INTORQ BFK470 Series, BFK470-10, BFK470-12, BFK470-14, BFK470-06 Translation Of The Original Operating Instructions

setting the standard

INTORQ BFK470

Spring-applied brake with electromagnetic release

Translation of the Original Operating Instructions

www.intorq.com

www.intorq.com

This documentation applies to the:

AABCD

A

A

BCD

Product key

Legend for the product key

INTORQ BFK470

Product group Brake
Product type Spring-applied brake

INTORQ B FK -

Type 470
Size 06, 08, 10, 12, 14, 16, 18

Not coded: Supply voltage, hub bore hole, options

INTORQ | BA 14.0199 | 08/2016 2

Identification

Packaging label Example

Manufacturer Bar code
Type (see product key) Type No.
Designation Qty. per box
Rated voltage Rated power Rated torque Hub diameter Packaging date
Note CE mark

Name plate Example

Manufacturer CE mark
Type (see product key)
Designation
Rated voltage Rated power Hub diameter
Type No. Rated torque

Date of manufacture

Document history

Material number Version Description

33001439 1.0 01/2012 TD09 First edition
33001439 1.1 03/2012 TD09 Supplemented the technical data
33001439 1.2 10/2012 TD09 Added to the "Brake assembly" chapter

Updated the "Abbreviations used" table
Supplemented the characteristics, rated data and operating times

33001439 2.0 05/2013 TD09 Degree of protection changed

Added note about the end shield characteristics
Shaft characteristic defined, "Mechanical installation" chapter
"Checking the brake" chapter (maintenance and repair) supple-

mented
33001439 3.0 05/2013 TD 09 Text with regard to the disengagement time updated
33001439 3.1 03/2014 SC

Restructured FM; note concerning brake seal 23
33001439 4.0 01/2015 SC Harmonized connection diagrams
33001439 5.0 08/2016 SC Additional sizes: 06, 08, 10, 12

Refer to www.intorq.de for the latest version of these operating instructions.

INTORQ | BA 14.0199 | 08/2016 3

Contents

1 Preface and general information ...........................................................................................................................5

1.1 About these Operating Instructions ...............................................................................................................5

1.2 Terminology used ...................................................................... ....................................................................5

1.3 Conventions in use ........................................................................................................................................5

1.4 Abbreviations used ........................................................................................................................................6

1.5 Safety instructions and notices .....................................................................................................................7

1.6 Scope of delivery ...........................................................................................................................................8

1.7 Disposal ........................................................................................................................................................8

1.8 Drive systems ................................................................................................................................................9

1.9 Legal regulations ...........................................................................................................................................9

2 Safety instructions ...............................................................................................................................................10

2.1 General safety instructions ..........................................................................................................................10

2.2 Application as directed ................................................................................................................................11

3 Technical specifications ......................................................................................................................................12

3.1 Product description .....................................................................................................................................12

3.2 Rated data ...................................................................................................................................................14

3.3 Rated data (dimensioning data) electrical data ...........................................................................................16

3.4 Switching energy / operating frequency ......................................................................................................18

3.5 Emissions ....................................................................................................................................................19

4 Mechanical installation ........................................................................................................................................20

4.1 Important notes ...........................................................................................................................................20

4.2 Assembly .....................................................................................................................................................22

5 Electrical installation ............................................................................................................................................25

5.1 Important notes ...........................................................................................................................................25

5.2 Electrical connection ............. .... .... .... ..........................................................................................................25

5.3 Technical data for inductive proximity sensors ...........................................................................................30

5.4 Minimum bend radius for the brake connection line ....................................................................................31

5.5 Bridge/half-wave rectifier (optional) .............................................................................................................31

6 Commissioning and operation ............................................................................................................................34

6.1 Important notes ...........................................................................................................................................34

6.2 Function checks before commissioning ......................................................................................................35

6.3 Brake with proximity sensor ........................................................................................................................36

6.4 Commissioning ............................................................................................................................................37

6.5 During operation ..........................................................................................................................................37

7 Maintenance and repair ......................................................................................................................................38

7.1 Wear of spring-applied brakes ....................................................................................................................38

7.2 Inspections ..................................................................................................................................................39

7.3 Maintenance ................................................................................................................................................40

7.4 Spare-parts list ............................................................................................................................................43

7.5 Electrical accessories .................................................................... .... .... .... ..................................................43

8 Troubleshooting and fault elimination ...............................................................................................................44

INTORQ | BA 14.0199 | 08/2016 4

Preface and general information

1 Preface and general information

1.1 About 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 electromagnetically released spring-applied brakes must have the Oper-

ating 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 compo-

1.3 Conventions in use

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

Spelling of numbers

Symbols

nents

Decimal separator Point The decimal point is always used.

For example: 1234.56

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.

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Preface and general information

1.4 Abbreviations used

Letter symbol Unit Designation

F

R

N Rated frictional force

I A Current
I

H

I

L

I

N

M

A

M

dyn

M

K

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
Nm Braking torque at a constant speed of rotation
Nm Rated torque of the brake, rated value at a relative speed of rotati on of

100 rpm

n

max

P

H

P

L

P

N

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

E

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

the brake

3

Q
Q

R
S

S
S

s
s
s
s
t

t

N

h

hue

hmax

L

LN

Lmin

Lmax

1

2

R

Smax

J Braking energy, friction energy
J Maximally permissible friction energy for cyclic switching, depending on the

operating frequency

Ohms Rated coil resistance at 20 °C
1/h Switching frequency: the number of switching operations evenly spread over

the time unit

1/h Transition operating frequency, thermal parameter of the brake
1/h Maximum permissible operating 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
mm Minimum air gap
mm Maximum air gap
ms Engagement time, sum of the delay time and braking torque - rise time

t

= t11 + t

1

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

12

dyn

t

3

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

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Preface and general information

Letter symbol Unit Designation

t

11

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

beginning of the torque rise)

t

12

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

ing the braking torque

t

ue

s Overexcitation time

UVVoltage
U

H

U

L

U

N

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,

U

N

1.5 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:

equals U

L

SIGNAL WORD

Icon

Indicates the type of danger

Signal word

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.

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Preface and general information

Danger level

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 surro unding
objects could be damaged.

1.6 Scope of 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 da mage immediately to the deliverer.
❚ Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.

1.7 Disposal

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

❚ Recycle metals and plastics.
❚ Ensure professional disposal of assembled PCBs according to the applicable environmental regulations.

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Preface and general information

1.8 Drive systems

Labelling

Drive systems and components are unambiguously designated by the indications on the name plate.
Manufacturer: INTORQ GmbH & Co. KG, Wülmser Weg 5, D-31855 Aerzen, Germany

1.9 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

Warranty

❚ Terms of warranty: Refer to the terms of sale and delivery for INTORQ GmbH&Co. KG.
❚ 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.

INTORQ | BA 14.0199 | 08/2016 9

Safety instructions

2 Safety instructions

2.1 General safety instructions

❚ INTORQ components ...

- ... must only be used as directed.

- ... must not be commissioned if they are noticeably damaged.

- ... must not be technically modified.

- ... must not be commissioned if they are incompletely mounted or connected.

- ... must not be operated wi thout 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 documentatio n must always be kept at the installation site.

- ... only permitted accessories are allowed to be used.

- ... only original spare pa rts of the manufacturer are allowed to be used.

❚ Follow all specifications and information found in the corresponding enclosed documentation.

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

❚ Only qualified, skilled personnel are permitted to work on and with INTORQ components.

According to IEC 60364 or CENELEC HD384, qualified, skilled personnel are persons ...

- ... who are familiar with th e installation, mounting, commissioning, and opera tion of the product.

- ... who have the qualific ations 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 opera ti on ! Pro vide for protection against accidental contact.

❚ Risk of injury due to a rotating shaft!

- Wait until the motor is at stan dstill before you start working on the motor.

❚ The friction lining and the friction surfaces must never contact oil or grease since e v en small amounts

reduce the braking torque considerably.

❚ The brake is designed for operation under the environmental conditions that apply to IP66 protecti on.

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 instructions

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 or excessive usage shall be deemed improper!

Possible applications of the INTORQ spring-applied brake

❚ No explosive or aggressive atmosphere.
❚ Humidity: no restrictions
❚ Ambient temperature:

- Standard desig n: -20 °C to +50 °C

- Optional CCV design: -40 °C to +50 °C

INTORQ | BA 14.0199 | 08/2016 11

Technical specifications

3 Technical specifications

3.1 Product description

3.1.1 Structure and function

Abb.1 Design of a BFK470 spring-applied brake

1.1 Stator 3 Complete rotor 10 Socket head cap screw, DIN EN ISO 4762

1.2 Pressure springs 4 Hub 12 Complete manual release (optional)

1.3 Plug (check for air gap) 6 Flange (optional) 30 Setting screw for the factory-set adjustment
of the spring force (sealed), applies only to
sizes 12-18

2 Armature plate 8 Coil X Bore holes are optional

The spring-applied brake is designed for converting mechanical work and kinetic energy into heat energy.
Due to the static braking torque, loads can be held at standstill. Emergency braking is possible at high speed
of rotation. The wear increases as the switching energy increases.

INTORQ | BA 14.0199 | 08/2016 12

Technical specifications

The spring-applied brakes BFK470 are electrically releas able single-disc brakes with two friction surfaces.
When de-energized, both of the rotor’s friction surfaces are tightened by the force of the compression springs
between the armature plate and the flange. The braking torque is applied over the friction radius of the rotor;
it is transferred to the shaft via a hub that has axial 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 stator´s coil is energized with
DC voltage. 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.

3.1.2 Brakes

During the braking procedure, the pressure springs (1.2) use the armature plate (2) to press the rotor (3)
(which can be shifted axially on the hub (4)) against the friction surface. The asbestos-free friction linings
ensure high braking torque and low wear. The braking torque is transmitted between the hub (4) and the rotor
(3) via gear teeth.

NOTICE

Due to the structural design of the stator, the air gap cannot be installed downstream. If the
wear limit is reached, the rotor must be replaced.

"

L

3.1.3 Brake release

When the brakes are applied, an air gap "s
To release the brake, the coil of the stator (1.1) is energ ized with the DC voltage provided. The resulting mag ­netic flux works against the spring force to draw the armature plate (2) to the stator (1.1). This releases the
rotor (3) from the spring force and allows it to rotate freely

3.1.4 Project planning notes

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

run-in process.

❚ However, as the organic frictio n linings used do not all have identical properties and because environ-

mental 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.

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

regularly.

" is present between the stator (1.1) and the armature pl ate (2).

L

INTORQ | BA 14.0199 | 08/2016 13

Technical specifications

3.2 Rated data

Type Max. speed

of rotation

nmax
[rpm]

Temperature

1)

class

Stator

Operating

time

[%]

Moment of

inertia

Rotor

[kgcm2]

without

flange

[kg]

Mass of brake

with

flange

[kg]

without flange

+ Manual

release

[kg]

with flange

+ Manual

release

[kg]

BFK470-06 6000 F (155°C) 100 0.15 1.3 1.5 1.4 1.6
BFK470-08 5000 F (155°C) 100 0.61 2.0 2.2 2.1 2.3
BFK470-10 4000 F (155°C) 10 0 2.0 3.5 3.9 3.7 4.0
BFK470-12 3600 F (155°C) 10 0 4.5 5.0 5.6 5.3 5.8
BFK470-14 3600 F (155°C) 10 0 6.3 7.7 8.5 8.1 8.9
BFK470-16 3600 F (155°C) 100 15.0 11.9 13.1 12.5 13.7
BFK470-18 3600 F (155°C) 100 29.0 17.6 19.1 18.6 20.0

Tab. 1: General brake characteristics

1)

Maximum speed of rotation when installed horizontally (for higher speeds, contact the manufac-

turer)

Type Air gap Rotor thickness

BFK470-06 0.2
BFK470-08 0.2
BFK470-10 0.2
BFK470-12 0.3

BFK470-14 0.3
BFK470-16 0.3

BFK470-18 0.4

Tab. 2: Air gap / rotor thickness

s

LN

[mm]

+0.08

-0.05

+0.08

-0.05

+0.13

-0.05

+0.08

-0.10
± 0.1

+0.15

-0.05

+0.20

-0.10

operating brake

[mm]

s

L max

holding brake

[mm]

operating brake

[mm]

min. New state

0.5 0.3 5.73 5.93

0.5 0.3 6.73 6.93

0.5 0.35 8.73 8.88

0.6 0.45 9.68 9.83

0.75 0.45 9.55 9.85

0.80 0.50 11.05 11.35

1.0 0.65 12.50 12.85

holding brake

[mm] [mm]

6.0

7.0

9.0

10.0

10.0

11.5

13.0

-0.05

-0.05

-0.1

-0.1

-0.1

-0.1

-0.1

INTORQ | BA 14.0199 | 08/2016 14

Technical specifications

Type

Outer

diameter

[mm]

Pitch

circle



[mm] Thread

Fixing screws

DIN EN ISO 4762

without flange

[mm]

with flange

[mm]

Minimum thread depth Tightening

torque

without flange

[mm]

with flange

[mm]

M

[Nm]

a

BFK470-06 89 72 M4 3 x M4x40 3 x M4x45 7.5 9.0 3.0
BFK470-08 106 90 M5 3 x M5x45 3 x M5x50 10.5 10.0 5.9
BFK470-10 130 112 M6 3 x M6x55 3 x M6x60 14.0 13.5 10.1
BFK470-12 148 132 M6 3 x M6x60 3 x M6x65 12.5 12.5 10.1
BFK470-14 168 145 M8 3 x M8x75 3 x M8x80 19.5 18.5 24.6
BFK470-16 200 170 M8 3 x M8x80 3 x M8x85 18.0 17.0 24.6
BFK470-18 226 196 M8 6 x M8x90 6 x M10x100 19.5 23.0 24.6

Tab. 3: Installation data

CAUTION

❚ The minimum thread depth of the end shield must be maintained! Tab. 3.
❚ If the required thread depth is no t maintained, the fixing screws may run on to the root. This

has the effect that the required pre-load force is no longer established – the brake is no
longer securely fastened!

❚ The material of the end shield must have a tensile strength of R

>= 250 N/mm2.

m

INTORQ | BA 14.0199 | 08/2016 15

Technical specifications

3.3 Rated data (dimensioning data) electrical data

Type Voltage

U [V DC]

BFK470-06

Rated current

[A]

I

N

Power
PN [W]

0.098 20 2101.0

Coil resistance

RN ± 4% []

BFK470-08 0.122 25 1681.0
BFK470-10 0.161 33 1273.0
BFK470-12 0.195 40 1051.0

205
BFK470-14 0.307 60 667.1
BFK470-16 0.332 68 618.0
BFK470-18 0.415 85 494.4

Tab. 4: Coil data at 20°C

Type Braking torques at relative speed of rotation n

Rated torque

[Nm]

100 rpm

Braking torque

X [%] of the rated torque

1500

rpm

3000

rpm

maximum horizontal mounting position

Maximum speed

rpm

BFK470-06 2.0 / 2.5 / 3.0 / 3.5 / 4.0 /

4.5 / 5.5 / 6.0 / 6.5 /

7.0 / 7.5

BFK470-08 3.5 / 5 / 6 / 7 / 8 / 10 /

11 / 12 / 14 / 15

BFK470-10 9 / 11 / 14 / 16 / 18 / 21 /

23 / 25 / 28 / 30 / 33 / 36

BFK470-12 12 / 14 / 15 / 16 / 18 /

23 / 27 / 32 / 36 / 40 /

45 / 46 / 48 / 50 / 55

BFK470-14 40 / 50 / 60 / 65 / 70 /

75 / 80 / 100 / 110

BFK470-16 55 / 80 / 90 / 100 /

105 / 125 / 150

BFK470-18 100 / 150 / 165 / 185 /

200 / 235 / 250

Tab. 5: Rated torques

87 80 74 6000

85 78

83 76 4000

73

5000

81 74

80 73 72

3600

79 72 70

77 70 68

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