INTORQ BFK455-28 Quick guide

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setting the standard
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INTORQ BFK455-28
Electromagnetically Released Spring-Applied Brake
Translation of the Original Operating Instructions

INTORQ | BA 14.0196 | 04/2016 2
This documentation applies to the:
Product key
Not coded: Supply voltage, hub bore, options
INTORQ B FK -
AA
B
C
D
Legend for the product key
INTORQ BFK455
Product group Brakes
Product type Spring-applied brake
Type 455
Size 28
AA
B
C
D

INTORQ | BA 14.0196 | 04/2016 3
Identification
Notes
The brake is marked with the following labels, which have to be observed:
Packaging label Example
Manufacturer Type number
Type (see product key) Bar code
Designation Qty. per box
Rated/holding voltage Rated torque
Rated/holding power Hub diameter Packaging date
Model identification CE mark
Note
Name plate Example
Manufacturer CE mark
Type (see product key) EC-type examination identification
Rated/holding voltage Rated/holding power Hub diameter
Type number Rated torque Date of manufacture
Label product traceability Example
Type (see product key)
QR-CodeType number
Serial number
Manufacturer
for the holding voltage for setting the air gap
Lüftspannung
Release voltage: 205 V DC
Haltespannung:
Holding voltage: 103 V DC
Nur mit BEG-561-255-130 betreiben!
Only use with BEG-561-255-130!
Nr./No. 33000224
DE: Den nach der Erstinstallation eingestellten Luftspalt
nicht verstellen!
EN: Do not re-adjust the air-gap after the first installation!
FR: Ne plus regler l‘entrefer après la première installa-
tion!

INTORQ | BA 14.0196 | 04/2016 4
Document history
Material number Version Description
33000756 1.0 05/2011 TD09 First edition
33000756 1.1 05/2012 TD09 Change in telephone and fax number
Front and back page new
Addition of the EC type test number
Supplemented by chapter “Project planning notes”
Supplemented by chapter “Wear of spring-applied brakes”
33002468 2.0 03/2013 TD09 Amended by new chapter on manual release installation
Tables of dimensions and switching times were changed
Supplement for spare parts list and the spare parts order
33002468 3.0 04/2013 TD09 Limitation of the adjustability
Note on the suppressor circuit added to the “Electrical installation”
chapter
Values for characteristic torque 2x2065 Nm added to “Dimensions”
table
33002468 4.0 01/2015 SC Restructured FM
33002468 4.1 11/2015 SC Changing the model identification test numbers
33002468 5.0 04/2016 SC Updates
Changing the model identification test numbers

INTORQ | BA 14.0196 | 04/2016 5
Contents
1 Preface and general information .......................................................................................................................... 6
1.1 About these Operating Instructions .............................................................................................................. 6
1.2 Terminology used ......................................................................................................................................... 6
1.3 Conventions in use ....................................................................................................................................... 6
1.4 Abbreviations used ....................................................................................................................................... 7
1.5 Safety instructions and notices ..................................................................................................................... 8
1.6 Scope of delivery .......................................................................................................................................... 9
1.7 Disposal ........................................................................................................................................................ 9
1.8 Drive systems ............................................................................................................................................. 10
1.9 Legal regulations ........................................................................................................................................ 10
2 Safety instructions .............................................................................................................................................. 11
2.1 General safety instructions ......................................................................................................................... 11
2.2 Application as directed ............................................................................................................................... 12
3 Technical specifications ..................................................................................................................................... 13
3.1 Product description ..................................................................................................................................... 13
3.2 Rated data .................................................................................................................................................. 16
3.3 Rated data (design data) ............................................................................................................................ 17
3.4 Switching energy / switching frequency ..................................................................................................... 19
3.5 Emissions ................................................................................................................................................... 20
4 Mechanical installation ....................................................................................................................................... 21
4.1 Important notes .......................................................................................................................................... 21
4.2 Necessary tools .......................................................................................................................................... 21
4.3 Assembly .................................................................................................................................................... 22
4.4 Installation .................................................................................................................................................. 23
4.5 Manual release ........................................................................................................................................... 29
4.6 Cover ring assembly ................................................................................................................................... 34
5 Electrical installation ........................................................................................................................................... 35
5.1 Important notes .......................................................................................................................................... 35
5.2 Bridge/half-wave rectifier (optional) ............................................................................................................ 36
5.3 Electrical connection .................................................................................................................................. 38
6 Commissioning and operation ........................................................................................................................... 39
6.1 Important notes .......................................................................................................................................... 39
6.2 Function checks before commissioning ..................................................................................................... 39
6.3 Commissioning ........................................................................................................................................... 40
6.4 During operation ......................................................................................................................................... 41
7 Maintenance and repair ...................................................................................................................................... 42
7.1 Wear of spring-applied brakes ................................................................................................................... 42
7.2 Inspections ................................................................................................................................................. 43
7.3 Maintenance ............................................................................................................................................... 44
7.4 Spare-parts list ........................................................................................................................................... 46
7.5 Ordering spare parts .................................................................................................................................. 47
8 Troubleshooting and fault elimination .............................................................................................................. 48

Preface and general information
INTORQ | BA 14.0196 | 04/2016 6
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 the electromagnetically released spring-applied brakes must have the Op-
erating 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
1.3 Conventions in use
This document uses the following styles to distinguish between different types of information:
Term In the following text used for
Spring-applied brake Electromagnetically Released Spring-Applied Brake
Drive system Drive systems with spring-applied brakes and other drive components
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 = 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.

Preface and general information
INTORQ | BA 14.0196 | 04/2016 7
1.4 Abbreviations used
Letter symbol Unit Designation
FRN Rated frictional force
I A Current
IHA Holding current, at 20 °C and holding voltage
ILA Release current, at 20 °C and release voltage
INA Rated current, at 20 °C and rated voltage
MANm Tightening torque of fixing screws
Mdyn Nm Braking torque
at a constant speed of rotation
MKNm Rated torque of the brake, rated value at a relative speed of rotation of
100 rpm
nmax rpm Maximum occurring speed of rotation during the slipping time t3
PHW Coil power during holding, after voltage change-over and 20 °C
PLW Coil power during release, before voltage change-over and 20 °C
PNW Rated coil power, at rated voltage and 20 °C
Q J Quantity of heat/energy
QEJ Maximally permissible friction energy for one-time switching, thermal
parameter of the brake
QRJ Braking energy, friction energy
QSmax J Maximally permissible friction energy for cyclic switching, depending on the
switching frequency
RNOhms Rated coil resistance at 20 °C
Sh1/h Switching frequency: the number of switching operations evenly spread
over the time unit
Shue 1/h Transition switching frequency, thermal parameter of the brake
Shmax 1/h Maximum permissible switching frequency, depending on the friction
energy per switching operation
sLmm Air gap: the 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= t11 + t12
t2ms Disengagement time, time from switching the stator until reaching 0.1 Mdyn
t3ms Slipping time, operation time of the brake (according to t11) until standstill

Preface and general information
INTORQ | BA 14.0196 | 04/2016 8
1.5 Safety instructions and notices
The following icons and signal words are used in this document to indicate dangers and important safety in-
formation:
Safety instructions
Structure of safety instructions:
t11 ms Delay during engagement (time from switching off the supply voltage to the
beginning of the torque rise)
t12 ms Rise time of the braking torque, time from the start of torque rise until
reaching the braking torque
tue s Over-excitation time
U V Voltage
UHV DC Holding voltage, after voltage change-over
ULV DC Release voltage, before voltage change-over
UNV DC Rated coil voltage; in the case of brakes requiring a voltage change-over,
UNequals UL
SIGNAL WORD
Icon
Indicates the type of danger
Signal word
Characterizes the type and severity of danger
Note
Describes the danger
Possible consequences
❚List of possible consequences if the safety instructions are disregarded
Protective measure
❚List of protective measures to avoid the danger
Letter symbol Unit Designation

Preface and general information
INTORQ | BA 14.0196 | 04/2016 9
Danger level
1.6 Scope of delivery
After receipt of the delivery, check immediately whether the items delivered match the accompanying pa-
pers. INTORQ does not accept any liability for deficiencies claimed subsequently.
❚Claim visible transport damage immediately to the deliverer.
❚Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.
1.7 Disposal
The spring-applied brake consists of different types of material.
❚Recycle the metal and plastic parts.
❚Ensure professional disposal of assembled circuit boards according to the applicable environmental reg-
ulations.
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 mod-
erate injury.
NOTICE
Notice about a harmful situation with possible consequences: the product itself or surrounding
objects could be damaged.

Preface and general information
INTORQ | BA 14.0196 | 04/2016 10
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, Germany
❚The spring-applied INTORQ brake is also delivered in single modules which can then be put together by
the customer according to their requirements. The specifications – particularly the packaging label,
nameplate and type code – apply to a complete stator.
❚The labelling is not included when modules are delivered individually.
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.

Safety instructions
INTORQ | BA 14.0196 | 04/2016 11
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 without the required covers.
- ... can include live (current-carrying) 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.
❚Follow all specifications and information found in the corresponding enclosed documentation.
These must be followed to maintain safe, trouble-free operations 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 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 never contact oil or grease since even small amounts
reduce the braking torque considerably.
❚The brake is designed for operation under the environmental conditions that apply to IP54 protection.
Because of the numerous possibilities of using the brake, it is still necessary to check the functionality
of all mechanical components under the corresponding operating conditions.

Safety instructions
INTORQ | BA 14.0196 | 04/2016 12
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 is considered improper!
Usage conditions for the INTORQ spring-applied brake
❚Humidity: no restrictions
- In the event of condensation or moisture formation: provide for appropriate ventilation to ensure that
all components will dry quickly.
❚Ambient temperature:
-5 °C to +40 °C
❚At high humidity and low temperature:
- Take measures to protect the armature plate and rotor from freezing.
❚Protect the electrical connections against any contact or touching.

Technical specifications
INTORQ | BA 14.0196 | 04/2016 13
3 Technical specifications
3.1 Product description
Versions
Fig. 1 Design of a BFK455 spring-applied brake
Basic module
1.1 Stator 3 Complete rotor 6 Flange
1.2 Pressure springs 4 Hub 8 Coil
2 Armature plate 5 Shaft 13 Cover ring

Technical specifications
INTORQ | BA 14.0196 | 04/2016 14
3.1.1 General information
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 (operating speeds 17).
The BFK455 spring-applied brake is a double-disk brake with four friction surfaces. The braking torque is
applied through two separate braking circuits, both electrical and mechanical, via several compression
springs (1.2) in the form of generated friction. The brake circuits are released electromagnetically. Due to its
division into two brake circuits, the brake is particularly suitable for applications such as lift systems and
stage/platform technology. The brake can be selected based on the rated torque for one brake circuit. The
second brake circuit meets the requirement for redundancy.
The division of the brake circuits is done using two separate armature disks (2) with their corresponding com-
pression springs (1.2) and electromagnetic coils (8). Each brake circuit can be operated individually due to
the separate supply lines for each stator and armature plate ( 36).
Each brake circuit has a micro-switch which monitors the switching state of the spring-applied brake. Using
the associated switching device, the supply voltage (AC voltage) is rectified and, when the brake is released,
lowered after a short period of time. This results in a reduction of the average electrical power of the brake.
The stator (1.1) is supplied in heat class F. The limit temperature of the coils (8) is 155 °C. The BFK455
spring-applied brake is designed for a maximum operating time of 60 % with holding current reduction.
Certificate
3.1.2 Brake
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.
Type Characteristic torque
[Nm]
EC-type examination certificate
Directive 95/16/EC UCM Directive 2014/33 EU
BFK455-28
2 x 1200
ABV 881/2 ESV 881/2 EU-BD 8812 x 1700, 2 x 1800
2 x 2065

Technical specifications
INTORQ | BA 14.0196 | 04/2016 15
3.1.3 Brake release
When the brakes are applied, an air gap “sL” is present between the stator (1.1) and the armature plate (2).
To release the brake, the coil of the stator (1.1) is energised 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 Release monitoring
The spring-activated brake has a micro-switch for each braking circuit to monitor the switching state. When
the brake is released, the micro-switches toggle. This means that it is possible to prevent the drive from being
operated when the brake is closed. The micro-switches can be connected as both normally open and also
normally closed.
To check that the micro-switches function correctly, we recommend testing the switching status (refer to ta-
ble 6) in both the released and applied braking states.
3.1.5 Encapsulated design (optional)
This design not only avoids the penetration of spray water and dust, but also the spreading of abrasion par-
ticles outside the brake. This is achieved by:
❚a cover seal over the armature plate and rotor.
3.1.6 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, since the organic friction linings used do not all have identical properties and because envi-
ronmental 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.

Technical specifications
INTORQ | BA 14.0196 | 04/2016 16
3.2 Rated data
3.2.1 Dimensions
Type Rated torque Air gap Permitted
wear
Rotor thickness Weight
complete
stator
[NM] sLN
+0.05
[mm] sLmax. [mm] [mm] min. [mm] max. [mm] m [kg]
BFK455-28
2 x 1100
0.4 0.7 0.3 17.7 18 46
2 x 1200
2 x 1700
2 x 1800
2 x 2065 0.6 0.2 17.8
Type Pitch circle Fixing screws
DIN 912
Minimum thread depth Tightening torque
without
flange
with
flange
without
flange
with
flange
without
flange
with
flange
∅[mm] Thread [mm] [mm] [mm] [mm] MA[Nm] MA[Nm]
BFK455-28 314 M16 6 x M16x210 6 x M16x220 25 22.5 206 265
Tab. 1: Dimensions of the BFK455-28
CAUTION
❚The minimum thread depth of the end shield must be maintained! Tab. 1.
❚If the required thread depth is not maintained, the fixing screws may run onto the root. This
has the effect that the required pre-load force is no longer established – the brake is no
longer securely fastened!
s
LN
s
LN

Technical specifications
INTORQ | BA 14.0196 | 04/2016 17
3.2.2 Electrical data
3.3 Rated data (design data)
Fig. 2 Operating/switching times of the spring-applied brakes
Type Voltage Power Coil resistance Current
Release ±10% Holding ±10% Brake release Holding
UL[V DC] UH[V DC] PN[W] PH[W] RN± 5% []I
L[A]
BFK455-28
103 52
2 x 434 2 x 108.5
2 x 24.5 2 x 4.21
205 103 2 x 97 2 x 2.12
360 180 2 x 298.6 2 x 1.21
Tab. 2: Coil power ratings of the BFK455-28
t1Engagement time t11 Reaction delay of engagement
t2Disengagement time (up to M = 0.1 Mdyn)t
12 Rise time of the braking torque
Mdyn Braking torque at a constant speed of rotation U Voltage

Technical specifications
INTORQ | BA 14.0196 | 04/2016 18
1) Minimum brake torque with run-in friction components at Δn=100 rpm
2) Typical values
3) Max. speed according to EC-type examination certificate (for higher speeds, consultation with the manufacturer is re-
quired)
4) Measured with induced voltage limitation of -800 V DC
Engagement time
The transition from a brake-torque-free state to a holding-braking torque is not free of time lags.
For emergency braking, short engagement times for the brake are absolutely essential. The DC switching in
connection with a suitable spark suppressor must therefore be provided.
❚The engagement times apply for DC switching with a spark suppressor.
- Spark suppressors are available for the rated voltages.
- Connect the spark suppressors in parallel to the contact. If this switching is not admissible for safety
reasons (e.g. with hoists and lifts), the spark suppressor can also be connected in parallel to the
brake coil.
- Circuit proposals: 36
❚If the drive system is operated with a frequency inverter so that the brake will not be de-energised before
the motor is at standstill, AC switching is also possible (not applicable to emergency braking).
Disengagement time
The disengagement time is the same for DC and AC switching. The specified disengagement times always
refer to control using over-excitation.
Type Rated torque1) Max.
permitted
switching
energy
Transitional
switching
frequency
Switching times [ms]2)
at sLN and 0.7 IN
Max. speed3)
MKQEShue Engaging DC side4) Disengaging
[Nm] [J] [1/h] t11 t12 t1t2
nmax.
[rpm]
BFK455-28
2 x 1100
360000 7
80
220
300 370 455
2 x 1200 60 280 255
2 x 1700 20 240 480 455
2 x 1800
2 x 2065 30 250 460 255
Tab. 3: Switching energy - switching frequency - switching times
NOTICE
If the brake is using AC-side switching, the engagement times increase approximately by a fac-
tor of 5 (refer to 35 for connection).

Technical specifications
INTORQ | BA 14.0196 | 04/2016 19
3.4 Switching energy / switching frequency
Fig. 3 Switching energy as a function of the switching frequency
The permissible switching frequency Shmax depends on the amount of heat QR(refer to Figure 3). At a pre-
set switching frequency Sh, the permissible amount of heat is QSmax.
With high speeds of rotation and switching energy, the wear increases strongly, because very high temper-
atures occur at the friction surfaces for a short time.
AA Switching energy Q [J] BSwitching frequency Sh[1/h]
Shmax
Shue –
ln 1
QR
QE
---------
–



--------------------------------=Qsmax QE1e
Shue –
Sh
-------------------
–







=

Technical specifications
INTORQ | BA 14.0196 | 04/2016 20
3.5 Emissions
Electromagnetic compatibility
If an INTORQ rectifier is used for the DC switching of the spring-applied brake: If the switching frequency
exceeds five switching operations per minute, the use of a mains filter is required.
If the spring-applied brake uses a rectifier from another manufacturer for the switching, it may become nec-
essary to connect a spark suppressor in parallel with the AC voltage. Spark suppressors are available on
request, depending on the coil voltage.
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. Un-
der unfavourable conditions, the surface temperature can reach 130 °C.
Noise
The switching noise during engagement and disengagement varies depending on the air gap, braking torque
and brake size.
Depending on the natural oscillation after installation, operating conditions and state of the friction surfaces,
the brake may squeak during braking.
Miscellaneous
The abrasion of the friction parts produces dust.
NOTICE
The user must ensure compliance with EMC Directive 2014/30/EU using appropriate controls
and switching devices.