INTORQ BFK458 Quick guide

INTORQ BFK458 for NORD Drivesystems
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
www.kendrion.com

Document history
Material number Version Description
33009766 1.0 09/2021 SC First edition for the series
33009766 2.0 05/2022 SC Update of chapters 4.2 and 4.3
Assignments for brake designations
NORD Drive Systems Kendrion INTORQ
BRE 5Nm ≙BFK 458-06
BRE 10Nm ≙BFK 458-08
BRE 20Nm ≙BFK 458-10
Tab.1: Table assigning brake designations of NORD Drive Systems to Kendrion INTORQ
Legal regulations
Liability
¾
The information, data and notes in these Operating Instructions are up to date at the time of printing.
Claims referring to drive systems which have already been supplied cannot be derived from this infor-
mation, illustrations and descriptions.
¾
We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorized modifications to the product
– improper work on or with the product
– operating errors
– disregarding the documentation
Warranty
Notice
The warranty conditions can be found in the terms and conditions of Kendrion INTORQ
GmbH.
¾
Warranty claims must be made to Kendrion INTORQ immediately after the defects or faults are de-
tected.
¾
The warranty is void in all cases when liability claims cannot be made.
Kendrion INTORQ | BA 14.0225 | 05/2022 2

Spring-applied brakes of type BFK458-06...10
Design E Design N
Product key
Product group: Brakes
Product family: Spring-applied brake
Type: 458
Size: 06, 08, 10
Design/type:
E - adjustable (brake torque can be reduced via torque adjustment ring)
N - not adjustable
B FKINTORQ
Not coded: Connection voltage, hub bore diameter, options
Checking the delivery
After receipt of the delivery, check immediately whether the items delivered match the accompanying pa-
pers.
Kendrion INTORQ does not accept any liability for deficiencies claimed subsequently.
¾
Claim visible transport damage immediately to the deliverer.
¾
Claim visible defects or incompleteness of the delivery immediately to Kendrion INTORQ.
Kendrion INTORQ | BA 14.0225 | 05/2022 3

Contents
1 General information....................................................................................................................................................6
1.1 Using these Operating Instructions.......................................................................................................................6
1.2 Conventions in use ...............................................................................................................................................6
1.3 Safety instructions and notices .............................................................................................................................6
1.4 Terminology used .................................................................................................................................................7
1.5 Abbreviations used ...............................................................................................................................................7
2 Safety instructions .....................................................................................................................................................9
2.1 General safety instructions ...................................................................................................................................9
2.2 Disposal................................................................................................................................................................9
3 Product description..................................................................................................................................................10
3.1 Proper and intended usage ................................................................................................................................10
3.1.1 Standard applications.............................................................................................................................10
3.1.2 Applications with special safety requirements ("Safety Brake") .............................................................10
3.2 Design.................................................................................................................................................................12
3.2.1 Basic module E ......................................................................................................................................12
3.2.2 Basic module N ......................................................................................................................................13
3.3 Function..............................................................................................................................................................13
3.4 Braking and release............................................................................................................................................14
3.5 Project planning notes ........................................................................................................................................14
3.6 Brake torque reduction .......................................................................................................................................14
3.7 Optional configuration.........................................................................................................................................14
3.7.1 Hand-release (optional)..........................................................................................................................14
4 Technical specifications ..........................................................................................................................................15
4.1 operating range for the Kendrion INTORQ spring-applied brake .......................................................................15
4.2 Brake torques .....................................................................................................................................................16
4.3 Characteristics....................................................................................................................................................17
4.4 Switching times...................................................................................................................................................20
4.5 Friction work / operating frequency.....................................................................................................................22
4.6 Electromagnetic compatibility .............................................................................................................................23
4.7 Emissions ...........................................................................................................................................................23
4.8 Hand-release ......................................................................................................................................................24
4.9 Labels on product ...............................................................................................................................................24
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5 Mechanical installation ............................................................................................................................................26
5.1 Design of end shield and shaft ...........................................................................................................................26
5.2 Tools...................................................................................................................................................................27
5.3 Preparing the installation ....................................................................................................................................27
5.4 Installing the hub onto the shaft..........................................................................................................................28
5.5 Mounting the brake.............................................................................................................................................29
5.6 Installing the friction plate (optional) ...................................................................................................................32
5.7 Cover ring assembly ...........................................................................................................................................33
5.8 Mounting the hand-release (retrofitting)..............................................................................................................34
6 Electrical installation................................................................................................................................................35
6.1 Electrical connection...........................................................................................................................................35
6.2 AC switching at the motor – extremely delayed engagement.............................................................................36
6.3 DC switching at the motor – fast engagement....................................................................................................37
6.4 AC switching at mains – delayed engagement...................................................................................................38
6.5 DC switching at mains – fast engagement .........................................................................................................39
6.6 Minimum bending radius for the brake connection cable ...................................................................................40
7 Commissioning and operation ................................................................................................................................41
7.1 Possible applications of the Kendrion INTORQ spring-applied brake ................................................................41
7.2 Function checks before initial commissioning.....................................................................................................42
7.2.1 Function check of the brake ...................................................................................................................42
7.2.2 Release / voltage control........................................................................................................................42
7.2.3 Testing the hand-release functionality....................................................................................................43
7.3 Commissioning ...................................................................................................................................................44
7.4 Operation............................................................................................................................................................44
7.4.1 Brake torque reduction (for the optional adjustable braking torque) ......................................................45
8 Maintenance and repair............................................................................................................................................46
8.1 Wear of spring-applied brakes............................................................................................................................46
8.2 Inspections..........................................................................................................................................................47
8.2.1 Maintenance intervals ............................................................................................................................47
8.3 Maintenance .......................................................................................................................................................48
8.3.1 Brake testing ..........................................................................................................................................48
8.3.2 Checking the air gap ..............................................................................................................................48
8.3.3 Release / voltage....................................................................................................................................49
8.3.4 Adjusting the air gap...............................................................................................................................49
8.3.5 Checking the rotor thickness..................................................................................................................50
8.3.6 Replacing the rotor.................................................................................................................................50
8.4 Spare parts list....................................................................................................................................................51
9 Troubleshooting and fault elimination....................................................................................................................52
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General information
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1 General information
1.1 Using these Operating Instructions
¾
These Operating Instructions will help you to work safely with the spring-applied brake with electro-
magnetic release. They contain safety instructions that must be followed.
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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.
¾
The Operating Instructions must always be in a complete and perfectly readable condition.
1.2 Conventions in use
This document uses the following styles to distinguish between different types of information:
Spelling of numbers Decimal separator Point The decimal point is always used. For ex-
ample: 1234.56
Page reference Underlined, red _____
Reference to another page with additional
information
For example: Using these Operating In-
structions,Page6
Symbols
Wildcard □
Wildcard (placeholder) for options or selec-
tion details
For example: BFK458-□□ = BFK458-10
Notice Important notice about ensuring smooth op-
erations or other key information.
1.3 Safety instructions and notices
The following icons and signal words are used in this document to indicate dangers and important safety
information:
Structure of safety notices:
CAUTION
Icon
Indicates the type of danger
Signal word
Characterizes the type and severity of danger.
Notice text
Describes the danger.
Possible consequences
List of possible consequences if the safety notices are disregarded.
Protective measures
List of protective measures required to avoid the danger.

General information
Kendrion INTORQ | BA 14.0225 | 05/2022 7
Danger level
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or seri-
ous 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 sur-
rounding objects could be damaged.
1.4 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-
nents
1.5 Abbreviations used
Letter symbol Unit Designation
FRN Rated frictional force
F N Spring 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
M4Nm Torque that can be transmitted without slippage occurring (DIN VDE 0580)
MANm Tightening torque of fastening screws
Mdyn Nm Average torque from initial speed to standstill
MKNm Rated torque of the brake, rated value at a relative speed of rotation of 100 rpm

General information
Kendrion INTORQ | BA 14.0225 | 05/2022 8
Letter symbol Unit Designation
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
QEJMax. permissible friction energy for one-time switching, thermal parameter of
the brake
QRJ Braking energy, friction energy
QSmax JMaximally permissible friction energy for cyclic switching, depending on the op-
erating frequency
RNOhms Rated coil resistance at 20 °C
Rzμm Averaged surface roughness
Sh1/h Operating frequency: the number of switching operations evenly distributed
over the time unit
Shue 1/h Transition operating frequency, thermal parameter of the brake
Shmax 1/h Maximum permissible operating 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
t11 ms Delay during engagement (time from switching off the supply voltage to the be-
ginning 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 period
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,
UN equals UL

Safety instructions
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2 Safety instructions
2.1 General safety instructions
¾
Never operate Kendrion INTORQ components when you notice they are damaged.
¾
Never make any technical changes to Kendrion INTORQ components.
¾
Never operate Kendrion INTORQ components when they are incompletely mounted or incompletely
connected.
¾
Never operate Kendrion INTORQ components without their required covers.
¾
Only use accessories that have been approved by Kendrion INTORQ.
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Only use original spare parts from the manufacturer.
Keep the following in mind during the initial commissioning and during operation:
¾
Depending on the degree of protection, Kendrion INTORQ components may have both live (voltage
carrying), moving and rotating parts. Such components require appropriate safety mechanisms.
¾
Surfaces can become hot during operation. Take appropriate safety measures (to ensure contact/
touch protection).
¾
Follow all specifications and information found in the Operating Instructions and the corresponding
documentation. These must be followed to maintain safe, trouble-free operations and to achieve the
specified product characteristics.
¾
The installation, maintenance and operation of Kendrion INTORQ components may only be carried out
by qualified personnel. According to IEC 60364 and CENELEC HD 384, skilled personnel must be
qualified in the following areas:
– Familiarity and experience with the installation, assembly, commissioning and operation of the
product.
– Specialist qualifications for the specific field of activity.
– Skilled personnel must know and apply all regulations for the prevention of accidents, directives,
and laws relevant on site.
2.2 Disposal
The Kendrion INTORQ components are made of various differing materials.
¾
Recycle metals and plastics.
¾
Ensure professional disposal of assembled PCBs according to the applicable environmental regula-
tions.

Product description
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3 Product description
3.1 Proper and intended usage
3.1.1 Standard applications
Kendrion INTORQ components are intended for use in machinery and facilities. They may only be used
for purposes as specified in the order and confirmed by Kendrion INTORQ. The Kendrion INTORQ com-
ponents may only be operated under the conditions specified in these Operating Instructions. They may
never be operated beyond their specified performance limits. The technical specifications (refer to Techni-
cal specifications,Page15) must be followed to comply with the proper and intended usage. Any other
usage is consider improper and prohibited.
3.1.2 Applications with special safety requirements ("Safety Brake")
A safety certificate for the system must be provided in accordance with DIN EN ISO 13849 whenever the
Kendrion INTORQ spring-applied brakes are being used in applications that have special safety require-
ments. The BFK458-series brakes are suitable for use as service brakes, as holding brakes, and as hold-
ing brakes with emergency-stop functionality for safety applications. The safety characteristics of the
safety brake apply to systems that are designed so that 80% of the characteristic torque of the brake is
sufficient for the safety function. The selected characteristic torque of the brake must, at a minimum, com-
ply with the standard braking torque in order to meet the high safety requirements.
Please note the following conditions:
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Proper and intended usage of the brake as described in Standard applications,Page10
¾
Compliance with the installation specifications in these Operating Instructions
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The following points are important when mounting the brake with special safety requirements:
– The material and the surface quality of the counter friction surface are listed in the table "End shield
as counter friction surface", in the chapter Design of end shield and shaft,Page26.
– To attach the brake to the motor end shield, use screws of strength class 8.8 which are capable of
handling the tightening torque listed in the table Rated data: Screw set for brake mounted on mo-
tor / friction plate,Page17.
– The fastening screws should be tightened evenly using a standard torque wrench, with a tightening
torque tolerance of +/- 10%.
– The following values apply for the minimum screw-in depths:
Steel: 1.0 x thread diameter
Cast aluminum: 1.5 x thread diameter
– When determining the possible screw-in depths of the fastening screws into the motor flange, the
max. adjustment (according to the table Characteristics for air gap specifications,Page17) and
the projection of the screws when the brake is new must be taken into account.
– The recommended dimensions of the screws and the screw-in depth (including the adjustment re-
serve for rotor wear) into the mounting holes in the motor flange can be found in the table Rated
data: Screw set for brake mounted on motor / friction plate,Page17.