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INTORQ BFK466−80
Electromagnetically released spring−applied brake
j
setting the standard
www.intorq.com
Operating Instructions
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This documentation applies to ...
BFK466−80
BFK46680−003.iso/dms
Product key
Product key INTORQ B FK 466
−
LL
0
1
2
3
Legend for the INTORQ BFK466 product key
0 Product group Brakes
1 Product family Spring−applied brake
2 Type 466
3 Size 80
Not coded: supply voltage, hub bore, options
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3
Identification
Package label
Example
Manufacturer Bar code
Name Type No.
Type (see product key) Quantity per box
Rated voltage Rated power Rated torque Packing date
Model identification Desired customer no.
Additional information CE designation
BFK46680_001.iso/dms
Nameplate
Example
Manufacturer CE designation
Type (see product key) Model identification
Rated voltage Rated power Desired customer no.
Type No. Rated torque Production date
BFK46680_002.iso/dms
Document history
Material number Version Description
33001612 1.0 02/2012 TD09 First edition
0Fig. 0Tab. 0
0Fig. 0Tab. 0
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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 Scope of supply 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Disposal 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Drive systems 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Legal regulations 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety information 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Application as directed 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Notes used 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product description 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Rated data 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operating times 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Operating frequency / friction work 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Emission 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Important notes 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Necessary tools 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mounting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Installation 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important notes 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical connection 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Microswitch 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Function checks before commissioning 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Commissioning 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 During operation 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance/repair 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Wear of spring−applied brakes 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Inspections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Spare parts order 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8 Troubleshooting and fault elimination 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Preface and general information1
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1 Preface and general information
1.1 About these Operating Instructions
| These Operating Instructions will help you to work safely on and with the multi−pole
spring−applied brake. They contain safety instructions that must be followed.
| All persons working on or with the multi−pole spring−applied brake must have these
Operating Instructions available and observe the information and notes relevant for
their work.
| The Operating Instructions must always be in a complete and perfectly readable
condition.
1.2 Terminology used
Term In the following text used for
Spring−applied brake Multi−pole spring−applied brake
Drive system Drive systems with spring−applied brakes and other drive components
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.
For example: 1234.56
Symbols
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: , software manual
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Preface and general information1
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1.4 Abbreviations used
Abbreviation Unit Name
I [A] Current
I
rated
[A] Rated current
M
a
[Nm] Tightening torque
n
max
[rpm] Maximum speed
P
20
[kW] Electrical power at 20°C
Q [J] Calculated friction work per operation
Q
perm
[J] Max. permissible friction work per operation
R
20
[Ohm] Coil resistance at 20°C
S
h
[h−1] Operating frequency, i.e. the number of periodical brakings
s
Lü
[mm] Rated air gap
S
hü
[h−1] Transition operating frequency, i.e. the maximally permissible
number of brakings per unit time
t
1
[ms] Engagement time, t1 = t11 + t
12
t
2
[ms] Disengagement time (time from the beginning of the torque drop to
reaching 0.1 M
K
)
t
11
[ms] Delay during engagement (time from switching off the supply voltage
to the beginning of the torque rise)
t
12
[ms] Torque rise time
U [V] Voltage
1.5 Scope of supply
| The spring−applied brakes are delivered preassembled, the brake disc is not included
in the scope of supply.
| 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 forwarder.
– visible deficiencies / incompleteness immediately to INTORQ GmbH & Co. KG.
1.6 Disposal
The spring−applied brake consists of different types of material.
| Recycle metals and plastics.
| Ensure professional disposal of assembled PCBs according to applicable
environmental regulations.
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1.7 Drive systems
1.7.1 Labelling
Drive systems and drive components are clearly labelled and defined by the indications on the
nameplates.
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D−31855 Aerzen
1.8 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 the information, illustrations and descriptions.
| We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorised modifications to the drive system
– improper working on and with the drive system
– operating faults
– disregarding these Operating Instructions
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 Safety instructions
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 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.
| Observe all specifications given in the attached documentation.
– This is the prerequisite for 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.
| Risk of burns!
– 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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2.2 Application as directed
| Drive systems
– 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
| Ambient temperature:
– −5°C to +40°C (standard)
| At high humidity and low temperature:
– Take measures to protect friction surfaces from freezing.
| Protect electrical connections against contact.
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Safety instructions2
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2.3 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!
Danger of personal injury through dangerous electrical voltage
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
} Danger!
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.
( Stop!
Danger of property damage
Reference to a possible danger that may result in property damage if the
corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
) Note!
Important note to ensure troublefree operation
I Tip!
Useful tip for simple handling
,
Reference to another documentation
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Technical data3
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3 Technical data
3.1 Product description
3.1.1 Structure and function
BFK46685−004.iso
Fig. 1 Design of a BFK466−80 spring−applied brake
1 Stator 6 Cheese head screw 11 Friction lining
2 Brake disk 7 Guide sleeve 12 Support of friction lining
3 Flange 8 Cheese head screw 13 Manual release lever
(detachable)
4 Armature plate 9 Microswitch (release
monitoring)
14 Microswitch (wear
monitoring)
5 Compression spring 10 Terminal box
3.1.2 General information
This spring−applied brake is designed as a floating caliper brake for mounting on direct
drive motors. The brake disk (2) is not included in the scope of supply. By using two or
more spring−applied brakes on one brake disk, the demand for redundancy can be fulfilled
for special applications such as lift and stage technology.
The braking torque is generated by the pressure of several compression springs (5) via
friction locking between the two friction linings (11) of the friction lining support (12) and
the flange (3) and the brake disc (2). The brake is released electromagnetically. For this,
an overexcitation voltage is applied to the brake for approx. 1...2 seconds. Then, the
voltage is decreased to 50%. Thus, the medium electrical brake power is reduced.
The BFK466 spring−applied brake is designed for converting mechanical work and kinetic
energy into heat energy. Thanks to the static breakaway torque, loads can be held at
standstill.
Emergency braking at higher speeds is possible. Here, the maximally permissible speed
must not be exceeded. (¶ 15).
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Technical data3
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The stator (1) is designed to be of thermal class F. The limit temperature of the coils is
155°C.
The spring−applied brake is designed for a maximum operating time of 60%.
3.1.3 Braking
During braking, the support of the friction lining (12) and the affixed friction lining (11) are
pressed against the axially fixed brake disc (2). Nearly at the same time, the caliper moves
on the guide sleeves (7) in the opposite direction, so that the friction lining (11) on the
flange (3) is pressed against the brake disc, too. The braking torque is supported by the
mounting flange via the guide sleeves (7). The asbestos−free friction linings ensure a high
braking torque with low wear.
3.1.4 Brake release
When the brake is applied, there is an air gap s
Lü
" between the armature plate (4) and the
pole faces of the stator (1). To release the brake, the respective switching device supplies
the coils of the stator (1) with the overexcitation voltage. The resulting magnetic force
draws the armature plate (4) against the spring force towards the pole faces of the stator
(1). Now, the spring force is taken from the support of the friction lining (12). The caliper
can move on the guide sleeves (7) until the brake disk (2) is relieved and can rotate freely.
After approx. 1...2 seconds, the supply voltage is decreased to 50%.
3.1.5 Release monitoring
The INTORQ BFK466 spring−applied brake is equipped with a microswitch (changeover
contact) which monitors the switching status. During brake release, the microswitch (9)
changes over. This must exclude drive operation against the applied brake.
3.1.6 Wear monitoring
An additional microswitch (14) is used to monitor the wear status of this spring−applied
brake. The microswitches can be used as NC contacts (series connection) or as NO
contacts (parallel connection).
3.1.7 Emergency release option
An optional manual release is available for short−time release of the brake. This allows for
lowering the load in case of a power failure.
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Technical data3
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3.1.8 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.
| Check the braking torque if the brake is inserted on the customer’s friction surfaces.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.
( Stop!
Stable properties of the organic friction lining are only achieved in the case of
continuous use. The readiness for operation of the brake has to be ensured with
a braking energy that is equivalent to one emergency stop per week. Unplanned
emergency stops occurring at a sufficient frequency have the same effect.
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Technical data3
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3.2 Rated data
Type Friction
force
Brake disk
radius
Max. sliding
speed
Voltage
1)
Power
2)
Coil
resistance
Max.
current
Overexcit
ation
time
FR [N] Ra [mm]
min. / max.
V
max.
[m/s] U ±10%
[V] DC
P20 [W] R20±5%
[W]
I
max.
[A] sec.
BFK466−80 8015 300 / 600 16.4
90/45
110/55
205/103
522/130.5
522/130.5
550/137.5
15.52
23.18
76.41
5.8
4.75
2.68
1...2
Type Air gap Max. air gap Fixing screws Tightening
torque
Max. perm.
switching
energy
Transition
operating
frequency
Weight
(without brake
disk)
sLü [mm] s
Lü max.
[mm] Ma [Nm] QE [J] Sfo [h−1] m [kg]
BFK466−80 0.4± 0.1 0.7 2 x M16 195 250000 24 45
1) Voltage for releasing / holding
2) Coil power at 20°C when releasing / holding
3.3 Operating times
BFKXXX−011.iso/dms
Fig. 2 Operating times of the spring−applied brakes
t
1
Engagement time t
11
Delay time during engagement
t
2
Disengagement time (up to M = 0.1 Mr)t12Rise time of the brake torque
M
rated
Braking torque U Voltage
Type Operating times [ms] at s
Lürated
Engage Disengage
t
11
t
12
t
1
t
2
BFK466−80 28 152 180 380
Tab. 1 Switching energy − operating frequency − operating times
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Disengagement time
The disengagement time is not affected by DC or AC switching. The indicated disengagement
time applies to an air gap of 0.4 mm. When the air gap is larger (as a result of wear), the
disengagement time increases.
Engagement time
Short brake engagement times are vital for emergency braking. DC switching together with
a suitable spark suppressor must therefore be provided.
If the drive system includes a frequency inverter so that the brake is deenergised only
when the motor is at standstill, switching on the AC side is also possible (not valid for
emergency braking). In this case, engagement times will be 5 times longer.
3.4 Operating frequency / friction work
S
h
[h−1]
Q [J]
1 10 100 1000
1
10
100
1000
10000
100000
1000000
KL 466−85−XXX.tiff
Fig. 3 Switching energy as a function of the operating frequency
0 Switching energy 1 Operating frequency
S
fperm
+
* S
fo
lnǒ1 *
Q
Q
E
Ǔ
Q
perm
+ Q
E
ǒ
1 * e
*S
fo
S
f
Ǔ
The permissible operating frequency "S
fperm
" depends on the friction work "Q" (see Fig. 3).
At a preset operating frequency "S
f
", the permissible friction work is "Q
perm
".
For "S
fo
" and "QE", please see chapter 3.2.
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3.5 Emission
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.
} Danger!
Risk of burns on brake and brake disc!
Noise
The switching noise during engagement and disengagement varies depending on the air gap
"s
air
" and the brake size. It is between approx. 55 and 60 dB [A].
Others
Abrasion due to braking occurs in the form of dust.
In case of high load, the friction face will become so hot that odours may occur.
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Mechanical installation4
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4 Mechanical installation
4.1 Important notes
( Stop!
| Do not lubricate the screws with oil or grease.
4.2 Necessary tools
Type Torque key Insert for hexagon
socket screws
Transport screw Crosstip screwdriver
Measuring range [Nm] Wrench size [mm] Wrench size [mm] Crosstip size
BFK466−80 250 14 x 1/2" square 6 x 1/4" square 2
Feeler gauge Caliper gauge Multimeter
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Mechanical installation4
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4.3 Mounting
4.3.1 Preparation
1. Unpack spring−applied brake.
2. Check for completeness.
3. Check nameplate data, especially rated voltage.
4.4 Installation
The brake is delivered preassembled with two transport safety bolts (17).
1. Fit the guide sleeve (19) on the drive and tighten it lightly with the fixing screw (21).
2. Use a through−hole and push the brake onto the guide sleeve until the friction faces
are in alignment with the brake disc (20).
3. Turn the brake around the guide sleeve (19) and position the brake radially over the
brake disc (20).
4. Push the second guide sleeve (19) into the second through−hole of the brake and
tighten it with the fixing screw (21).
( Stop!
The sum total of the distances measured must not exceed "s
Lü max
"!
5. Tighten both fixing screws (21) with the given torque (^ 15).
6. Remove the transport safety bolts (17)!
7. Switch the current on and off several times, checking the movability of the brake on
the guide sleeves.
8. Check the clearance of the brake disc and the air gap "s
Lü
" between the two friction
linings (3.2) and the brake disc (20) with a feeler gauge (24).
s
Lü/2
s
Lü/2
BFK46685−005.iso
Fig. 4 Installation of the BFK466−80 spring−applied brake
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Electrical installation5
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5 Electrical installation
5.1 Important notes
{ Danger!
| Electrical connection must only be carried out by skilled personnel!
| Connections must only be made when the equipment is de−energised! Danger
through unintended starts or electric shocks.
( Stop!
| It must be ensured that the supply voltage corresponds to the nameplate
data.
| Voltages must be adapted to the local environment!
( Stop!
| If emergency switching off is carried out without the required suppressor
circuit, the control unit may be destroyed.
| Observe the correct polarity of the suppressor circuit!
5.2 Electrical connection
Earthing
Use the PE screw in the terminal box (Fig. 6 and Fig. 8) for PE connection.
PE connection via the fixing screws on the motor is not permitted because there is no
electrically conductive connection between the brake and the guide sleeves!
Temperature sensor connection (optional)
The spring−applied brake can be delivered with PTC sensors according to DIN 44082 for
temperature monitoring (reference temperature 130°C). The signal is evaluated via a PTC
thermistor tripping device provided by the customer.
Connection: AWG 26 blue/blue
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Electrical installation5
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5.3 Microswitch
) Note!
Application range recommended for the microswitch
| DC current: 10 mA to 100 mA at 12 V
| AC current: 10 mA to 5 A at 12 V / max. 250 V
5.3.1 Microswitch as NC contact (series connection)
{ Danger!
| Perform electrical connection only when no voltage is applied.
| If an "emergency stop" is carried out without the protective circuit provided,
the control device may be destroyed. Observe the correct polarity of the
protective circuit!
BFK466XX−017.iso
Fig. 5 BFK466 connection diagram (circuit proposal for series connection)
Pin assignment for microswitch
BFK466XX−019.iso
Fig. 6 BFK466 terminal box (as option: series connection with integrated varistor)
Microswitch:
Input connection BK
NO contact BU
NC contact GY
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Electrical installation5
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22
When current is fed to the spring−applied brake, the armature plate is released. The
microswitch (NC contact) is actuated and gives the signal Spring−applied brake released".
When the maximum working air gap is exceeded, the release monitoring circuit is opened by
the wear monitoring microswitch connected in series. In this case, the signal "Spring−applied
brake applied" will not be given when the brake is deenergised.
Microswitch (NC contact, series connection)
Brake released Brake worn−out Circuit
no no closed
yes no open
no yes open
yes yes open
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5.3.2 Microswitch as NO contact (parallel connection)
{ Danger!
| Perform electrical connection only when no voltage is applied.
| If an "emergency stop" is carried out without the protective circuit provided,
the control device may be destroyed. Observe the correct polarity of the
protective circuit!
BFK466XX−018.iso
Fig. 7 BFK466 connection diagram (circuit proposal for parallel connection)
Pin assignment for microswitch
BFK466XX−020.iso
Fig. 8 BFK466 erminal box (optional with integrated varistor)
Microswitch:
Input connection BK
NO contact BU
NC contact GY
When current is fed to the spring−applied brake, the armature plate is released. The
microswitch (NO contact) is actuated and gives the signal Spring−applied brake released".
When the maximum working air gap is exceeded, the wear monitoring circuit is closed. In this
case, the signal "Spring−applied brake released" will also be given when the brake is
deenergised.
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Microswitch (NO contact, parallel connection)
Brake released Brake worn−out Circuit
no no open
yes no closed
no yes closed
yes yes closed
Page 25
Commissioning and operation6
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6 Commissioning and operation
6.1 Important notes
} Danger!
The brake must be free of residual torque. The motor must not rotate.
{ Danger!
Live connections must not be touched.
| 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.
| Check the braking torque if the brake is inserted on the customer’s friction surfaces.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.
( Stop!
Stable properties of the organic friction lining are only achieved in the case of
continuous use. The readiness for operation of the brake has to be ensured with
a braking energy that is equivalent to one emergency stop per week. Unplanned
emergency stops occurring at a sufficient frequency have the same effect.
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Commissioning and operation6
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6.2 Function checks before commissioning
6.2.1 Release / voltage check
} Danger!
Disconnect the drive from the load to prevent accidents. During the next
inspection steps of the spring−applied brake, the motor must not
run!
1. Remove two bridges from the motor terminals. Do not switch off the voltage supply for
the brake.
2. Measure the AC voltage at the motor terminals. It must be zero!
3. Switch on the current for the brake.
4. Measure the AC voltage at the motor terminals. It must be equal to the mains voltage!
5. Check the air gap "s
Lü
" between the brake disk and the friction lining. Altogether it
must be 0.4 ±0.1 mm. The brake disk must rotate freely!
6. Switch off the current.
7. Bolt bridges to the motor terminals.
6.2.2 Microswitch
These spring−applied brakes are equipped with two microswitches. One for release monitoring
and one for wear monitoring (see Fig. 1). The microswitches are either connected in series
(NC contacts, black and grey connections) or in parallel as NO contacts (black and blue
connections).
) Note!
The microswitches are checked for correct operation when the brake is applied
(not actuated). During the check, the other microswitch must not be actuated.
Checking the release control
) Note!
The brake is deenergised, the transport screws are removed.
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Commissioning and operation6
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BFK466XX−003.iso
1 Hexagon head cap screw
2 Microswitch tappet
Check the setting of the microswitch for release monitoring using a feeler gauge with
thickness "Y
max.
and Y
min.
" between hexagon head cap screw (1) and microswitch tappet (2).
Feeler gauge
thickness
NC contact NO contact
Y
max.
= s
Lü
− 0.10 Switch open Switch closed
Y
min.
= s
Lü
− 0.25 Switch closed Switch open
Checking the wear monitoring
BFK466XX−002.iso
1 Brake disk
2 Support of friction lining
3 Microswitch tappet
1. Measure the air gap "sLü" between brake disk (1) and friction linings (2) using a feeler
gauge (brake energised, (¶ 26).
2. Switch off the voltage supply
3. Calculate the thickness "X" of the feeler gauge: 0.75 − "s
Lü
" = X
4. Insert a feeler gauge of thickness "X" between microswitch tappet (3) and support of
friction lining (2) (brake deenergised). The feeler gauge must be fitted evenly. The
switch must be actuated.
5. Use a feeler gauge with a thickness lower by 0.05 mm and check if the switch remains
in the original switch position. The feeler gauge must be fitted evenly.
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Commissioning and operation6
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6.2.3 Checking the manual release function
( Stop!
This operational test is to be carried out additionally!
} Danger!
The drive system must be load−free. The motor must not rotate.
( Stop!
If the brake is operated above the maximally permissible working air gap "s
Lü
max
" (¶ 15), the braking torque is considerably reduced by the manual release.
The function of the brake is not guaranteed anymore.
Manual release with lever
The installed manual release is designed for manual operation in two directions. The lever is
detachable.
Motor and brake deenergised.
1. Pull the lever with approx. 270 N until the resistance significantly increases.
2. Release the lever.
BFK46685−001.iso
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Commissioning and operation6
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Manual release with bowden cable (optional)
) Note!
The manual release is designed for operation using a bowden cable.
BFK46680−004.iso
Motor and brake deenergised.
1. Suspend bowden cable (not included in the scope of supply) and pull with approx.
800 N.
– The drive must rotate freely. A small residual torque is permissible.
2. Release lever.
– Torque must be available!
The preparations for commissioning are completed.
6.3 Commissioning
1. Switch on drive system.
2. Carry out a braking test.
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6.4 During operation
{ Danger!
Live connections must not be touched.
| Check the brake regularly during operation. Take special care of:
– unusual noises or temperatures
– loose fixing elements
– the condition of the electrical cables.
| The armature plate must be attracted and the drive must move without residual
torque.
| Measure the DC voltage at the brake.
– Compare the DC voltage measured with the voltage specified on the nameplate. A
±10 % deviation is permissible.
| If faults should occur, go through the error search table (¶ 35). If the fault cannot be
eliminated, please contact your customer service.
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7 Maintenance/repair
7.1 Wear of spring−applied brakes
INTORQ spring−applied brakes are wear−resistant and designed for long maintenance
intervals. The friction lining and the mechanical brake components are subject to
function−related wear. For safe and trouble−free operation, the brake must be checked at
regular intervals, and, if necessary, be replaced.
The following table describes different causes of wear and their effects on the components
of the spring−applied brake. For calculating the service life of rotor and brake and determining
the maintenance intervals to be observed, the relevant factors of influence must be quantified.
The most important factors are the friction work, initial speed of braking and the operating
frequency. If several of the causes of wear indicated for the friction lining occur in an
application at the same time, the influencing factors must be added for calculating the wear.
The INTORQ Select dimensioning program can be used to calculate the maintenance
intervals.
Component Cause Effect Influencing factors
Friction lining Braking during operation
Wear of friction lining
Friction work
Emergency stops
Overlapping wear during start and
stop of drive
Active braking via the drive motor
with support 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
flange
Rubbing of brake lining Armature plate and flangeare run in Friction work
Brake support Load alternation and jerks in the
backlash between armature plate,
sleeve bolts and guide bolt
Breaking of armature plate, sleeve
bolts and guide bolt
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. 2 Causes for wear
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7.2 Inspections
7.2.1 Important notes
To ensure safe and trouble−free operation, spring−applied brakes must be checked and
maintained at regular intervals. Servicing can be made easier if good accessibility of the
brakes is provided in the plant. This must be considered when installing the drives in the plant.
Primarily, the necessary maintenance intervals for industrial brakes result from the load during
operation. When calculating the maintenance interval, all causes for wear must be taken into
account, ((¶ 31). For brakes with low loads such as holding brakes with emergency stop,
we recommend a regular inspection at a fixed time interval. To reduce the cost, the inspection
can be carried out along with other regular maintenance work in the plant if necessary.
( Stop!
Stable properties of the organic friction lining are only achieved in the case of
continuous use. The readiness for operation of the brake has to be ensured with
a braking energy that is equivalent to one emergency stop per week. Unplanned
emergency stops occurring at a sufficient frequency have the same effect.
If the brakes are not maintained, failures, production losses or damage to the system may
occur. Therefore, a maintenance concept 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 below table must be provided.
The maintenance operations must be carried out as described in the detailed descriptions.
7.2.2 Maintenance intervals
The spring−applied brake must be checked during the prescribed inspections of the drive
system in which it is installed.
| The service life of the brake before replacement does not only depend on the number
of emergency brakings.
| The wear of the brake friction linings varies depending on the operating conditions.
| The friction work possible before replacement decreases with every braking when
friction work increases.
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7.2.3 Air gap check
} Danger!
Disconnect the drive from the load to prevent accidents. During the next
inspection steps of the spring−applied brake, the motor must not
run!
1. Switch on the current for the brake(¶ 26).
2. Measure the air gap sLü" between the brake disk and the friction lining with a feeler
gauge. It must not exceed the maximally permissible air gap s
Lü max.
" specified in the
table. (¶ 15).
3. Switch off the current.
4. Reconnect the motor.
7.2.4 Braking torque / delay check
In case of drives with several brakes, one brake at a time can be released with the cheese head
screws of the transport safety device or the manual release when checking redundancy. The
cheese head screws of the transport safety device must be removed again after checking.
( Stop!
The screws of the transport locking device must not be used for releasing the
brake during evacuation!
The stopping distances of the drive must be within the permissible tolerance range of the
corresponding system ( ,documentation for the system).
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Maintenance/repair7
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7.3 Maintenance operations
The brake does not require any maintenance when it is being used as a holding brake. The
brake is replaced in the reverse order to assembly (¶ 19).
} Danger!
Disconnect the drive from the load to prevent accidents. During the next
inspection steps of the spring−applied brake, the motor must not
run!
1. Screw in the transport screws (17; DIN912 M8x70) (¶ 19).
2. Switch off the power supply and disconnect the connecting cables.
3. Loosen a fixing screw (4) and remove the guide sleeve (2) from the through−hole.
4. Turn the brake around the second guide sleeve (2) away from the brake disc (3).
5. Remove the brake from the guide sleeve (2).
7.4 Spare parts order
INTORQ BFK466spring−applied brake
Order quantity _________ Pc.
Size \ 80
Voltage \ 90/45 VDC \ 110/55 VDC \ 205/103 VDC
Cable length \ Standard
_________ mm (from 100 mm − 1000 mm in steps of 100 mm,
from 1000 mm − 2500 mm in 250 mm steps)
Terminal box mounted \
PTC sensor \
Manual release \ Lever detachable
\ Lever for bowden cable
Page 35
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8 Troubleshooting and fault elimination
If any malfunctions should occur during operation of the drive system, please check the
possible causes using the following table. If the fault cannot be eliminated by one of the listed
measures, please contact the aftersales service.
Fault Cause Remedy
Brake cannot be released, air gap is
zero
Coil interruption | Measure coil resistance using multimeter:
– Compare the measured resistance with the
rated resistance, ^ 15.
– Replace the brake when the resistance is too
high.
Coil has interturn fault or short circuit to
ground
| Measure coil resistance using multimeter:
– Compare the measured resistance with the
rated resistance, ^ 15. Replace the brake
when the resistance is too low.
| Check coil for short circuit to ground using a
multimeter:
– Replace the brake in case of short circuit to
ground.
| Check brake voltage (see "defective rectifier,
voltage too low").
Wiring incorrect or defective | Check and correct wiring.
| Check cable continuity using a multimeter:
– Replace defective cable.
Rectifier defective or wrong | Measure rectifier DC voltage using a multimeter.
If DC voltage is zero:
| Check AC rectifier voltage.
If AC voltage is zero:
– Apply voltage,
– check fuse,
– check wiring
– Check microswitch
If AC voltage is ok:
– Check rectifier
– replace defective rectifier
Measure the DC voltage:
– Overexcitation 90 V (approx. 1 sec.) holding
voltage 45 V (tolerance ±10 %)
| Check coil for fault between turns and short
circuit to ground.
| If the rectifier defect occurs again, replace the
brake even if you cannot find any fault between
turns or short circuit to ground. The defect may
occur later during heating−up.
Air gap too large Brake replacement. ^ 34
Brake disc cannot rotate freely Air gap "sLü" too small | Check the air gap "sLü" and replace the brake if
necessary.
| Check the thickness of the brake disc and replace
the brake disc, if necessary.
| Check the movability of the brake on the guide
sleeves and, if necessary, replace the guide
sleeves.
Brake cannot be released with
manual release
Wrong setting of manual release Replace the brake and complain about the manual
release setting to the manufacturer.
Microswitch furnishes wrong signal
despite correct function of the brake
Incorrect microswitch wiring Check microswitch wiring and correct it.
Defective microswitch or incorrect
setting
Replace the brake and send the defective brake to
the manufacturer.
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Troubleshooting and fault elimination8
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RemedyCauseFault
Voltage too high
Supply voltage too high Adapt the coil voltage to the supply voltage
Rectifier defective Replace rectifier
Bridge rectifier used instead of
bridge/half−wave rectifier
Replace the bridge rectifier by a bridge/half−wave
rectifier.
Voltage too low Supply voltage too low Adapt the coil voltage to the supply voltage
AC voltage is not mains voltage
Fuse is missing or defective Select a connection with proper fusing.
Incorrect microswitch wiring Check microswitch wiring and correct it.
Defective microswitch or incorrect
setting
Replace the brake and send the defective brake to
the manufacturer.
Page 37
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Page 38
Notes!
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Page 39
Notes!
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39
Page 40
F INTORQ GmbH & Co KG
Wülmser Weg 5
D−31855 Aerzen
Germany
( +49(0)515470 53 4−0
Ê +49(0)515470 53 4−100
info@intorq.com
ü www.intorq.com
Service
( 0080002446877 (24 h helpline)
Ê +49(0)515482 13 96
setting the standard
www.intorq.com
j
33001612 | BA 14.0204 | EN | 1.0 | ©02.2012 | TD09 | 10 9 8 7 6 5 4 3 2 1
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