INTORQ BFK458 User manual

Spring-applied brake
INTORQ BFK458
The versatile modular system
2–600 Nm
setting the standard

2
INTORQ BFK458 - The modular system
Our modular system forms the basis for a product range that
offers versions tailored for almost any task. The BFK458
spring-applied brake, as a standard product, can be used
anywhere, but its modular structure also meets the
requirements of specific industries. Its strength lies in its
versatility.
Electromagnetically released spring-applied brakes are used
wherever masses in motion have to be decelerated as
quickly as possible or where masses must be held in a
defined position. The braking force is applied by
compression springs. Thus the braking torque generated by
friction locking remains available in the deenergised status –
even in the event of mains failure. The brake is released
electromagnetically.
The INTORQ BFK458 range replaces the 14.448/14.449
and 14.450 models of spring-applied brake. The main
components of the new modular system are the two basic
modules E (adjustable braking torque) and N (braking torque
not adjustable). The greatest degree of flexibility is achieved
for a broad range of applications by the combination of the
basic module with specific modules. This catalogue is
intended to help you to select and to order the spring-
applied brake you require quickly and easily.
The modular system for all applications
|Brake motors
|Cranes
|Storage technology
|Industrial trucks
|Wood working machines
|Stage machinery
|Vehicles for the disabled
|Automation technology
|Regulated drives
|Gate drives
|Escalators

3
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
Contents
Product key 4
List of abbreviations 5
Product information 6
Principle of operation 7
Example applications 8
Technical data
Braking torques 9
E/N + basic module 10
Flange + manual release
Brake module N + 11
centring flange
Basic module N + 12
Connection flange +
basic module N
Rated data 13
Operating times 14
Service life and wear 15
Accessories
Manual release/flange/ 16
friction plate
Centring flange/ 17
connection flange/Seal
Brake cover 18
Microswitch 19
Terminal box 20
Type code 21
Bridge rectifier and
half-wave rectifier BEG
Spark suppressor 21
INTORQ 14.198.00.O ò
Bridge rectifiers and 22
half-wave rectifiers BEG
Fastening options 25
Connection diagrams 26
Mains voltage selection table 27
Dimensioning
Basic information 28
Calculation example 29
Order form 30
Sales and service 32
around the world

4
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
INTORQ BFK458-òòò product key
Friction plate
Flange
Connection
flange
(double
brake)
Centring flange
(tacho flange)
Seal
Hub
Rotor
Complete stator
brake module N
Plug
Shaft
sealing ring
Complete stator
brake module E
Manual release
Sizes
06, 08, 10, 12, 14, 16, 18, 20, 25
Stator design
E – Adjustable (braking torque can be reduced using
torque adjustment ring)
N – Non-adjustable
Not coded:
Supply voltage, hub bore,
Options
BFK 4 5 8 - òò ò
Product group: Brakes
Product family: Spring-applied brakes
Type
Sizes
Design

5
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
List of abbreviations
P[kW] Drive power
MK[Nm] Rated torque of brake
ML[Nm] Load torque
Merf [Nm] Required braking torque
Ma[Nm] Deceleration torque
∆n0[rpm] Initial relative speed of the brake
JL[kgm2] Moment of inertia of all
driven parts, referred to the shaft
to be braked
t1[s] Engagement time, t1= t11 + t12
t2[s] Disengagement time (time from the
beginning of the torque drop until
0.1 MKis reached)
t3[s] Slipping time
(time during which a relative motion
occurs between the input and output,
with brake applied)
t11 [s] Delay time
(time from disconnecting the voltage until
the torque begins to rise)
t12 [s] Rise time of braking torque
KSafety factor
Q[J] Calculated friction energy per switching
cycle
Qzul [J] Maximum permissible friction energy per
switching cycle
Sh[h-1]Operating frequency, i.e. the number of
periodical brake operations
Slü Rated air gap

6
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
Product information
INTORQ BFK458 spring-applied brake
A powerful and complete range
|9 sizes
|Standard voltages 24 V, 96 V, 103 V, 170 V, 180 V, 190 V,
205 V
|Graduated torque range from 2 – 600 Nm
|Short delivery times for the complete range, thanks to
optimised logistics
|IP54 enclosure, depending on the particular operating
conditions
|CSA and UL over all sizes
|ATEX:
The product is suitable for use in potentially explosive
atmospheres in zone II for stationary operation (holding or
parking brake), explosion group II and temperature class
T4.
Versatile
|Modular structure for virtually all applications
|Interchangeable with brake models 14.448 and 14.450
Torque transmission
|Designed for dry running
Ready for operation immediately
|Preset air gap, quick and easy mounting
|Special machining of the friction surfaces ensures that the
rated torques are achieved after very few switching
operations
|No fixed bearing is required on the brake
Durable
|The insulation system to temperature class F (155°C)
ensures that the winding has a long service life
|These brakes are designed for 100% duty time (current
applied to the brake)
Low maintenance
|Long rotor/hub connection with low rate of wear and a
tried-and-tested involute gear
|Asbestos-free fiction linings with low rate of wear
|Air gap must be checked as a function of the friction
energy used
Reliable
|The quality assurance system is certified to ISO 9001 and
ISO 14001 and provides the basis for consistently high-
quality products
|Production and testing to VDE 0580
Options
|Manual release for all sizes, both directions can be used
for release and mounting (one exception is the tacho
brake)
|Noise-reduced design
|Various types of corrosion protection and enclosures
|Microswitches used to monitor air gap and
wear (size 12 and above)
|Monitoring of manual release function (page 19)
|Non-standard voltages and bores on request

7
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
INTORQ BFK458 spring-applied brake
6
1
5
4
3
9
Principle of operation
INTORQ BFK458 spring-applied brakes are single-disc
brakes with two friction surfaces. When a de-energised,
several compression springs are used to generate the
braking torque through friction locking. The brake is
released electromagnetically. During the braking procedure,
the rotor (3), which can be shifted axially on the hub (4), is
pressed against the counter friction face (6) via the
armature plate (1), by means of the compression springs (2).
When the brakes are applied, an air gap slü is present
between the armature plate and the stator (7). The stator's
coil is energised with DC voltage in order to release the
brake.
The resulting magnetic flux works against the spring force to
draw the armature plate to the stator. This releases the rotor
from the spring force and allows it to rotate freely. Brake
module E supports the use of the torque adjustment ring (8)
to reduce the braking torque.
Brake module E + rotor + hub + flange
7
2
8
Brake module N + rotor + hub
1
3
4
2
9
7
1=Armature plate
2=Compression springs
3=Rotor
4=Hub
5=Shaft
6=Flange
7=Stator
8=Torque adjustment ring
9=Sleeve bolts
slü = Air gap
slü
slü

8
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
Example applications
INTORQ BFK458 spring-applied brake
Rotate, lift, move – whenever cranes are in motion,
INTORQ spring-applied brakes are never far away
Corrosion resistant designs and various sealing variants for
spring-applied brakes in cranes.
INTORQ opens and closes gates and doors
Spring-applied brakes with manual release monitoring via
microswitches and electromagnetic clutches ensure safe
operation of door drives and automatic doors.
Curtain up for INTORQ brakes
A silenced version of the double spring-applied brake is used
in the theatre as a redundant braking system.

9
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
Size 06 08 10 12 14 16 18 20 25
80 E
1.5 E 3.5 N/E 25 N/E 35 N/E 65 N/E 115 N/E 175 N/E
2 N/E 4 E 7 N/E 14 N/E 35 N 45 N/E 80 N/E 145 N/E 220 N
2.5 N/E 5 N/E 9 N/E 18 N/E 40 N/E 55 N/E 100 N/E 170 N/E 265 N/E
3 N/E 6 N/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 7 N/E 14 N/E 27 N/E 55 N/E 70 N/E 130 N/E 230 N/E 350 N/E
4 N/E 8 N/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 9 N/E 18 N/E 36 N/E 65 N/E 90 N/E 165 N/E 290 N/E 445 N/E
5 E 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
6 N/E 12 N/E 125 N/E 235 N/E 400 N/E 600 N/E
Size 06 08 10 12 14 16 18 20 25
Torque reduction
per detent position [Nm] 0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2
Technical data
Braking torques
Holding brake with emergency stop
(slümax approximately 1.5 x slü)
Service brake
(slümax approximately 2.5 x slü)
Standard braking torque
Depending on the individual application, the graduated
torques listed in the tables below are available. A pole shim
(brass film) must be placed between the stator and the
Brake module E, reduced braking torque
The braking torque on brake module E can be reduced
using the torque adjustment ring located in the stator.
The torque adjustment ring can be unscrewed to a
maximum dimension of h1max (see table on page 10).
It should be noted that the engagement and disengagement
times change in accordance with the braking torque. Torque
reduction is independent of the rated torque used.
| N ... Braking torque for design N (without torque adjustment ring)
| E ... Braking torque for design E (with torque adjustment ring)
Characteristic torques [Nm],
related to the relative speed
∆n = 100 rpm
armature plate if you want to achieve short operating times
with low torques.

10
INTORQ IINTORQ BFK458 spring-applied brake Ien 3/2007
Size h h1h1h2h3h4h5h57) h6h7h8h9ll
15) slü
ab
6)
min. max. standard max.
06 36.3 39.3 43.25 1 6 15.8 107 – 54.5 23 32.8 56.3 18 400 0.2 25° 12°
08 42.8 46.8 50.8 1.5 7 16.3 116 – 63 23 41.3 65 20 400 0.2 25° 10°
10 48.4 52.4 55.9 2 9 27.4 132 – 73.8 23 42.4 77.8 20 400 0.2 25° 9°
12 54.9 58.9 67.53 2 9 29.4 161 – 85 23 47.4 88.5 25 400 0.3 25° 10°
14 66.3 71.3 77.3 2 11 33 195 – 98 32 50 101.5 30 400 0.3 25° 9°
16 72.5 77.5 85.5 2.25 11 37.5 240 – 113 32 53.5 116 30 600 0.3 25° 10°
18 83.1 89.1 97.09 2.75 11 41.1 279 394 124 32 59.1 128.5 35 600 0.4 25° 9°
20 97.6 104.6 114.6 3.5 11 47.6 319 416 146 32 68.6 149.5 40 600 0.4 25° 10°
25 106.7 115.7 127.7 4.5 12.5 57.7 445 501 170 32 88.7 175.5 50 600 0.5 25° 10°
Size b dJ7 1) dH7 2) d1d2d3H7 d5d6j7 d7d8d9H8 d10 d11 d12 d13 d143) d153) d16 di da
spec. standard
06 88 10 10/11/12/14/15 3xM4 72 25 91 87 87 52 24 31 8 13 9.6 4xM4 37.7 3x4.5 40 60
08 106.5 10 11/12/14/15/20 3xM5 90 32 109 105 105 60 26 41 8 13 9.6 4xM5 49 3x5.5 47 77
10 132 10 11/12/14/15/20 3xM6 112 42 134 130 130 68 35 45 10 13 12 4xM5 54 3x6.6 66 95
12 152 14 20/25 3xM6 132 50 155 150 150 82 40 52 10 13 12 4xM5 64 3x6.6 70 115
14 169 14 20/25/30 3xM8 145 60 169 165 165 92 52 55 12 24 14 4xM6 75 3x9 80 124
16 194.5 15 25/30/35/38* 3xM8 170 68 195 190 190 102 52 70 12 24 14 4xM6 85 3x9 104 149
18 222 20 30/35/40/45 6xM8 196 75 222 217 217 116 62 77 14 24 15.5 4xM8 95 4x94) 129 174
20 258 25 35/40/45/50 6xM10 230 85 259 254 254 135 72 90 14 24 16.5 4xM10 110 4x114) 148 206
25 302 30 40/45/50/55/60/65/70* 6xM10 278 115 307 302 302 165 85 120 16 24 18.4 4xM10 140 6x11 199 254
slü
Thickness of friction plate: 1.5 mm
(sizes 06-16)
|1) pre-drilled without keyway
|2) Standard keyway in accordance with DIN 6885/1 P9, selection of the shaft diameter
depending on the type of loading (see Operating Instructions)
|* Ø 38 and Ø 70 mm, keyway in accordance with DIN 6885/3 P9
|3) Bores are made on customer request for sizes 06–12
|4) The thread in the mounting surface is offset by 30° in relation to the centre axle of the
manual release lever
|Dimensions in mm
|5) Length of the connecting cable
|6) Manual release angle tolerance +3°
|7) Recommended lever length for 1.5 MK
|Recommended ISO shaft tolerances: up to Ø 50 mm = k6
over Ø 50 mm = m6
Technical data
Brake module E/N + flange + manual release