INTORQ BFK458 User manual

INTORQ BFK458
j
setting the standard
Operating Instructions
Electromagnetically-released spring-applied brake
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This documentation applies to ...
BFK458-06...25
Single version Double version
BFK458XX_XXX.iso/dms BFK458XX_XXX.iso/dms
Product key
Product key INTORQ BFK  - 





Legend for the product key INTORQ BFK458
Product group Braking
Product family Spring-applied brake
Type 458
Size 06, 08, 10, 12, 14, 16, 18, 20, 25
Design E - adjustable (brake torque can be reduced via adjuster nut)
N - not adjustable
Not coded: Supply voltage, hub bore, options
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Identification
Package label Example
Manufacturer Bar code
Type (see product key) Type-No.
Name
Rated voltage Rated brake torque Qty. per box
Rated power Hub diameter Packaging date
Supplement CE mark
BFK458-017.iso/dms
Nameplate
Content Example
Manufacturer CE marking
BFK458-25E
180V DC 110W 38H7
No.: 15049627 350NM 01.03.05

D - AERZEN
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Brake type
Rated voltage Rated power Hub diameter
Type no. Rated torque Date of manufacture
Document history
Material number Version Description
405520 1.0 08/1998 TD09 Initial edition for series
405520 1.1 05/2000 TD09 Address revision
Changed values of brake torques in Tab. 1 and Tab. 3
Supplementation of Tab. 4, ”operating times”
460730 2.0 11/2002 TD09 All chapters: Completely revised
Change of company name
Changed values of brake torques
Amendment of 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 Change of company name to INTORQ
13284675 3.0 01/2009 TD09 Change of tightening torques
Supplementation of Tab. 5
Revision of chapter 3.5
Supplementation of chapter 7.1 and 7.2
13284675 3.1 01/2010 TD09 Change of the maintenance intervals for holding brakes with emergency
stop
13343893 4.0 07/2010 TD09 Values of brake torque and speed modified (Tab. 3)
13343893 4.1 05/2012 TD 09 Property class of the fixing screws changed
13343893 5.0 10/2013 TD 09 Complete revision
0Fig. 0Tab. 0
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Contentsi
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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 Notes used 8......................................................
1.6 Scope of supply 9..................................................
1.7 Disposal 9........................................................
1.8 Drive systems 9....................................................
1.9 Legal regulations 10.................................................
2 Safety instructions 11...................................................
2.1 General safety information 11..........................................
2.2 Application as directed 12............................................
3Technicaldata 13.......................................................
3.1 Product description 13...............................................
3.2 Characteristics 15..................................................
3.3 Operating times 21..................................................
3.4 Friction work / operating frequency 23..................................
3.5 Emission 24.......................................................
4 Mechanical installation 25................................................
4.1 Overview 25........................................................
4.2 Important notes 25..................................................
4.3 Necessary tools 26..................................................
4.4 Mounting 27.......................................................
4.5 Installation 27......................................................
5 Electrical installation 35.................................................
5.1 Electrical connection 35..............................................
5.2 Bridge/half-wave rectifiers (option) 38...................................
6 Commissioning and operation 41..........................................
6.1 Important notes 41..................................................
6.2 Function checks before commissioning 41................................
6.3 Commissioning 45...................................................
6.4 During operation 45.................................................
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Contentsi
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7 Maintenance/repair 47..................................................
7.1 Wear of spring-applied brakes 47.......................................
7.2 Inspections 48......................................................
7.3 Maintenance 48....................................................
7.4 Spare-parts list 52..................................................
7.5 Spare parts order 54................................................
8 Troubleshooting and fault elimination 56...................................
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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
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.
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: Operating instructions
Wildcard Wildcard for options, selections
For example: BFK458- = BFK458-10
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Preface and general information1
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1.4 Abbreviations used
Letter symbol Unit Name
I A Current
IHAHolding current, at 20 °C and withstand voltage
ILARelease current, at 20 °C and release voltage
INARated current, at 20 °C and rated voltage
MANm Tightening torque of the fixing screws
MKNm Characteristic torque of the brake, characteristic value of a relative
speed of 100 rpm
nmax rpm Maximum occurring speed during the slipping time t3
PHWCoil power during holding, at voltage change-over and 20 °C
PLWCoil power during release, at voltage change-over and 20 °C
PNWRated coil power, at rated voltage and 20 °C
Q J Quantity of heat/energy
QEJMaximally permissible friction energy for one-time switching,
thermal parameter of the brake
QRJBraking energy, friction energy
QSmax JMaximally permissible friction energy for cyclic switching, depending
on the operating frequency
RmN/mm2Tensile strength
RNOhms Rated coil resistance at 20 °C
RzμmAveraged surface roughness
Sh1/h Operating frequency, i.e. the number of switching operations evenly
spreadoverthetimeunit
Shue 1/h Transition operating frequency, thermal parameter of the brake
Shmax 1/h Maximally permissible operating frequency, depending on the
friction energy per switching operation
sLmm Air gap, i.e. lift of the armature plate while the brake is switched
sLN mm Rated air gap
sLmin mm Minimum air gap
sLmax mm Maximum air gap
t1ms Engagement time, sum of the delay time and braking torque
rise time t1=t
11 +t 12
t2ms Disengagement time, time from switching the stator until reaching
0.1 Mrated
t3ms Slipping time, operation time of the brake (according to t11)until
standstill
t11 ms Delay time during engagement, time from voltage switch-off
to the start of torque rise
t12 ms Rise time of the braking torque, time from the start of torque rise
until reaching the braking torque
tue sOverexcitation time
U V Voltage
UHVDC Withstand voltage, during voltage change-over
ULVDC Release voltage, during voltage change-over
UNVDC Rated coil voltage; in the case of brakes requiring a voltage
change-over, Urated equals UL
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Preface and general information1
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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!
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
Tip! Useful tip for simple handling
Reference to another documentation
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Preface and general information1
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1.6 Scope of supply
After receipt of the delivery, check immediately whether it corresponds to the accompanying
papers. INTORQ does not grant any warranty for deficiencies claimed subsequently.
| Claim visible transport damage immediately to the forwarder.
| Claim visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG.
1.7 Disposal
The spring-applied brake consists of different types of material.
| Recycle metals and plastics.
| Ensure professional disposal of assembled PCBs according to applicable
environmental regulations.
1.8 Drive systems
Labelling
Drive systems and components are unambiguously designated by the indications on the
nameplate.
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D-31855 Aerzen
| The spring-applied INTORQ brakeis 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
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1.9 Legal regulations
Liability
| The information, data and notes in this documentation met the state of the art at the
time of printing. Claims referring to products which have already been supplied cannot
be derived from the information, illustrations and descriptions.
| We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorised modifications to the product
– improper working on and with the product
– operating faults
– disregarding the documentation
Warranty
| Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG.
| Warranty claims must be made to INTORQ immediately after detecting defects or
faults.
| The warranty is void in all cases where liability claims cannot be made.
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Safety instructions2
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2 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 and connected incompletely.
– ... must not be operated without the required covers.
– ... can hold live as well as moving or rotary parts during operation according to their
degree of protection. Surfaces may be hot.
| For INTORQ components ...
– ... the documentation must always be kept at the installation site.
– ... only permitted accessories are allowed to be used.
– ... only original spare parts of the manufacturer are allowed to be used.
| All specifications of the corresponding enclosed documentation must be observed.
This is vital for a safe and trouble-free operation and for achieving the specified product
features.
| Only qualified, skilled personnel are permitted to work on and with INTORQ
components.
In accordance with IEC 60364 or CENELEC HD 384, qualified, skilled personnel are
persons ...
– ... who are familiar with the installation, mounting, commissioning, and operation of
the product.
– ... who have the qualifications necessary for their occupation.
– ... who know and apply all regulations for the prevention of accidents, directives, and
laws relevant on site.
|Riskofburns!
– Surfaces may be hot during operation! Provide for protection against accidental
contact.
| Risk of injury due to a rotating shaft!
– Wait until the motor is at standstill before you start working on the motor.
| The friction lining and the friction surfaces must by no means have contact to oil or
grease since even small amounts reduce the brake torque considerably.
| The brake is designed for operation under the environmental conditions that apply to
IP54. Because of the numerous possibilities of using the brake, it is however necessary
to check the functionality of all mechanical components under the corresponding
operating conditions.
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Safety instructions2
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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
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3Technicaldata
3.1 Product description
3.1.1 Structure and function
21.2
3
4
5
6
31
9
1
sL
KL 14.0606/1
Fig. 1 Design of the spring-applied brake INTORQ BFK458: basic module E (complete stator) + rotor +
hub + flange
1 Complete stator 3 Rotor 6 Flange
1.2 Compression springs 4 Hub 9 Sleeve bolts
2 Armature plate 5 Shaft 31 Torque adjustment ring
sLAir gap
2
1.2
3
4
9
1
sL
KL 14.0623
Fig. 2 Design of the spring-applied brake INTORQ BFK458: basic module N (complete stator) + rotor +
hub + flange
1 Complete stator 3 Rotor sLAir gap
1.2 Compression spring 4 Hub
2Armatureplate 9Sleevebolts
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Technical data3
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This spring-applied brake is a single-disk brake with two friction surfaces. The braking torque
is generated by several compression springs (1.2) by friction locking. The brake is released
electromagnetically.
The spring-applied brake INTORQ BFK458- is a single-disk brake with two friction
surfaces. Several compression springs (1.2) create the braking torque by friction locking. The
brake is released electromagnetically.
The spring-applied brake is designed for the conversion of mechanical work and kinetic energy
into heat. For operating speed, see chapter 3.2 Rated data. Due to the static brake torque,
the brake can hold loads without speed difference. Emergency braking is possible at high
speed, see chapter 3.2 Rated data. The more friction work, the higher the wear.
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 the braked state, there is an air gap ”sL” between the stator (1) and the armature plate (2).
To release the brake, the coil of the stator (1) is excited with the DC voltage provided. The
magnetic force generated attracts the armature plate (2) towards the stator (1) against the
spring force. The rotor (3) is then released and can rotate freely.
3.1.4 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), (46).
3.1.5 Manual release (optional)
The manual release is optionally available for short-term releases when no voltage is applied.
The manual release can be retrofitted.
3.1.6 Microswitch (optional)
The manufacturer offers the microswitch for air-gap or wear monitoring. The user must provide
the corresponding electrical connection (35et 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.
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Technical data3
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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).
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.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.
3.2 Characteristics
General data
Stop!
Please observe that engagement times and disengagement times change
depending on the brake torque.
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Technical data3
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Size 06 08 10 12 14 16 18 20 25
80 E
Rated torques [Nm],
relating to the
relative speed
Δn = 100 rpm
1.5 E 3.5 N/E 25 N/E 35 N/E 65 N/E 115 N/E 175 N/E
2N/E 4E 7N/E 14 N/E 35 N 45 N/E 80 N/E 145 N/E 220
2.5 N/E 5N/E 9N/E 18 N/E 40 N/E 55 N/E 100 N/E 170 N/E 265 N/E
3N/E 6N/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
4N/E 8N/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
5E 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
6N/E 12 125 N/E 235 N/E 400 N/E 600 N/E
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 (sLmax. approx. 1.5 x sLrated)
Service brake (sLmax. approx. 2.5 x sLrated)
Standard braking torque
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 ”hEmax.”, 15 and 46.
Size 06 08 10 12 14 16 18 20 25
Torque reduction
per detent [Nm] 0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2
Tab. 2
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Technical data3
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3.2.2 Brake torques depending on the speed and permissible limit speeds
Type Rated torque at Δn = 100
rpm
Braking torque at Δn0[rpm] [%] max. speed Δn0max. with
horizontal mounting position
[%] 1500 3000 maximum [rpm]
BFK458-06
100
87 80 74 6000
BFK458-08 85 78
73
5000
BFK458-10 83 76 4000
BFK458-12 81 74
3600
BFK458-14 80 73 72
IBFK458-16 79 72 70
IBFK458-18 77 70 68
BFK458-20 75 68
66
BFK458-25 73 66 3000
Tab. 3 Brake torques depending on the speed and permissible limit speeds
Type sLN
+0.1 mm
-0.05 mm
sLmax.
Service
brake
sLmax.
Holding
brake
Max.
adjustment,
permissible
wear
distance
Rotor thickness Excess
of the torque
adjustment
ring hEmax.
[mm] [mm] [mm] [mm] min. 1) [mm] max. [mm] [mm]
BFK458-06
0.2 0.5 0.3 1.5
4.5 6.0
4.5
BFK458-08 5.5 7.0
BFK458-10 7.5 9.0 7.5
BFK458-12
0.3 0.75 0.45
2.0 8.0
10.0
9.5
BFK458-14 2.5 7.5 11
BFK458-16 3.5 8.0 11.5 10
BFK458-18
0.4 1.0 0.6
3.0 10.0 13.0 15
BFK458-20 4.0 12.0 16.0 17
BFK458-25 0.5 1.25 0.75 4.5 15.5 20.0 19.5
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Technical data3
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Type Pitch circle Screws for
flange
mount.
DIN912 8.8
Minimum
depth of
clearing
holes
(mounting
flange)
Tightening torque Weight
of complete
stator
∅[mm] Thread 2) [mm] Screws [Nm] Complete
lever [Nm]
[kg]
BFK458-06 72 3xM4 3xM4 0.5 3.0
2.8
0.75
BFK458-08 90 3xM5 3xM5 15.9 1.2
BFK458-10 112 3xM6 3xM6 2
10.1 4.8
2.1
BFK458-12 132 3xM6 3xM6 33.5
BFK458-14 145
3xM8 3xM8
1.5
24.6 12
5.2
BFK458-16 170 0.5 7.9
BFK458-18 196 6xM8 4xM83) 0.8
23
12.0
BFK458-20 230
6xM10
4xM103) 2.1
48
19.3
BFK458-25 278 6xM10 540 29.1
Tab. 4 Characteristics of INTORQ BFK458 spring-applied brake
1) The friction lining is designed such that the brake can be adjusted at least 5 times.
2) The screw length is dependent on the material and the thickness of the mounting surface provided by the customer.
3) The threads are positioned in the mounting surface, offset 30° each to the centre axis of the hand-release lever.
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Technical data3
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Type Electrical power P20 1) Rated current INRelease
voltage/holding voltage
U
Coil resistance R20 ±8%
[W] [A] [V] [Ω]
BFK458-06 20
0.83 24 20
0.21 96 460.8
0.194 103 530.5
0.114 170 1445
0.111 180 1620
0.105 190 1805
0.098 205 2101
BFK458-08 25
1.04 24 23
0.26 89 368
0.242 103 424.4
0.147 170 1156
0.138 180 1296
0.131 190 1444
0.121 205 1681
BFK458-10
30 1.25 24 19.2
31 0.322 96 297.3
32 0.31 103 331.5
30 0.176 170 963.3
32 0.177 180 1013
30 0.157 190 1203
33 0.160 205 1273
BFK458-12 40
1.66 24 14.4
0.41 96 230.4
0.388 103 265.2
0.235 170 722.5
0.222 180 810
0.210 190 902.5
0.195 205 1051
BFK458-14
50
2.08 24 11.5
0.52 96 184.3
53 0.514 103 200.2
50 0.294 170 578
53 0.294 180 611.3
50 0.263 190 722
53 0.258 205 792.9
BFK458-16
55
2.29 24 10.5
0.573 96 167.6
56 0.543 103 189.5
55
0.323 170 525.5
0.305 180 589.1
60 0.315 190 601.7
56 0.292 205 750.5
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Technical data3
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Type Electrical power P20 1) Rated current INRelease
voltage/holding voltage
U
Coil resistance R20 ±8%
[W] [A] [V] [Ω]
BFK458-18 85
3.54 24 6.8
0.885 96 108.4
0.825 103 124.8
0.5 170 340
0.472 180 387.2
0.447 190 424.7
0.414 205 494.4
BFK458-20 100
4.16 24 5.76
1.04 96 92.2
0.970 103 106.1
0.588 170 289
0.55 180 324
0.487 205 420.3
110 0.578 190 328.2
BFK458-25 110
4.58 24 5.24
1.14 96 83.8
1.06 103 96.5
0.647 170 262.7
0.611 180 294.6
0.578 190 328.2
0.536 205 382.1
Tab. 5 Coil power
1) Coil power at 20_C
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