INTORQ BFK468 Operating Instructions Manual
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setting the standard
INTORQ BFK468
Electromagnetically released spring−applied brake
Operating Instructions
www.intorq.com
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This documentation applies to ...
BFK468
BFK46825−002.iso/dms
Product key
Product key INTORQ B FK LLL
Legend for INTORQ BFK468 product key
Product group Brakes
Product family Spring−applied brake
Type 468
Size 18, 20, 25, 31
Design E − adjustable (brake torque can be reduced via adjuster nut)
N − not adjustable
Not coded: Supply voltage, hub bore, options
−
LL L
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Identification
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Package label
Manufacturer Bar code
Type (see product key) Type No.
Name Rated torque Quantity per box
Release/holding voltage Release/holding power Packing date
Additional information CE designation
Nameplate
Manufacturer CE designation
Type (see product key)
Rated voltage Rated power Hub diameter
Type No. Rated torque Production date
Document history
Material number Version Description
13190474 1.0 01/2007 TD09 First edition
33002357 2.0 11/2012 TD09 Complete revision
0Fig. 0Tab. 0
Example
BFK458−002.iso/dms
Example
BFK468−001.iso/dms
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Contentsi
1 Preface and general information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 About these Operating Instructions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Terminology used 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Conventions used 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Abbreviations used 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Notes used 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Scope of supply 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Disposal 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Drive systems 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Legal regulations 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety information 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Application as directed 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product description 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Brake torques 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Rated data 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Operating times 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Operating frequency / friction work 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Emission 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Necessary tools 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mounting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Installation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Bridge/half−wave rectifiers (option) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical connection 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Functional test 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Reducing the brake torque 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 During operation 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance/repair 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Wear of spring−applied brakes 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Inspections 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Spare−parts list 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Spare parts order 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Troubleshooting and fault elimination 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Preface and general information1
1 Preface and general information
1.1 About these Operating Instructions
| These Operating Instructions will help you to work safely on and with the
spring−applied brake with electromagnetic release. They contain safety instructions
that must be followed.
| All persons working on or with the electromagnetically released spring−applied brakes
must have the Operating Instructions available and observe the information and notes
relevant for them.
| The Operating Instructions must always be in a complete and perfectly readable
condition.
1.2 Terminology used
Term In the following text used for
Spring−applied brake Spring−applied brake with electromagnetic release
Drive system Drive systems with spring−applied brakes and other drive
components
1.3 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
Spelling of numbers Decimal separator Point The decimal point is always used.
Symbols
For example: 1234.56
Page reference Reference to another page with additional information
For example: 16 = see page 16
Document reference Reference to another documentation with additional
information
For example: Operating instructions
Wildcard Wildcard for options, selections
For example: BFK458− = BFK458−10
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Preface and general information1
1.4 Abbreviations used
Abbreviation Unit Name
I [A] Current
I
N
M
A
M
N
n
max
P
N
Q [J] Quantity of heat/energy
Q
E
Q
R
Q
Smax
R
N
S
h
S
hue
S
hmax
s
L
s
LN
s
Lmin
s
Lmax
t
1
t
2
t
11
t
11
t
12
U [V] Voltage
U
N
[A] Rated current at 20 °C and rated voltage
[Nm] Tightening torque of the fixing screws
[Nm] Characteristic torque of the brake / clutch
[r/min] Maximum speed during the slipping time t3
[W] Rated coil power at rated voltage and at 20 °C
[J] Maximally permissible friction energy for one−time switching
[J] Braking energy, friction energy
[J] Maximally permissible friction energy for cyclic switching
[Ohm] Rated coil resistance at 20 °C
[1/h] Operating frequency, i.e. the number of periodical switching opera-
tions
[1/h] Transition operating frequency for thermal characteristic of the
brake / clutch
[1/h] Maximally permissible operating frequency, depending on the fric-
tion energy per switching operation
[mm] Air gap, i.e. lift of the armature plate while the brake is switched, or
lift of the armature part when the clutch is switched
[mm] Rated air gap
[mm] Minimum air gap
[mm] Maximum air gap
[s] Engagement time, i.e. sum of the delay time and the braking torque
exit time t
= t11 + t
1
12
[s] Disengagement time, i.e. time between switching the stator and
reaching 0.1 M
K
[s] Slipping time, i.e. engagement time of the brake (after t11) until
standstill
[m] Delay during engagement, i.e. time from switching off the supply
voltage to the beginning of the torque rise
[m] Rise time of the braking torque, i.e. time from the start of the torque
rise until reaching the braking torque
[V] Rated coil voltage
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Preface and general information1
1.5 Notes used
The following pictographs and signal words are used in this documentation to indicate dangers
and important information:
Safety instructions
Structure of safety instructions:
Danger!
Characterises the type and severity of danger
Note
Describes the danger
Possible consequences:
| List of possible consequences if the safety instructions are disregarded.
Protective measure:
| List of protective measures to avoid the danger.
Pictograph and signal word Meaning
Danger of personal injury through dangerous electrical voltage
Danger!
Danger!
Stop!
Application notes
Pictograph and signal word Meaning
Note!
Tip!
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Danger of personal injury through a general source of danger
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Danger of property damage
Reference to a possible danger that may result in property damage if the
corresponding measures are not taken.
Important note to ensure troublefree operation
Useful tip for simple handling
Reference to another documentation
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Preface and general information1
1.6 Scope of supply
1.7 Disposal
1.8 Drive systems
After receipt of the delivery, check immediately whether it corresponds to the accompanying
papers. INTORQ does not grant any warranty for deficiencies claimed subsequently.
| Claim visible transport damage immediately to the forwarder.
| Claim visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG.
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.
Labelling
Drive systems and components are unambiguously designated by the indications on the
nameplate.
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D−31855 Aerzen
| The spring−applied INTORQ brakeis also delivered in single modules and individually
combined to its modular design. The data − package labels, nameplate, and type code
in particular − apply to one complete stator.
| If single modules are delivered, the labelling is missing.
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Preface and general information1
1.9 Legal regulations
Liability
| The information, data and notes in this documentation met the state of the art at the
time of printing. Claims referring to products which have already been supplied cannot
be derived from the information, illustrations and descriptions.
| We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorised modifications to the product
– improper working on and with the product
– operating faults
– disregarding the documentation
Warranty
| Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG.
| Warranty claims must be made to INTORQ immediately after detecting defects or
faults.
| The warranty is void in all cases where liability claims cannot be made.
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Safety instructions2
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.
| All specifications of the corresponding enclosed documentation must be observed.
This is vital for a safe and trouble−free operation and for achieving the specified product
features.
| Only qualified, skilled personnel are permitted to work on and with INTORQ
components.
In accordance with IEC 60364 or CENELEC HD 384, qualified, skilled personnel are
persons ...
– ... who are familiar with the installation, mounting, commissioning, and operation of
the product.
– ... who have the qualifications necessary for their occupation.
– ... who know and apply all regulations for the prevention of accidents, directives, and
laws relevant on site.
| 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.
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| The brake is designed for operation under the environmental conditions that apply to
IP54. Because of the numerous possibilities of using the brake, it is however necessary
to check the functionality of all mechanical components under the corresponding
operating conditions.
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Safety instructions2
2.2 Application as directed
| INTORQ components ...
– ... are intended for use in machinery and systems.
– ... must only be used for the purposes ordered and confirmed.
– ... must only be operated under the ambient conditions prescribed in these
Operating Instructions.
– ... must not be operated beyond their corresponding power limits.
Any other use shall be deemed inappropriate!
Possible applications of the INTORQ spring−applied brake
| Humidity: no restrictions
– In case of formation of condensed water and moisture: provide for appropriate
ventilation to ensure that all components will dry quickly.
| Ambient temperature:
– −20 °C to +40 °C (standard)
| At high humidity and low temperature:
– Take measures to protect armature plate and rotor from freezing.
| Protect electrical connections against contact.
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Technical data3
3 Technical data
3.1 Product description
BFK46820−003.iso/dms
Fig. 1 Design of the BFK468 spring−applied brake: basic module E (complete stator) + rotor + hub +
flange
1 Complete stator 3 Complete rotor 6 Flange
1.2 Compression springs 4 Hub 9 Sleeve bolts
2 Armature plate 5 Shaft 31 Torque adjustment ring
KL 46820−001.iso/dms
Fig. 2 Design of the BFK468 spring−applied brake: basic module N (complete stator) + rotor + hub +
flange
1 Complete stator 3 Complete rotor 6 Flange
1.2 Compression springs 4 Hub 9 Sleeve bolts
2 Armature plate 5 Shaft
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Technical data3
3.1.1 General information
The spring−applied brake is designed for the conversion of mechanical work and kinetic energy
into heat. Due to the static brake torque, the brake can hold loads without speed difference.
Emergency braking is possible at high speed. The more friction work, the higher the wear.
(Operating speeds 16)
The BFK468− spring−applied brake is a single−disk brake with two friction surfaces.
Several compression springs (1.2) generate the braking torque by friction locking. The brake
is released electromagnetically by a reduction of the holding current via an INTORQ bridge
half−wave rectifier.
The stator (1) is designed to be of thermal class F. The limit temperature of the coils is 155°C.
3.1.2 Braking
During braking the rotor (3) axially slidable on the hub (4) is pressed against the friction
surface by the inner and outer springs (1.2) via the armature plate. The asbestos−free
friction linings ensure a high braking torque and low wear. The braking torque transmission
between hub (4) and rotor (3) is effected by means of toothing.
3.1.3 Brake release
In braked state, there is an air gap "s
To release the brake, the coil of the stator (1.1) is excited with the DC voltage provided. The
magnetic force generated attracts the armature plate (2) towards the stator (1.1) against the
spring force. The rotor (3) is then released and can rotate freely.
3.1.4 Brake torque reduction
For basic module E (adjustable), the spring force and thus the brake torque can be reduced
by unscrewing the adjuster nut (8), ( 38).
3.1.5 Manual release (optional for sizes 18 to 25)
The manual release is optionally available for short−term releases when no voltage is applied.
The manual release can be retrofitted.
" between the stator (1.1) and the armature plate (2).
L
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Technical data3
3.1.6 Microswitch (optional)
The manufacturer offers the microswitch for air−gap or wear monitoring. The user must provide
the corresponding electrical connection ( 31et seqq.).
When air−gap monitoring, the motor does not start before the brake has been released. With
this set−up, all possible faults are monitored. For example, in the event of defective rectifiers,
interrupted connection cables, defective coils, or excessive air gaps the motor will not start.
When checking the wear, no current will be applied to the brake and the motor if the air gap
is too large.
3.1.7 Encapsulated design (optional)
This design not only avoids the penetration of spray water and dust, but also the spreading
of abrasion particles outside the brake. This is achieved by:
| a cover seal over the armature plate and rotor,
| a cover in the adjuster nut,
| a shaft seal in the adjuster nut for continuous shafts (option).
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Technical data3
3.2 Brake torques
Stop!
Please observe that engagement times and disengagement times change
depending on the brake torque.
Size 18 20 25 31
Rated torques [Nm],
relating to the
relative speed Dn =
100 rpm
Depending on the
rated torque (spring
assembly), the angle
of rotation for the
braking torque
reduction can be
60°, 120° or 180°
for basic module E.
Characterist
ic torque
[Nm] [Nm] [Nm] [Nm] [Nm] [Nm] [Nm]
100 N/E 6.4 170 N/E 19.8 260 N/E 16.5
115 N/E 6.4 200 N/E 19.8 300 N/E 8.2 720 N
130 N/E 6.4 230 N/E 9.9 350 N/E 8.2 960 N
150 N/E 3.2 260 N/E 9.9 400 N/E 8.2 1200 N
165 N/E 3.2 300 N/E 19.8 445 N/E 16.5 1440 N
185 N/E 6.4 345 N/E 19.8 490 N/E 8.2 1680 N
200 N/E 6.4 400 N/E 19.8 520 N/E 16.5 1920 N
235 N/E 6.4 440 N/E 19.8 600 N/E 16.5 2160 N
265 N/E 6.4 480 N/E 19.8 700 N/E 16.5 2400 N
300 N/E 6.4 520 N/E 19.8 800 N/E 16.5
Torque
reduction E
per detent
position
Characterist
ic torque
Torque
reduction E
per detent
position
Characterist
ic torque
230 N
Torque
reduction E
per detent
position
Characterist
ic torque
Tab. 1 N.....Brake torque for module N (without torque adjustment ring)
E......Brake torque for module E (with torque adjustment ring)
Holding brake with emergency stop operation (s
Service brake (s
Standard braking torque
approx. 4.0 x sLN)
L max.
3.2.1 Basic module E, brake torque reduction
For basic module E, the braking torque can be reduced by means of the torque adjustment
ring in the stator. The torque adjustment ring must only be screwed out up to the maximum
projection "h
", 16 and 38.
Emax.
approx. 2.0 x sLN)
L max.
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