INTORQ BFK455-25 Quick guide

INTORQ BFK455-25
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
setting the standard
www.intorq.com

Document history
Material number Version Description
33008102 1.0 07/2019 SC First edition
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 in-
formation, illustrations and descriptions.
¾
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
Notice
The warranty conditions can be found in the terms of sale and delivery from INTORQ
GmbH & Co. KG.
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Warranty claims must be made to INTORQ immediately after the defects or faults are detected.
¾
The warranty is void in all cases when liability claims cannot be made.
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Spring-applied brakes of type BFK455-25
Version without hand-release Version with hand-release
Product key
Product group: Brakes
Product family: Spring-applied brake
Type: 455
Size: 25
INTORQ B FK
Not coded: Connection voltage, hub bore hole, options
Checking the 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.
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Claim visible transport damage immediately to the deliverer.
¾
Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.
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Contents
Spring-applied brakes of type BFK455-25............................................................................................................... 3
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............................................................................................................................................... 8
2 Safety instructions................................................................................................................................................... 10
2.1 General safety instructions................................................................................................................................. 10
2.2 Disposal ............................................................................................................................................................. 10
3 Product description ................................................................................................................................................. 11
3.1 Proper and intended usage................................................................................................................................ 11
3.1.1 Standard applications ............................................................................................................................ 11
3.2 Layout ................................................................................................................................................................ 11
3.2.1 Basic module ......................................................................................................................................... 12
3.3 Function ............................................................................................................................................................. 12
3.4 Braking and release ........................................................................................................................................... 13
3.5 Release monitoring ............................................................................................................................................ 13
3.6 Project planning notes........................................................................................................................................ 13
3.7 Optional configuration ........................................................................................................................................ 13
3.7.1 Hand-release (optional) ......................................................................................................................... 13
3.7.2 Optional encapsulated design ............................................................................................................... 13
4 Technical specifications.......................................................................................................................................... 14
4.1 Possible applications of the INTORQ spring-applied brake ............................................................................... 14
4.2 Rated data.......................................................................................................................................................... 14
4.3 Switching times .................................................................................................................................................. 16
4.4 Friction work / operating frequency .................................................................................................................... 18
4.5 Electromagnetic compatibility............................................................................................................................. 19
4.6 Emissions........................................................................................................................................................... 19
4.7 Labels on product............................................................................................................................................... 20
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5 Mechanical installation............................................................................................................................................ 22
5.1 Design of end shield and shaft........................................................................................................................... 22
5.2 Tools .................................................................................................................................................................. 23
5.3 Preparing the installation.................................................................................................................................... 23
5.4 Installing the hub onto the shaft ......................................................................................................................... 24
5.5 Brake mounting .................................................................................................................................................. 25
5.6 Cover ring assembly .......................................................................................................................................... 30
5.7 Mounting the hand-release (retrofitting) ............................................................................................................. 31
6 Electrical installation ............................................................................................................................................... 37
6.1 Electrical connection .......................................................................................................................................... 38
6.2 Bridge/half-wave rectifier (optional).................................................................................................................... 39
6.2.1 Assignment: Bridge/half-wave rectifier – brake size.............................................................................. 39
6.2.2 Technical specifications......................................................................................................................... 40
6.2.3 Permissible current load at ambient temperature.................................................................................. 40
7 Commissioning and operation ............................................................................................................................... 41
7.1 Function checks before initial commissioning .................................................................................................... 41
7.1.1 Brake with micro-switch......................................................................................................................... 41
7.2 Commissioning................................................................................................................................................... 42
7.3 During operation................................................................................................................................................. 42
8 Maintenance and repair........................................................................................................................................... 43
8.1 Wear of spring-applied brakes ........................................................................................................................... 43
8.2 Inspections ......................................................................................................................................................... 44
8.2.1 Maintenance intervals............................................................................................................................ 44
8.3 Maintenance....................................................................................................................................................... 44
8.3.1 Release / voltage................................................................................................................................... 45
8.3.2 Checking the air gap.............................................................................................................................. 45
8.3.3 Checking the rotor thickness ................................................................................................................. 46
8.3.4 Replacing the rotor ................................................................................................................................ 46
8.4 Spare parts list ................................................................................................................................................... 47
9 Troubleshooting and fault elimination................................................................................................................... 48
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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 Underscore, orange _____
Reference to another page with additional
information
For example: Conventions in use,Page6
Symbols
Wildcard □
Wildcard (placeholder) for options or selec-
tion details
For example: BFK455-25-□□ =
BFK455-25-10
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:

General information
INTORQ | BA 14.0215 | 07/2019 7
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 causes
List of possible consequences if the safety notices are disregarded.
Protective measures
List of protective measures required to avoid the danger.
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 com-
ponents

General information
INTORQ | BA 14.0215 | 07/2019 8
1.5 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 fastening 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
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
operating frequency
RmN/mm2Tensile strength
RNOhms Rated coil resistance at 20 °C
Rzμm Averaged surface roughness
Sh1/h Operating frequency: the number of switching operations evenly spread 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
sHL mm Air gap for hand-release
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 MK

General information
INTORQ | BA 14.0215 | 07/2019 9
Letter symbol Unit Designation
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
beginning of the torque rise)
t12 ms Rise time of the braking torque, time from the start of torque rise until reach-
ing the braking torque
tue s Overexcitation 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
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Never operate INTORQ components when you notice they are damaged.
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Never make any technical changes to INTORQ components.
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Never operate INTORQ components when they are incompletely mounted or incompletely connected.
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Never operate INTORQ components without their required covers.
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Only use accessories that have been approved by 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:
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Depending on the degree of protection, INTORQ components may have both live (voltage carrying),
moving and rotating parts. Such components require the appropriate safety mechanisms.
¾
Surfaces can become hot during operation. Take the 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 INTORQ components may only be carried out by quali-
fied 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 INTORQ components are made of various differing materials.
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Recycle metals and plastics.
¾
Ensure professional disposal of assembled PCBs according to the applicable environmental regula-
tions.