INTORQ BFK455-28 Quick guide

www.intorq.com
setting the standard
www.intorq.com
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.