (volta ge carrying),

moving and rotating parts. Such components require the appropriate safety mechanisms.

❚ Surfaces can become hot during operation. Take the appropriate safety measures (to ensure contact/

touch protection).

❚ Follow all specifications and information found in the Operating Instructions and the corresponding doc-

umentation. These must be followed to maintain safe, trouble-free operations and to achieve the specified product characteristics.

❚ The installation, maintenance and operation of INTORQ components may only be carried out by quali-

fied personnel. According to IEC 60364 and CENELEC HD 384, skilled personnel must be qualified in the following areas:

- Familiarity and experience with the installation, assembly, commissioning and operation of the product.

- Specialist qualifications for the specific field of activity.

- Skilled personnel must know and apply all regulations for the prevention of accidents, directives, and laws relevant on site.

2.2 Disposal

The spring-applied brake consists of different types of material.

❚ Recycle the metal and plastic parts. ❚ Ensure professional disposal of assembled circuit boards according to the applicable environmental reg-

ulations.

Product description

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3 Product description

3.1 Application as directed

INTORQ's spring-applied brakes are intended for use in machines and systems. They may only be used for purposes as specified in the ordered and confirmed by INTORQ. The spring-applied brakes may only be operated under the conditions specified in these Operating Instructions. They may never be operated beyond their specified performance limits. The technical specifications ( 16) must be considered for proper and intended usage. Any other usage is consider improper and prohibited.

3.2 Layout

This chapter describes the variants, layout and functionality of the INTORQ BFK458 spring-applied brake. The basic module E is adjustable (the braking torque can be reduced using the adjustment ring). The special feature for basic module L (with an identical design) is the more dura ble materials (torque support, guide pins, toothed intermediate ring, friction lining and gear teeth). The double-brake version is especially useful in redundant braking applications.

3.2.1 Basic module E

Fig. 1 Design of the INTORQ BFK458 spring-applied brake: Basic module E (complete stator) + rotor + hub + flange



Compression piece



Torque adjustment ring



Stator



Socket head cap screw



Manual release (optional)



Sleeve bolt



Flange



Rotor



Hub



Compression spring



Armature plate

Product description

INTORQ | BA 14.0168 | 09/2015 13

3.2.2 Basic module N

Fig. 2 Design of the INTORQ BFK458 spring-applied brake: Basic module N (complete stator) + rotor + hub + flange

3.2.3 Basic module L

Description of the LongLife design:

❚ Armature plate with low backlash and reinforced torque support ❚ Compression springs with guide pins for protection against shearing forces ❚ Aluminium rotor with toothed intermediate ring: Low-wear friction lining and low-wear gear teeth

The LongLife design can be configured modularly for sizes 6 to size 12 in combination with the specified rated torques. The specifications are as follows:

❚ The magnetic part corresponds to the design N. ❚ Rear holes and extensions are not possible. ❚ A microswitch in the size 12 is not configurable.



Stator



Socket head cap screw



Manual release (optional)



Sleeve bolt



Rotor



Hub



Compression spring



Armature plate



Flange

Product description

INTORQ | BA 14.0168 | 09/2015 14

3.2.4 Basic module N, doubled design

Fig. 3 Design of the INTORQ BFK458 spring-applied brake: Basic module N, doubled design with intermediate flange

Function

The spring-applied brake is a single-disk brake wi th two friction surfaces. The braking torque is generated by several pressure springs with friction locking. The braking circuits are released electromagnetically. During the braking procedure, the spring-applied brake converts kinetic energy into heat energy. Due to the static braking torque, loads can be held at standstill. Emergency braking is possib le at high speed of rotation. Note that the wear will increase when there is emergency braking with high switching energy.

Braking and release

During the braking procedure, the inner and outer springs use the armature plate to press the rotor (which can be shifted axially on the hub) against the frict io n surfa c e. T he asb est os-fre e f r ict ion lining s e nsure h igh braking torque and low wear. The braking torque is transmitted between the hu b and the rotor via gear teeth.

When the brakes are applied, an air gap "s

" is present between the stator and the armature plate. To release the brake, the coil of the stator is energised with the DC voltage provided. The resulting magnetic flux works against the spring force to draw the armature plate to the stator. This releases the rotor from the spring force and allows it to rotate freely.

Brake torque reduction

For the basic module E, the spring force and thus the brake torque can be reduced by un screwing the central adjustment ring.



Stator



Socket head cap screw



Screw for intermediate flange



Intermediate flange



Manual release (optional)



Sleeve bolts



Flange



Hub



Rotor



Compression spring



Armature plate

Product description

INTORQ | BA 14.0168 | 09/2015 15

3.3 Optional configuration

3.3.1 Manual release (optional)

To temporarily release the brake when there is no electricity available, a manual relea se function is available as an option. The manual release can be retrofitted (for installation refer to 41).

3.3.2 Optional microswitch

The micro-switch is used for the release check or for wear monitoring. The user is responsib le for arrang ing the electrical connection for this optional microswitch.

❚ Usage for the (air) release check: The motor will start only after the brake has been released. This ena-

bles the microswitch to monitor for errors (e.g. when the motor does not start because of a defective rectifier, if there are broken connecting cables, defective coils, or an excessive air gap).

❚ Usage for monitoring wear: The brake and motor are supplied with no power when the air ga p is too

large.

3.3.3 Optional encapsulated design

This design not only prevents the penetration of spray water and dust, but also the spreading of abrasion particles outside the brake. This is achieved by the following encapsul ation:

❚ A cover ring over the armature plate and rotor. ❚ Cover plate ❚ Shaft seal (can be supplied for continuous shaft).

3.3.4 Optional CCV

The Cold Climate Version (CCV) allows the brake to be operated at lower ambient temperatures.

Technical specifications

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4 Technical specifications

Usage conditions for the INTORQ spring-applied brake

❚ Degree of protection:

- The brake is designed for operation under the environmental conditions that apply to IP54 protection. Because of the numerous possibilities of using the brake, it is still necessary to check the f unctionality of all mechanical components under the corresponding operating conditions.

❚ Ambient temperature:

- -20 °C to +40 °C (standard)

- -40 °C to +40 °C (Cold Climate Version: CCV)

4.1 Brake torque reduction

For basic module E, the brake torque can be reduced using the adjustment ring in the stator. The adjustment ring can be unscrewed to the maximum protrusion of "h

Emax.

" ( 17 and 56).

NOTICE

Please observe that engagement times and disengagement times change de pending on the brake torque.

Size 06 08 10 12 14 16 18 20 25

Rated torque MK [Nm] of the brake, rated value at a relative

speed of rotation of 100 rpm

80 E

1.5 E 3.5 N/E 25 N/E 35 N/E 65 N/E 115 N/E 175 N/E

2 N/E 4 E 7 N /E 14 N/E 35 N 45 N/E 80 N/E 145 N/E 220 N

2.5 N/E 5 N/E 9 N/E 18 N/E 40 N/E 55 N/E 100 N/E 170 N/E 265 N/E 3 N/E 6 N/E 11 N/E 23 N/E 45 N/E 60 N/E 115 N/E 200 N/E 300 N/E

3.5 N/E 7N/E 14 N/E 27 N/E 55 N/E 70 N/E 130 N/E 230 N/E 350 N/E 4 N/E 8 N/E 16 N/E 32 N/E 60 N/E 80 N/E 150 N/E 260 N/E 400 N/E

4,5 N/E 9N/E 18 N/E 36 N/E 65 N/E 90 N/E 165 N/E 290 N/E 445 N/E

5 E 10 E 20 E 40 E 75 N/E 100 N/E 185 N/E 315 N/E 490 N/E

5.5 E 11 E 23 N/E 46 N/E 80 N/E 105 N/E 200 N/E 345 N/E 530 N/E

6 N/E 12 N/E 125 N/E 235 N/E 400 N/E 600 N/E

Torque reduction per latch-in position [Nm] for type E

0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2

Tab. 1: N Braking torque for the N design (without adjustment ring)

E Braking torque for the E design (with adjustment ring) L LongLife design

Operating brake (s

Lmax

approx. 2.5 x sLN)

Standard braking torque Holding brake with emergency stop (s

Lmax.

approx. 1.5 x sLN)

Technical specifications

INTORQ | BA 14.0168 | 09/2015 17

4.2 Rated data

Tab. 3: Rated data for air gap specifications

The friction lining is designed so that the brake can be adjusted at least 5 times.

Size

Rated brake torque at

n=100 rpm

Braking torque at n

[rpm] [%]

Max. rotation speed n

0max

for

horizontal mounting position

[%] 1500 3000 maximum [rpm]

100

87 80 74 6000

08 85 78

5000 10 83 76 4000 12 81 74

3600

14 80 73 72 16 79 72 70 18 77 70 68 20 75 68

25 73 66 3000

Tab. 2: Rated data for braking torques, depending on the speed and permissible limiting speeds

Size s

+0.1 mm

-0.05 mm

Lmax.

operating

brake

Lmax.

holding

brake

Max. adjustment,

permissible

wear path

Rotor thickness Protrusion

torque

adjustment ring

Emax.

[mm] [mm] [mm] [mm] min.1) [mm] max. [mm] [mm]

0.2 0.5 0.3 1.5

4.5 6.0

4.5

08 5.5 7.0 10 7.5 9.0 7.5 12

0.3 0.75 0.45

2.0 8.0

10.0

9.5 14 2.5 7.5 11 16 3.5 8.0 11.5 10 18

0.4 1.0 0.6

3.0 10.0 13.0 15 20 4.0 12.0 16.0 17 25 0.5 1.25 0.75 4.5 15.5 20.0 19.5

Technical specifications

INTORQ | BA 14.0168 | 09/2015 18

The screw length depends on the material and the thickness of the customer's mounting place.

The thread in the threading surface is offset by 30° in reference to the centre axle of the manual release lever.

Hex head screw according to DIN EN ISO 4017 - 8.8.

Size Pitch circle Screws

for the flange mount

DIN EN ISO 4762 (8.8)

Minimum depth

of the clearing holes

(in end shield)

Tightening torque

±5%

 [mm]

[mm]

Screws

[NM]

Complete lever

[NM]

06 72 3 x M4 0.5 3.0

2.8

08 90 3 x M5 1 5.9 10 112 3 x M6 2

10.1 4.8

12 132 3 x M6 3 14 145

3 x M8

1.5

24.6

16 170 0.5 18

196

4 x M8

0.8 23

20 230

4 x M10

2.1

278

6 x M10

Tab. 4: Rated data for the screw set for flange mounting

Size

Pitch circle

 [mm]

Screw set for

mounting to the

flange

Minimum depth

of the clearing

hole

[mm]

Screw set for

mounting onto the

motor/friction plate

Screw set for

flange with

through hole

06 72 3 x M4x35 0.5 3 x M4x40 3 x M4x45 08 90 3 x M4x40 1 3 x M5x45 3 x M5x50 10 112 3 x M6x50 2 3 x M6x55 3 x M6x65 12 132 3 x M6x55 3 3 x M6x60 3 x M6x70 14 145 3 x M6x60 1.5 3 x M8x70 3 x M8x80 16 170 3 x M8x70 0.5 3 x M8x80 3 x M8x90 18 196 6 x M8x80 0.8 6 x M8x90 20 230 6 x M10x90 2.1 6 x M10x100 25 278 6 x M10x100 5 6 x M10x110 -

Tab. 5: Rated data for the screw set for brake mounting

Technical specifications

INTORQ | BA 14.0168 | 09/2015 19

Size Pitch circle Screw set for mounting

double flange on stator, complete

DIN EN ISO 4762

strength grade 8.8 (10.9)

Thread depth in

the magnet

housing

Tightening

torque

±5%

[mm] Thread (4 pieces) [mm] [NM]

06 37.7 4 x M4 M4x16 10 3.0 08 49

4 x M5

M5x16

5.910 54 12 64 M5x20 14 75

4 x M6

M6x20

10.1

16 85 M6x25 15 18 95 4 x M8 M8x25 17 24.6 20 110

4 x M10

M10x25

25 140 M10x30 - 10.9 71

Tab. 6: Rated data for the screw set, intermediate flange installation for double brake

Size Electrical power

[W]

Coil voltage

[V]

Coil resistance

±8 %

[]

Rated current

[A]

06 20

24 28.8 0.83

96 460.8 0.21 103 530.5 0.194 170 1445 0.114 180 1620 0.111 190 1805 0.105 205 2101 0.098

08 25

24 23 1.04

96 368 0.26 103 424.4 0.242 170 1156 0.147 180 1296 0.138 190 1444 0.131 205 1681 0.121

Tab. 7: Rated data for coil power

Technical specifications

INTORQ | BA 14.0168 | 09/2015 20

30 24 19.2 1.25 31 96 297.3 0.322 32 103 331.5 0.31 30 170 963.3 0.176 32 180 1013 0.177 30 190 1203 0.157 33 205 1273 0.160

12 40

24 14.4 1.66

96 230.4 0.41 103 265.2 0.388 170 722.5 0.235 180 810 0.222 190 902.5 0.210 205 1051 0.195

24 11.5 2.08

96 184.3 0.52

53 103 200.2 0.514 50 170 578 0.294 53 180 611.3 0.294 50 190 722 0.263 53 205 792.9 0.258

24 10.5 2.29

96 167.6 0.573

56 103 189.5 0.543 55

170 525.5 0.323 180 589.1 0.305

60 190 601.7 0.315 56 205 750.5 0.292

Size Electrical power

[W]

Coil voltage

[V]

Coil resistance

±8 %

[]

Rated current

[A]

Tab. 7: Rated data for coil power

Technical specifications

INTORQ | BA 14.0168 | 09/2015 21

Coil power at 20 °C

18 85

24 6.8 3.54

96 108.4 0.885 103 124.8 0.825 170 340 0.5 180 387.2 0.472 190 424.7 0.447 205 494.4 0.414

20 100

24 5.76 4.16

96 92.2 1.04 103 106.1 0.970 170 289 0.588 180 324 0.55 190 328.2 0.578 205 420.3 0.487

25 110

24 5.24 4.58

96 83.8 1.14 103 96.5 1.06 170 262.7 0.647 180 294.6 0.611 190 328.2 0.578 205 382.1 0.536

Size Electrical power

[W]

Coil voltage

[V]

Coil resistance

±8 %

[]

Rated current

[A]

Tab. 7: Rated data for coil power

Technical specifications

INTORQ | BA 14.0168 | 09/2015 22

4.3 Switching times

The switching times listed here are guide values which apply to DC switching with rated air gap s

, warm coil and standard characteristic torque. The switching times given are mean values and subject to variations. The engagement time t

is approximately 8 to 10 times longer for AC switching.

Fig. 4 Operating/switching times of the spring-applied brakes

The maximum permissible friction energy QE relates to the standard friction lining.

These switching times are specified for the usag e of INTORQ bridge/half-wave rect ifiers and coils with a

supply voltage of 205 V DC at s

and 0.7 IN.

t1Engagement time t11Reaction delay of engagement t

Disengagement time (up to M = 0.1 MK)t

Rise time of the braking torque

Rated torque U Voltage

Size Rated torque

[Nm]

[J]

hue

[1/h]

Switching times [ms]

DC engagement Disengage

06 4 30007915132845 08 8 75005015163157 10 16 12000 40 28 19 47 76 12 32 24000 30 28 25 53 115 14 60 30000 28 17 25 42 210 16 80 36000 27 27 30 57 220 18 150 60000 20 33 45 78 270 20 260 80000 19 65 100 165 340 25 400 120000 15 110 120 230 390

Tab. 8: Switching energy - switching frequency - switching times

Technical specifications

INTORQ | BA 14.0168 | 09/2015 23

Engagement time

The transition from a brake-torque-free state to a holding-braking torque is no t free of time lags. For emergency braking, short engagement times for the brake are absolutely essential. The DC switching in

connection with a suitable spark suppressor must therefore be provided. Engagement time for DC-side switching: A braking torque reduction via the torque adjustment ring prolongs

the engagement time and reduces the d iseng ageme nt time. An a nti-magne tic plate is availab le when there is excessive prolongation. This plate is installed between the stator and the armatu re plate. The plate redu ces the engagement time and prolongs the disengagement time.

Engagement time for AC-side switching: The engagement time is sign ificantly prolonged (approx. 10 times longer).

❚ If the drive system is operated with a frequency inverter so that the brake will not be de-energised befo re

the motor is at standstill, AC switching is also possible (not applicable to emergency braking).

❚ The specified engagement times are valid for DC switching with a spark suppressor.

- Circuit proposals: ( 46).

Disengagement time

The disengagement time is the same for DC and AC switching. The specified disengagement times always refer to control using INTORQ rectifiers and rated voltage.

NOTICE

Connect the spark suppressors in parallel to the contact. If this is not admissible for safety reasons (e.g. with hoists and lifts), the spark suppressor can also be connected in parallel to the brake coil.

NOTICE

Spark suppressors are available for the rated voltages.

Technical specifications

INTORQ | BA 14.0168 | 09/2015 24

4.4 Switching energy / switching frequency

Fig. 5 Switching energy as a function of the switching frequency

The permissible switching frequency S

hmax

depends on the amount of heat QR (refer to Figure 5). At a pre-

set switching frequency S

, the permissible amount of heat is Q

Smax

NOTICE

With high speeds of rotation and switching energy, the wear increases strongly, becau s e very high temperatures occur at the friction surfaces for a short time.

Sizes

Switching frequency Sh [h-1]

Switching energy Q [J]

hmax

hue

–

ln 1

---------

–







--------------------------------=

smaxQE

hue

–

-------------------

–







Technical specifications

INTORQ | BA 14.0168 | 09/2015 25

4.5 Electromagnetic compatibility

4.6 Emissions

Heat

Since the brake converts kinetic energy as well as mechanical and electrical energy into heat, the surface temperature varies considerably, depending on the operating conditions and possible heat dissipation. Under unfavourable conditions, the surface temperature can reach 130 °C.

Noise

The loudness of the switching noise during engaging and disengaging depends on the air gap "s

" and the

brake size. Depending on the natural oscillation after installation, operating conditions and the state of the friction sur-

faces, the brake may squeak during braking.

NOTICE

The user must ensure compliance with EMC Directive 2004/108/EC usin g ap propriate co ntrols and switching devices.

NOTICE

If an INTORQ rectifier is used for the DC switching of the spring-applied brake: If the switching frequency exceeds five switching operations per minute, the use of a mains filter is required.

If the spring-applied brake uses a rectifier from another manufacturer for the switching, it may become necessary to connect a spark suppressor in parallel with the AC voltage. Spark suppressors are available on request, depending on the co il voltage.

Technical specifications

INTORQ | BA 14.0168 | 09/2015 26

4.7 Manual release

The manual release mechanism is used to release the brake by hand and can be retrofitted. The manual release springs back to its base position automatically after operation. The manual release re-

quires an additional air gap "s

" in order to function; this is factory-set prior to delivery. Check for the dimen-

sion "s

" after the installation.

Size

+0.1

-0.05

+0.1

(mm) (mm)

0.2 108 10 12

0.3 1.514 16 18

0.4 2 20

25 0.5 2.5

Tab. 9: Adjustment setting for manual release

Technical specifications

INTORQ | BA 14.0168 | 09/2015 27

4.8 Labels on product

There is a packaging label on the package. The nameplate is glued to the ou ter surface of the brake.

Fig. 6 Packaging label (example)

INTORQ Manufacturer

Bar code BFK458-12E Type (see product key) FEDERKRAFTBRREMSE (SPRING-APPLIED BRAKE) Designation of the product family Nr. (No.) 15049627 Type number 24 V DC Rated voltage 32 NM Rated torque 1 St. (1 piece) Quantity per box

CSA_CUS approval 40W Rated power

20 H7 Hub diameter

02.06.15 Packaging date Rostschutzverpackung-Reibfläche fettfrei halten!

(Anti-rust packaging: keep friction surface free of grease!)

Addition

CE mark

Technical specifications

INTORQ | BA 14.0168 | 09/2015 28

Fig. 7 Nameplate (example)

INTORQ Manufacturer

CSA_CUS approval

t=40°C Ambient temperature BFK458-25E Type (see product key) Class F Insulation class 180 V DC Rated voltage 110 W Rated power Nr. (No.) 15049627 Type number 350 NM Rated torque 30/07/2015 Date of manufacture

CE mark

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 29

5 Mechanical installation

This chapter provides step-by-step instructions for the installation.

Important notes

Design of end shield and shaft

❚ Comply with the specified minimum requirements regarding the end shield and the motor shaft to ensure

a correct function of the brake.

❚ The diameter of the shaft shoulder must not be greater than the tooth-base diameter of the hub. ❚ The form and position tolerances apply only to the materials mentioned. Con s ult with INTORQ before

using other materials; INTORQ's written confirmation is required for such usage.

❚ The brake flange must be supported by the end shield across the full surface.

Minimum requirements of the end shield

Consult with INTORQ before using other materials.

The diameter of the shaft shoulder must not be greater than the tooth-base diameter of the hub.

NOTICE

The toothed hub and screws must not be lubricated with grease or oil.

Size Axial run-out

[mm]

Material

Evenness

[mm]

Roughness Tensile

strength

[N/mm2]

Miscellaneous

06 0.03

S235JR; C15; EN-GJL-250

< 0.06 Rz6

250

❚ Threaded holes

with minimum thread depth

❚ Free of grease

and oil

08 0.03 10 0.03 12 0.05 14 0.05

< 0.10 RZ10

16 0.08 18 0.08 20 0.08 25 0.10

Tab. 10: End shield as counter friction surface

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 30

5.1 Tools

5.2 Preparing the installation

1. Remove the packaging from the spring-applied brake and dispose of it properly.

2. Check the delivery for completeness.

3. Check the nameplate specifications (especially rated voltage)!

Size Torque key

Insert for hexagonal socket

(Allen) screws

Wrench size of

open-jawed spanner

[mm]

Spanner wrench

DIN 1810 design A

Socket spanner for

flange mounting,

outer

Measurement

range

[NM]

Wrench width

[mm]

Sleeve

bolts

Manual release screws

Diameter

[mm]

Width across flats

[mm]

1 to 12

3 8 7 / 5.5 45 - 55 7

08 4 9

10 / 7

52 - 55 8

512

68 - 75

80 - 90

20 to 100

615

12 / 8

1316 95 - 100

- / 10

11 0 - 115

20 135 - 145

25 8 17 155 - 165

Multi-meter Calliper gauge Feeler gauge

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 31

5.3 Installing the hub onto the shaft

Fig. 8 Installing the hub onto the shaft

1. Press the hub with a moderate amount of force to the shaft.

2. Secure the hub against axial displacement (for example, by using a circlip).

NOTICE

The customer is responsible for constructing the shaft-hub connection. Make sure that the bearing length of the key is identical to the length of the hub.

NOTICE

Check the tensile strength of the hub material: When operating with high torque, consult with INTORQ and use a steel hub with a higher tensile strength.



Circlip



Hub



Keyway



End shield

NOTICE

If you are using the spring-applied brake for reverse operations, glue the hub to the shaft.

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 32

5.4 Installing the brake

Installing the rotor (without friction plate)

Fig. 9 Assembly of the rotor

1. Push the rotor on the hub.

2. Check if the rotor can be moved manually.

Fig. 10 Mounting the complete stator

3. Screw the complete stator to the end shield Use the supplied set of screws and a torque wrench.



Rotor



Hub



End shield



Socket head cap screw



Stator, complete



Terminal clip



Rotor



End shield

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 33

4. Remove the terminal clips and dispose of properly.

Fig. 11 Tightening the screws with a torque wrench

5. Check the air gap near the screws using a feeler gauge. These values These values must match the specifications for "s

" in the table ( 17).

Fig. 12 Adjusting the air gap

6. If the measured value "sL" is outside of the tolerance "sLN", readjust this dimension. Loosen the socket head cap screws slightly and adjust the air gap (turn the sleeve bolts using a wrench).

7. Use a torque wrench to tighten the socket head cap screws (refer to Figure 11).

NOTICE

Do not push on the feeler gauge more than 10 mm between the armature plate and the stator!

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 34

5.5 Installing the friction plate (optional)

Fig. 13 Mounting the friction plate

1. Place the friction plate against the end shield. The lip edging of the friction plate must remain visible!

2. Align the pitch circle and the thread along the bore holes.

5.6 Mounting the flange

5.6.1 Mounting the flange without additional screws

1. Place the flange against the end shield.

2. Check the pitch circle and the threads of the bore holes.

3. Use the proper screw set ( 32 and 62) to mount the brake.



Stator



Rotor



Friction plate



End shield

NOTICE

When dimensioning the thread depth in the end shield, be sure to take into account the permissible wear ( 18).

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 35

5.6.2 Installing the flange (variants: size 06)

The flange can be screwed to the end shield on the outer pitch circle (screw dimensioning is specified in

18).

Fig. 14 Flange mounting for sizes 06 - 16

1. Make sure that there are clearing holes in the end shield (refer to the table) at the positions of the screws in the stator.

2. Place the flange against the end shield.

3. Use the three screws to screw the flange to the end shield.

4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thickness. Use screws according to the table 18.

NOTICE

Clearing holes for the screws in the end shield must be behind the threaded screw holes in the flange. Without the clearing holes, the minimal rotor thickness cannot be used. The screws must not press against the end shield.



Screw from the screw set



Flange



Hub



End shield

NOTICE

Tighten the screws evenly (tightening torques 18).

NOTICE

When mounting the flange, the various size classes must be distinguished: sizes 06 - 16, 18 - 20 and 25 are mounted differently.

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 36

5.6.3 Installing the flange (variants: sizes 18 - 20)

The flange can be screwed to the end shield on the outer pitch circle (refer to Tab. 4).

Fig. 15 Flange mounting for sizes 18 - 20

1. Place the flange against the end shield.

2. Check the pitch circle and the threads of the bore holes .

3. Use the four screws to screw the flange to the end shield.

4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thickness. Use screws according to the table 18.

NOTICE

❚ Clearing holes for the screws in the end shield must be behind the t hreaded screw holes in

the flange. Without the clearing holes, the minimal rotor thickness cannot be used. The screws must not press against the end shield.

❚ For sizes 18 and 20, the fastening surface threading must be angled at 30° to the centre

axis to the manual release lever.



Screw from the screw set



Flange



Hub



End shield

NOTICE

Tighten the screws evenly (tightening torques: 18).

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 37

5.6.4 Installing the flange (variants: size 25)

The flange can be screwed to the end shield on the outer pitch circle (refer to Tab. 4).

Fig. 16 Flange mounting for size 25

1. Place the flange against the end shield.

2. Check the pitch circle and the threads of the bore holes .

3. Use the six screws to screw the flange to the end shield.

4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thickness. Use screws according to the table 18.

NOTICE

❚ Clearing holes for the screws in the end shield must be behind the t hreaded screw holes in

the flange (refer to Chapter 3.2). Without the clearing holes, the minimal rotor thickness cannot be used. The screws must not press against the end shield.

❚ For size 25, the fast ening surface thre ading must be angle d at 30° to the centre axis to the

manual release lever.



Hex screw



Flange



Hub



End shield

NOTICE

Tighten the screws evenly (tightening torques: 18).

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 38

5.7 Installing the double-rotor brake

Fig. 17 Installing the intermediate flange

Required: The front hub has to be mounted on the shaft!

1. Mount the intermediate flange with the four screws in the threads of the rear magnet housing.

All other steps for mounting the front brake are carried out as described in Chapter 5.4.



Screw from the screw set



Intermediate flange



Rear stator



Front hub

NOTICE

When installing the double brake, use screws with the required strength grade. Screw them in with the proper torque as specified in Tab.6, 19).

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 39

5.8 Cover ring assembly

Fig. 18 Cover ring assembly

1. Pull the cables through the cover ring.

2. Slide the cover ring over the stator.

3. Press the correspon ding lips of the co ver ring in the groove of the stator an d in the gro ove of the flange. If a friction plate is used, the lip must be pulled over the edging.



Cover ring



Socket head cap screw



Stator



Armature plate



Sleeve bolt



Flange



End shield



Friction plate

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 40

5.9 Installing the shaft seal

Fig. 19 Installing the shaft seal

NOTICE

When using a shaft seal, the brake has to be mounted so that it is centred properly! The shaft diameter must be implemented in accordance with ISO tolerance h11, with a radial

eccentricity tolerance according to IT8 and an averaged su rface ro ug hn ess o f R

 3.2 µm in

the sealing area.



Socket head cap screw



Shaft sealing ring



Stator, complete



Terminal Clip



Rotor



End shield

NOTICE

Please note the following for the version "brake with shaft sealing ring in torque adjustment ring":

❚ Lightly lubricate the lip of the shaft seal with grease. ❚ No grease should be allowed to contact the friction surfaces. ❚ When assembling the stator, push the shaft sealing ring carefully over the shaft. The shaft

should be located concentrically to the shaft seal.

Mechanical installation

INTORQ | BA 14.0168 | 09/2015 41

5.10 Installing the manual release (retrofitting)

Fig. 20 Assembly of the manual release BFK458

1. Insert the bolt into the bore holes of the yoke.

2. Insert the pressure springs in the holes of the armature plate.

3. Push the hex head screw through the pressure spring in the armature plate and through the bore hole in the stator.

4. Screw the hex head screws into the yoke bolts.

5. Tighten the hex head screws to fasten the armature plate against the stator.

6. Remove the terminal clips and dispose of properly.

7. Set the gap "s

+ sHL" evenly using the hex head screws and the feeler gauge. Refer to Tab .11 for the

values for the dimension "s

+ sHL".



Trunnion



Yoke



Lever



Stator



Terminal clip



Armature plate



Compression spring



Washer



Hexagon head screw

Size

+0.1

-0.05

+0.1

(mm) (mm)

0.2 108 10 12

0.3 1.514 16 18

0.4 2 20

25 0.5 2.5

Tab. 11: Adjustment setting for manual release

Electrical installation

INTORQ | BA 14.0168 | 09/2015 42

6 Electrical installation

Important notes

6.1 Electrical connection

Circuit suggestions

DANGER

There is a risk of injury by electrical shock!

❚ The electrical connections may only be made by trained electricians! ❚ Make sure that you switch off the elec tricity before working o n the connection s! There is a

risk of unintended start-ups or electric shock.

NOTICE

❚ Make sure that the supply voltage matches the voltage specification on the nameplate.

NOTICE

The terminal pin sequence shown here does not match the actual order.

Electrical installation

INTORQ | BA 14.0168 | 09/2015 43

6.2 AC switching at the motor – extremely delayed engagement

Fig. 21 Supply: Phase-neutral

Bridge rectifier Half-wave rectifier BEG-1xx: U

[VDC]=0.9 • [VAC] BEG-2xx: UN [VDC]=0.45 • [VAC]

Fig. 22 Supply: Phase-phase

Bridge rectifier

Half-wave rectifier

BEG-1xx: U

[VDC]=0.9 • UV [VAC] BEG-2xx: UN [VDC]=0.45 • UV [VAC]

Not recommended for most regional/national high-voltage mains systems

U2W2 V2

L1L1L2

V1U1 W1

4-pole BEG-14x BEG-24x

6-pole BEG-16x BEG-26x

-------- -

U2W2 V2

L1L1 L2L2 L3L3

V1U1 W1

4-pole BEG-14x BEG-24x

6-pole BEG-16x BEG-26x

Electrical installation

INTORQ | BA 14.0168 | 09/2015 44

6.3 DC switching at the motor – fast engagement

Fig. 23 Supply: Phase-neutral

Bridge rectifier Half-wave rectifier BEG-1xx: U

[VDC]=0.9 • [VAC] BEG-2xx: UN [VDC]=0.45 • [VAC]

Fig. 24 Supply: Phase-phase

Bridge rectifier1) Half-wave rectifier BEG-1xx: U

[VDC]=0.9 • UV [VAC] BEG-2xx: UN [VDC]=0.45 • UV [VAC]

Not recommended for most regional/national high-voltage mains systems

L1L1L2

UVU

U2W2 V2

V1U1 W1

6-pole BEG-16x BEG-26x

-------- -

U2W2 V2

L1L1L2

V1U1 W1

6-pole BEG-16x BEG-26x

Electrical installation

INTORQ | BA 14.0168 | 09/2015 45

6.4 AC switching at mains – delayed engagement

Fig. 25 Supply: Phase-N

Bridge rectifier Half-wave rectifier BEG-1xx: U

[VDC]=0.9 • UV [VAC] BEG-2xx: UN [VDC]=0.45 • UV [VAC]

Fig. 26 Supply: Phase-phase

Bridge rectifier

Half-wave rectifier

BEG-1xx: U

[VDC]=0.9 • UV [VAC] BEG-2xx: UN [VDC]=0.45 • UV [VAC]

Not recommended for most regional/national high-voltage mains systems

L1 N

4-pole BEG-14x BEG-24x

6-pole BEG-16x BEG-26x

L1L1 L2L2

4-pole BEG-14x BEG-24x

6-pole BEG-16x BEG-26x

Electrical installation

INTORQ | BA 14.0168 | 09/2015 46

6.5 DC switching at mains – fast engagement

Fig. 27 Supply: Phase-phase or phase-N via 6-pole rectifier

Bridge rectifier

Half-wave rectifier

BEG-16x: U

[VDC]=0.9 • UV [VAC] BEG-26x: UN [VDC]=0.45 • UV [VAC]

For most regional/national high-voltage mains systems, this only makes sense for supplies on L1 and N.

Fig. 28 Supply: Phase-phase or phase-N via 4-pole rectifier

Bridge rectifier

Half-wave rectifier

BEG-14x: U

[VDC]=0.9 • UV [VAC] BEG-24x: UN [VDC]=0.45 • UV [VAC]

Spark suppressor:

14.198.00.xx (required once, select position)

For most regional/national high-voltage mains systems, this only makes sense for supplies on L1 and N.

L1L1 N

L1L1 L2L2

6-pole BEG-16x BEG-26x

L1 N

4-pole BEG-14x BEG-24x

14.198.00.xx

Electrical installation

INTORQ | BA 14.0168 | 09/2015 47

6.6 Technical specifications for the microswitch

The brake can be equipped with a microswitch for monitoring the release or wear. The microswitch can be integrated into the circuit as an NO or NC contact.

As of June 2012, a new small microswitch (with UL acceptance) is in use, which is perfectly adapted to the contour of the brake. The old switch design can be converted by co nnecting an adapter to the same threaded holes.

6.7 Bridge/half-wave rectifier (optional)

BEG-561- -

The bridge/half-wave rectifiers are used to supply electromagnetic DC spring-applied brakes which are approved for the use with such rectifiers. Other use is only permitted with the approval of INTORQ.

Once a set over-excitation time has elapsed, the bridge/half-wave rectifiers switch over from bridge rectification to half-wave rectification.

Terminals 3 and 4 are located in the DC circuit of the brake. The inductio n voltage peak for DC switching (see "DC switching - fast engagement" circuit diagram) is limited by an integrated overvoltage protection at terminals 5 and 6.

Design Microswitch 3-pole connecting cable 3 x 0.34 mm² (AWG22)

black / brown / blue D = 4.8 mm, black, CSA

Style 2517/105°

Length 1000 mm Contacts Silver Current carrying capacity 250 V AC Ma x. 3 A Current carrying capacity 30 V DC Max. 3 A Minimum load at 24 V DC 10 mA Temperature range: -40 °C to +85 °C Protection class IP67

Tab. 12: Technical specifications for the microswitch

Switching states

= 0 s

Lmax

(-0.1)

Check of air gap 1 - 4 1 - 2 1 - 2 Monitoring wear 1 - 4 1 - 4 1 - 2

Tab. 13: Switching states of the mechanical microswitches

Electrical installation

INTORQ | BA 14.0168 | 09/2015 48

6.7.1 Assignment: Bridge/half-wave rectifier – brake size

Fig. 29 BEG-561 attachment options

Rectifier type Supply voltage Over-excitation Holding current

reduction

Coil voltage Size Coil voltage Size

[V AC] [V DC] [V DC]

BEG-561-255-030

230 103

06 ... 16

205

06 ... 14 BEG-561-255-130 – 16 ... 25 BEG-561-440-030-1 400 180 06 ... 25 – –

Electrical installation

INTORQ | BA 14.0168 | 09/2015 49

6.7.2 Technical specifications

input voltage (40 ... 60 Hz)

6.7.3 Reduced switch-off times

AC switching must also be carried out for DC switching (fast engagement)! Otherwise, there will be no overexcitation when it is switched back on.

Rectifier type Bridge / half-wave rectifier

Output voltage for bridge rectification 0.9 x U

Output voltage for half-wave rectification 0.45 x U

Ambient temperature (storage/operation) [°C] -25 ... +70

Type Input voltage U

(40 Hz ... 60 Hz)

Max. current I

max

Over-excitation time tue (± 20 %)

Min.

[V ~]

Rated

[V ~]

max.

[V ~]

Bridge

[A]

half-wave

[A]

at U

1 min

[s]

at U

1 Nom

[s]

at U

1 max

[s]

BEG-561-255-030

160 230 255 3.0 1.5

0.430 0.300 0.270 BEG-561-255-130 1.870 1.300 1.170 BEG-561-440-030-1 230 400 440 1.5 0.75 0.500 0.300 0.270

Tab. 14: Data for bridge/half-wave rectifier type BEG-561

Delayed engagement Fast engagement

Mains

Bridge

Coil

Electrical installation

INTORQ | BA 14.0168 | 09/2015 50

6.7.4 Permissible current load at ambient temperature

1 For screw assembly with metal surface (good heat dissipation) 2 For other assembly (e.g. adhesive)

I I

max.

[°C]

0,2

0,4

0,6

0,8

1,0

-20

40 60

100

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 51

7 Commissioning and operation

Usage conditions for the INTORQ spring-applied brake

7.1 Protect the electrical connections against any contact or touching.

Important notes

❚ The brake is designed for operation under the environmental conditions that apply to IP54 protection.

Because of the numerous possibilities of using the brake, it is still necessary to check the functionality of all mechanical components under the corresponding operating conditions.

NOTICE

In case of high humidity: If condensed water and moisture are present, provide for the appropriate ventilation for the brake to ensure that all friction components dry quickly.

At high humidity and low temperatures: Take measures to ensure that the armature plate and rotor do not freeze.

DANGER

Danger: rotating parts!

The brake must be free of residual torque. The drive must not be running when checking the brake.

DANGER

There is a risk of injury by electrical shock!

The live connections must not be touched.

NOTICE Functionality for different operating conditions

❚ The brakes are dimensioned in such a way that the given rated torques are reached safely

after a short run-in process.

❚ However, since the orga nic friction linings used do not all have identical properties and be-

cause environmental conditions can vary, deviations from the specified braking torques are possible. These must be taken into account in the form of appropriate dimensioning tolerances. Increased breakaway torque is common, in particular after long downtimes in humid environments where temperatures vary.

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 52

7.2 Function checks before commissioning

7.2.1 Function check of brake without microswitch

If a fault or malfunction arises during the function check, you can find important information for troubleshooting in the troubleshooting table 64. If the fault cannot be fixed or eliminated, please con tact your customer service.

7.2.2 Release / voltage check for brakes without microswitch

1. Remove the two bridges from the motor terminals.

-Do not disconnect the supply voltage from the brake.

- When the rectifier is connected to the neutral point of the motor: also conn ect the neutral conductor to this connection.

2. Switch the power on.

3. Measure the DC voltage at the brake.

- Compare the measured voltage to the voltage specified on the nameplate. A deviation of up to 10% is permitted.

4. Check the air gap "s

". The air gap must be zero and the rotor must rotate freely.

5. Switch the power off.

6. Connect the bridges to th e motor terminals. Remove the extra neutral conductor.

7.2.3 Release / voltage check for brakes with microswitch

Required: The switching contact for the brake must be open.

1. Make sure that the brake's switch contact is opened.

2. Remove the two bridges from the motor terminals.

-Do not disconnect the supply voltage from the brake.

- When the rectifier is connected to the neutral point of the motor: also conn ect the neutral conductor to this connection.

3. Turn on the DC voltage for the brake.

4. Measure the AC voltage at the moto r terminal. The AC voltage must be zero.

5. Close the switching contact for the brake.

- The brake is released.

NOTICE Operation without dynamic loads (functioning as a pure holding brake)

❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be

reactivated regularly.

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 53

6. Measure the DC voltage at the brake.

- Compare the measured DC voltage with the voltage indicated on the nameplate. A deviation of ± 10% is permitted.

7. Check the air gap "s

". The air gap must be zero and the rotor must rotate freely.

7.2.4 Microswitch – checking for wear

Required: Do not turn off the power supply for the brake; the power must be switched on twice during this testing procedure.

1. Remove the two bridges from the motor terminals.

2. Adjust the air gap to "s

Lmax

". Description: 33.

3. Switch the power on.

4. Measure the AC voltage at the motor terminals and measure the DC voltage at the brake. Both the AC and the DC voltages must be zero.

5. Switch the power off.

6. Adjust the air gap to "s

". Description: 33.

7. Switch the power on.

8. Measure the AC voltage at the motor terminal. It must be the same as the mains voltage.

9. Measure the DC voltage at the brake.

- Compare the measured DC voltage with the voltage indicated on the nameplate. A deviation of

± 10% is permitted.

10. Check the air gap "s

". The air gap must be zero and the rotor must rotate freely.

11. Switch off the brake current.

12. Screw the bridges back onto the motor terminals.

13. Remove the additional neutral conductor again.

NOTICE

When connecting the rectifier to the neutral point of the motor, the PE conductor must also be connected to this point.

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 54

7.2.5 Test that the manual release functions

Fig. 30 Turning direction of the lever

1. Make sure that the motor and brake are de-energized.

2. Pull (with some force) on the lever until the force increases sharply.

- The rotor must now rotate freely. A small residual torque is permissible.

3. Release the lever.

- A sufficient torque must build up immediately!

The preparations for commissioning are completed.

NOTICE

This operational test is to be carried out additionally!

NOTICE

❚ Make sure that the brake it not subject to excessive force. ❚ Do not use auxiliary tools (e.g. extension pipes) to facilitate the air release. Auxiliary tools

are not permitted and are not considered as proper and intended usage.

NOTICE

If faults or malfunctions occur, refer to the the error search table ( 64). If the fault cannot be fixed or eliminated, please contact your customer service.

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 55

7.3 Commissioning

1. Switch on your drive system.

2. Perform a test braking procedure; if necessary, reduce the braking torque (depending on your specifications and requirements)

7.4 Operation

❚ Checks must be carried out regularly. Pay special attention to:

- unusual noises or temperatures

- loose fixing elements

- the condition of the electrical cables.

❚ Make sure that the armature plate is tightly attached and the drive moves without residual torque. ❚ Measure the DC voltage at the brake. Compare the measured DC voltage with the voltage indicated on

the nameplate. The deviation must be less than ± 10%!

DANGER

Danger: rotating parts!

❚ The running rotor must not be touched. ❚ Take structural design measures on your final product and implement organizational safety

rules to ensure that nobody can touch a rotor.

DANGER

There is a risk of injury by electrical shock!

❚ Live connections must not be touched. ❚ Take structural design measures on your final product and implement organizational safety

rules to ensure that nobody can touch a connection.

Commissioning and operation

INTORQ | BA 14.0168 | 09/2015 56

7.4.1 Brake torque reduction

Fig. 31 Reducing the brake torque

1. Use a spanner wrench to turn the a djustment ring counter-clockwise. This reduces the braking torque.

- Note the correct position of the tappet notches on the torque adjustment ring: Only the latched-in

positions are permitted. It is forbidden to operate the br ake when the notches are adjuste d between these latched-in positions! (Values for the brake torque reduction for each l atched-in position:

16).

- Observe the max. permissible projection ("h

Emax

") of the adjustment ring over the stator (the values

for "h

Emax

" 17).

Operating procedures

The friction lining and the friction surfaces must never contact oil or grease since even small amounts reduce the braking torque considerably.

DANGER

The reduction of the braking torque does not increase the max. permissible air gap "s

L max.

Do not change the manual release setting for models with manual release.

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 57

8 Maintenance and repair

8.1 Wear of spring-applied brakes

The table below shows the different causes of wear and their impact on the compon ents of the spring-applied brake. The influential factors must be quantified so that the service life of the rotor and brake can be calculated and so the prescribed maintenance intervals can be specified accurately. The most important factors in this context are the applied friction energy, the initial speed of rotation of braking and the switching frequency. If several of the causes of friction lining wear occur in an application at the same time, the influencing factors should be added together when the amount of wear is calculated.

Component Cause Effect Influencing factors

Friction lining Braking during operation Wear of the friction lining Friction work

Emergency stops Overlapping wear during start and stop of

drive Active braking via the drive motor with sup-

port of brake (quick stop) Starting wear in case of motor mounting

position with vertical shaft, even when the brake is not applied

Number of start-stop cycles

Armature plate and counter friction face

Rubbing and friction of the brake lining Run-in of armature plate

and counter friction face

Friction work

Gear teeth of brake rotor

Relative movements and shocks between brake rotor and brake shaft

Wear of gear teeth (primarily on the rotor side)

Number of start-stop cycles

Armature plate support

Load reversals and jerks in the backlash between armature plate, adjustment tubes and guide pins

Breaking of armature plate, adjustment tubes and guide pins

Number of start/stop cycles, braking torque

Springs Axial load cycle and shear stress of springs

through radial backlash on reversal of armature plate

Reduced spring force or fatigue failure

Number of switching operations of brake

Tab. 15: Causes for wear

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 58

8.2 Inspections

To ensure safe and trouble-free operations, the spring-ap plied b rakes mu st be che cked at regu lar in tervals and, if necessary, replaced. Servicing will be easier at the plant if the brakes are made accessible. This must be considered when installing the drives in the plant.

Primarily, the required maintenance intervals for industrial brakes result from their load during operation. When calculating the maintenance interval, all ca uses for wear must be taken into account, 57. For brakes with low loads (such as holding brakes with emerge ncy stop function), we recommend a regular inspection at a fixed time interval. To reduce costs, the inspection can be carried out along with other regular maintenance work in the plant.

Failures, production losses or damage to the system may occur when the brakes are not serviced. Therefore, a maintenance strategy that is adapted to the particular operating conditions and brake loads must be defined for every application. For the spring-applied brakes, the maintenance intervals and maintenance operations listed in the table below must be followed. The maintenance opera ti on s must be carried out as described in the detailed descriptions.

8.2.1 Maintenance intervals

Attention: 10 million cycles for the L design

8.3 Maintenance

Versions Service brakes Holding brakes with emergency stop:

BFK458- E / N BFK458- L

❚ according to the service life calcu-

lation

❚ or else every six months ❚ after 4000 operating hours at the

latest

❚ at least every two years ❚ after 1 million cycles at the latest

❚ plan shorter intervals for frequent

emergency stops

NOTICE

Brakes with defective armature plates, springs or flanges must be completely replaced. Observe the following for inspections and maintenance works: ❚ Contamination by oils and greases should be removed using brake cleaner, or the brake

should be replaced after determining the cause. Dirt and particles in the air gap between the stator and the armature plate endanger the function and should be removed.

❚ After replacing the rotor, the original braking torque will not be reached until the run-in oper-

ation for the friction surfaces has been completed. After re placing the rotor, the run-in armature plates and the flanges have an increased initial rate of wear.

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 59

8.3.1 Checking the component parts

8.3.2 Check the rotor thickness

1. Remove the fan cover.

2. Remove the cover ring, when pre s ent.

3. Measure the rotor thickness using a calliper gauge. For the friction-plate version: observe the edging on outer diameter of friction plate.

4. Compare the measured rotor thickness with the minimum permissible rotor thickness (values: 17). If the measured rotor thickness is insufficient, the rotor must be replaced completely. Description: 61.

8.3.3 Check the air gap

1. Measure the air gap "s

" between the armature plate and the stator near the fixing screws using a feeler

gauge (values: 17).

2. Compare the measured air gap to the value for the max. permissible air gap "s

Lmax

" (values: 17).

3. Adjust the air gap to "s

" ( 60).

With mounted brake

❚ Check release function and control ❚ Measure the air gap (adjust if required) ❚ Measure the roto r thickness (replace rotor if required) ❚ Thermal damage of armature plate or flange (dark-blue tar-

nishing)

60 60 59

After removing the brake

❚ Check the play of the rotor gear teeth (replace worn-out

rotors)

❚ Check for breaking out of the torque support at the sleeve

bolts and the armature plate

❚ Check the springs for damage ❚ Check the armature plate and flange or bearing shield

- Evenness depending on the size

- Max. run-in depth = rated air gap for the size

29 17

DANGER

Danger: rotating parts!

The motor must not be running when checking the rotor thickness.

DANGER

Danger: rotating parts!

The motor must not run while the air gap is being checked.

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 60

8.3.4 Release / voltage

1. Check the brake functionality when the drive is running: The armature plate must be tightened and the rotor must move without residual torque.

2. Measure the DC voltage at the brake.

- The DC voltage measured after the over-excitation time (see bridge/half-wave rectifier) must be half

the voltage indicated on the nameplate. The devia tion must be less than ± 10%.

8.3.5 Adjusting the air gap

1. Loosen the screws (Figure 12).

2. Screw the sleeve bolts (using a wrench) furthe r into the stator. A 1/6 turn will decrease the air gap by approximately 0.15 mm.

3. Re-tighten the screws (torque: 18).

4. Check the "s

" near the screws using a feeler gauge (sLN: 17).

DANGER

Danger: rotating parts!

The running rotor must not be touched.

DANGER

There is a risk of injury by electrical shock!

Live connections must not be touched.

DANGER

Danger: rotating parts!

The brake must be free of residual torque.

NOTICE

Please observe when mounting the flange with additional screw s: Clearing holes for the screws in the end shield must be behind the threaded screw holes in

the flange. Without the clearing holes, the minimal rotor thickness cannot be used. The screws must not press against the end shield.

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 61

8.3.6 Replacing the rotor

1. Remove the connecting cables.

2. Loosen the screws evenly and then remove them.

3. Pay attention to the connecting cable during this step! Remove the complete stator from the end shield.

4. Pull the rotor off the hub.

5. Check the hub's gear teeth.

6. Replace the hub if wear is visible.

7. Check the end shield's friction surface. Replace the friction surface on the end shield when there is clearly visible scoring at the flange. In case of strong scoring on the end shield, rework the friction surface.

8. Measure the rotor thickness of the new rotor and the head height of the sleeve bolts (use a calliper gauge).

9. Calculate the distance between the stator and the armature plate as follows:

Distance = rotor thickness + s

- head height

" 17

10. Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is reached.

11. You can now install and adjust the new rotor and the complete stator ( 32).

12. Re-connect the connecting cables.

DANGER

Danger: rotating parts!

Switch off the voltage. The brake must be free of residual torque.

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 62

8.4 Spare-parts list

Spring-applied brake INTORQ BFK458-06 to 25

Designation Variant

Complete stator, module E Complete stator, module N

Voltage / braking torque

Complete rotor Aluminium rotor

Aluminium rotor with sleeve

- Low-noise version Hub Hole diameter [mm] slot according to DIN 6885/1 Flange

Hard chrome-plated flange Centring flange (tacho flange) Friction plate Cover ring Shaft sealing ring Cap Manual release Brake cover

(degree of protection corresponds to IP65) Terminal box as mounting kit Screw set: DIN EN ISO 4762 - 8.8

in various designs and lengths

❚ for mounting to the flange ❚ for mounting to the motor / friction plate ❚ for flange with through hole

Maintenance and repair

INTORQ | BA 14.0168 | 09/2015 63

Double spring-operated brake INTORQ BFK458-06 to 25

Electrical accessories

Designation Variant

Complete stator, module N Voltage / braking torque

- Optionally with rear threads Complete rotor Aluminium rotor

Aluminium rotor with sleeve

- Low-noise version Hub with standard bore Hole diameter [mm] slot according to DIN 6885/1 Flange

Hard chrome-plated flange Connection flange for double brake Friction plate Shaft sealing ring Shaft diameter on request Cover ring Cap Basic module N Manual release with standard lever Mounting kit Screw set; socket head cap screw

DIN EN ISO 4762 8.8 / size 25 10.9

for connection flange / double brake

Screw set: DIN EN ISO 4762 - 8.8 in various designs and lengths

❚ for mounting to the flange ❚ for mounting to the motor / friction plate ❚ for flange with through hole

Bridge / half-wave rectifier

Supply voltage Over-excitation Holding current

reduction

Coil

voltage

Size Coil

voltage

Size

[V AC] [V DC] [V DC]

BEG-561-255-030

230 103

06 ... 16

205

06 ... 14 BEG-561-255-130 – 16 ... 25 BEG-561-440-030-1 400 180 06 ... 25 – –

Troubleshooting and fault elimination

INTORQ | BA 14.0168 | 09/2015 64

9 Troubleshooting and fault elimination

If any malfunctions should occur during operations, please ch eck for possible causes based on the following table. If the fault cannot be fixed or eliminated by one of the listed measures, please contact customer service.

Fault Cause Remedy

Brake cannot be released, air gap is not zero

Coil interruption ❚ Measure the coil resistance using a multimeter:

- If resistance is too high, replace the complete springapplied brake.

Coil has contact to earth or between windings

❚ Measure the coil resistance using a multimeter:

- Compare the measured resistance with the nominal resistance. Refer to 19 for the values. If resistance is too low, replace the complete stator.

❚ Check the coil for short to ground using a multimeter:

- If there is a short to ground, replace the complete spring-applied brake.

❚ Check the brake voltage (refer to section on defective

rectifier, voltage too low).

Wiring defective or wrong ❚ Check the wiring and correct.

❚ Check the cable for contin uity using a multimeter:

- Replace defective cable.

Rectifier defective or incorrect ❚ Measure rectifier DC voltage using a multimeter.

If DC voltage is zero: ❚ Check AC rectifier voltage. If AC voltage is zero:

- Switch on power supply.

- Check fuse.

- Check wiring.

If AC voltage is OK:

- Check rectifier.

- Replace the defective rectifier.

- Diode is defective; use a suitable new rectifier.

❚ Check the coil for winding short or groun d sh ort. ❚ If the rectifier defect occurs again, replace the entire

spring-applied brake, even if you cannot find any fault between turns or short circuit to ground. The error may only occur on warming up.

Brake cannot be released, air gap is not zero

Incorrect micro-switch wiring Check the wiring of the micro-switch and correct it. Micro-switch incorrectly set Replace the complete stator and make a complaint about

the setting of the microswitch to the manufacturer.

Air gap "s

" is too large

Adjust the air gap: 60.

Troubleshooting and fault elimination

INTORQ | BA 14.0168 | 09/2015 65

Rotor cannot rotate freely Wrong setting of manual

release

Check the dimension "sLN + sHL" with the brake energised. The dimension must be the same on both sides. Correct if

required ( 41).

Air gap "s

" too small

Check air gap "s

" and adjust if necessary ( 60).

Rotor thickness too small Rotor has not been replaced

in time

Replace the rotor ( 61).

Voltage too high Brake voltage does not match

the rectifier

Adjust rectifier and brake voltage to each other.

Voltage too low Brake voltage does not match

the rectifier

Adjust rectifier and brake voltage to each other.

Defective rectifier diode Replace defective rectifier with a suitable undamaged one.

AC voltage is not mains voltage

Fuse is missing or defective Select a connection with proper fusing.

Fault Cause Remedy

Notes

INTORQ | BA 14.0168 | 09/2015 66

Notes

www.intorq.com

 INTORQ GmbH & Co KG

Germany PO Box 1103 D-31849 Aerzen, Germany Wülmser Weg 5 D-31855 Aerzen, Germany

 +49 5154 70534-444

 +49 5154 70534-200  info@intorq.com

 INTORQ (SHANGHAI) Co., Ltd

China No. 600, Xin Yuan Road Building No. 6 / Zone B Nan Hui District, Lingang Shanghai, China 201306

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 +86 21 20363-810

 +86 21 20363-805  info@cn.intorq.com

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USA 300 Lake Ridge Drive SE Smyrna, GA 30082, USA

 +1 678 309-1155

 +1 678 309-1157  info@us.intorq.com

 INTORQ India Private Limited

India Plot No E-7/3 Chakan Industrial Area, Phase 3 Nighoje, Taluka - Khed Pune, 410501, Maharashtra, India

 +91 2135625500

 info@intorq.in

INTORQ BFK458-06...25 Operating Instructions Manual

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