INTORQ BFK455 User manual

INTORQ BFK455
j
setting the standard
Operating Instructions
www.intorq.com
Electromagnetically released spring-applied brake

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This documentation applies to ...
BFK455-28 - double-disk version
BFK455-001.iso/dms BFK455-020.iso/dms
Product key
Product key INTORQ BFK  -




Legend for the INTORQ BFK455 product key
Product group Brakes
Product type Spring-applied brake
Type 455
Size 28
Not coded: supply voltage, hub bore, options

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Identification
Package label Example
Manufacturer Bar code
Type (see product key) Type No.
Name Quantity per box
Rated voltage Rated torque Packing date
Rated power Hub diameter
Additional information CE designation
BFK455-101.iso/dms
Nameplate Example
Manufacturer
Type (see product key) CE designation
Rated voltage Rated power Hub diameter
Type No. Rated torque Production date
BFK455-002.iso/dms
Notes
The brake is marked with the following labels, which have to be observed:
for holding voltage for air gap setting
Document history
Material number Version Description
33000803 1.0 05/2011 TD09 First edition
33000803 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 hand-release installation
Tables of dimensions and operating times were changed
Amendment of the spare parts list and the spare parts order
33002468 3.0 05/2013 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
0Fig. 0Tab. 0

Contentsi
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1 Preface and general information 6.......................................
1.1 About these Operating Instructions 6...................................
1.2 Terminology used 6.................................................
1.3 Conventions used 6.................................................
1.4 Abbreviations used 7................................................
1.5 Notes used 8......................................................
1.6 Scope of supply 9..................................................
1.7 Disposal 9........................................................
1.8 Drive systems 9....................................................
1.9 Legal regulations 10.................................................
2 Safety instructions 11...................................................
2.1 General safety information 11..........................................
2.2 Application as directed 12............................................
3Technicaldata 13.......................................................
3.1 Product description 13...............................................
3.2 Rated data 16......................................................
3.3 Rated data (selection data) 17.........................................
3.4 Friction work / operating frequency 19..................................
3.5 Emission 20.......................................................
4 Mechanical installation 21................................................
4.1 Important notes 21..................................................
4.2 Necessary tools 21..................................................
4.3 Mounting 21.......................................................
4.4 Installation 22......................................................
4.5 Manual release 28..................................................
4.6 Assembly of the cover ring 34..........................................
5 Electrical installation 35.................................................
5.1 Electrical connection 35..............................................
5.2 Bridge/half-wave rectifiers (option) 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.................................................

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7 Maintenance/repair 42..................................................
7.1 Wear of spring-applied brakes 42.......................................
7.2 Inspections 43......................................................
7.3 Maintenance operations 44............................................
7.4 Spare-parts list 46..................................................
7.5 Spare parts order 47................................................
8 Troubleshooting and fault elimination 48...................................

Preface and general information1
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1 Preface and general information
1.1 About these Operating Instructions
| These Operating Instructions will help you to work safely on and with the
spring-applied brake with electromagnetic release. They contain safety instructions
that must be followed.
| All persons working on or with the electromagnetically released spring-applied brakes
must have the Operating 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
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
components
1.3 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
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 = see page 16
Document reference Reference to another documentation with additional
information
For example: Operating instructions
Wildcard Wildcard for options, selections
For example: BFK458- = BFK458-10

Preface and general information1
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1.4 Abbreviations used
Abbreviation Unit Name
I A Current
IHA Holding current at 20 °C and holding voltage
ILARelease current at 20 °C and release voltage
INARated current at 20 °C and rated voltage
MANm Tightening torque of the fixing screws
MKNm Rated torque of brake, rated value at a relative speed of 100 rpm
nmax rpm Maximum speed during the slipping time t3
PHWCoil power during holding, through normal excitation and 20 °C
PLWCoil power during release, through normal excitation and 20 °C
PNWRated coil power at rated voltage and 20 °C
Q J Heat/energy
QEJMax. permissible friction work per switching cycle, thermal rating of
the brake
QRJBraking energy, friction work
QSmax JMax. permissible friction work during cyclic switching, depending on
the operating frequency
RNOhm Rated coil resistance at 20 °C
Sh1/h Operating frequency, the number of repeated operations per unit
time
Shue 1/h Transitional operating frequency, thermal rating of the brake
Shmax 1/h Maximum permissible operating frequency, depending on the
friction work per operation
sLmm Air gap, movement of armature plate by switching the brake
sLN mm Rated air gap
sLmin mm Minimum air gap
sLmax mm Maximum air gap
t1ms Engagement time, the total of the reaction delay and torque rise
time t1=t
11 +t 12
t2ms Disengagement time, time from switching the stator until the torque
has reduced to 0.1 MK
t11 ms Slipping time to standstill (after t11)
t11 ms Delay time when connecting, time from disconnecting the
voltage until the torque begins to rise
t12 ms Rise time of braking torque, time from beginning of rise of torque
until braking torque is reached
tue SOverexcitation time
U V Voltage
UHVDC Holding voltage by change of voltage
ULVDC Release voltage by change of voltage
UNVDC Rated coil voltage for brakes which require automatic voltage
changing, the rated coil voltage Urated isthesameastherelease
voltage UL

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1.5 Notes used
The following pictographs and signal words are used in this documentation to indicate dangers
and important information:
Safety instructions
Structure of safety instructions:
Danger!
Characterises 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.
Pictograph and signal word Meaning
Danger!
Danger of personal injury through dangerous electrical voltage
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Danger!
Danger of personal injury through a general source of danger
Reference to an imminent danger that may result in death or serious
personal injury if the corresponding measures are not taken.
Stop!
Danger of property damage
Reference to a possible danger that may result in property damage if the
corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
Note! Important note to ensure troublefree operation
Tip! Useful tip for simple handling
Reference to another documentation

Preface and general information1
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1.6 Scope of supply
After receipt of the delivery, check immediately whether it corresponds to the accompanying
papers. INTORQ does not grant any warranty for deficiencies claimed subsequently.
| Claim visible transport damage immediately to the forwarder.
| Claim visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG.
1.7 Disposal
The spring-applied brake consists of different types of material.
| Recycle metals and plastics.
| Ensure professional disposal of assembled PCBs according to applicable
environmental regulations.
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
| The spring-applied INTORQ brakeis also delivered in single modules and individually
combined to its modular design. The data - package labels, nameplate, and type code
in particular - apply to one complete stator.
| If single modules are delivered, the labelling is missing.

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1.9 Legal regulations
Liability
| The information, data and notes in this documentation met the state of the art at the
time of printing. Claims referring to products which have already been supplied cannot
be derived from the 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 working on and with the product
– operating faults
– disregarding the documentation
Warranty
| Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG.
| Warranty claims must be made to INTORQ immediately after detecting defects or
faults.
| The warranty is void in all cases where liability claims cannot be made.

Safety instructions2
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2 Safety instructions
2.1 General safety information
| INTORQ components ...
– ... must only be applied as directed.
– ... must not be commissioned if they are noticeably damaged.
– ... must not be technically modified.
– ... must not be commissioned if they are mounted and connected incompletely.
– ... must not be operated without the required covers.
– ... can hold live 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.
| All specifications of the corresponding enclosed documentation must be observed.
This is vital for a safe and trouble-free operation and for achieving the specified product
features.
| Only qualified, skilled personnel are permitted to work on and with INTORQ
components.
In accordance with 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.
|Riskofburns!
– 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 by no means have contact to oil or
grease since even small amounts reduce the brake torque considerably.
| The brake is designed for operation under the environmental conditions that apply to
IP54. Because of the numerous possibilities of using the brake, it is however necessary
to check the functionality of all mechanical components under the corresponding
operating conditions.

Safety instructions2
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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 shall be deemed inappropriate!
Possible applications of the INTORQ spring-applied brake
| Humidity: no restrictions
– In case of formation of condensed water and moisture: 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 armature plate and rotor from freezing.
| Protect electrical connections against contact.

Technical data3
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3Technicaldata
3.1 Product description
Versions
Basic module
BFK455-005.iso/dms
Fig. 1 Design of a BFK455 spring-applied brake
1.1 Stator 3 Complete rotor 6 Flange
1.2 Compression springs 4 Hub 8 Coil
2Armatureplate 5Shaft 13Coverring
3.1.1 General information
The spring-applied brake is designed for the conversion of mechanical work and kinetic energy
into heat. Due to the static brake torque, the brake can hold loads without speed difference.
Emergency braking is possible at high speed. The more friction work, the higher the wear,
(operating speeds 16).
The BFK455 spring-applied brake is a double disc brake with four friction surfaces. The braking
torque is generated within two electrically and mechanically separated braking circuits by
means of several compression springs (1.2) with friction locking. The braking circuits are
released electromagnetically. Due to its division into two braking circuits, the brake is
especially suitable for applications in the fields of lift technology and stage machinery. The
brake is selected on the basis of the characteristic torque for one braking circuit. The second
braking circuit meets the requirement for redundancy.
The braking circuits are divided by two separate armature plates (2) with the respective
compression springs (1.2) assigned and electromagnetic coils (8). The separate connecting
cables for each stator and armature plate render it possible to switch each braking circuit
individually, 36.

Technical data3
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The switching status of the spring-applied brake is monitored by one microswitch (16) for each
braking circuit. The associated switchgear rectifies the supply voltage (AC voltage) which is
reduced after a short time while the brake is in the released state. Thus the mean electrical
power of the brake is reduced.
The stator (1) is designed in temperature class F. The temperature limit of the coils (8) is
155 °C. The BFK455 spring-applied brake is designed for a maximum operating time of 60 %
with a reduction of the holding current.
Certificate
Type Characteristic torque [Nm] EC type-examination certificate
BFK455-28
2 x 1100, 2 x 1200
ABV 881/1
2 x 1700, 2 x 1800
2 x 2065
3.1.2 Braking
During braking, the rotor (3), which is axially movable on the hub (4), is pressed against
the friction surface - via the armature plates (2) - by means of the springs (1.2). The
asbestos-free friction linings ensure a high braking torque with low wear. The braking
torque is transmitted between hub (4) and rotor (3) via the splines.
3.1.3 Brake release
In braked state, there is an air gap ”sL” between the stator (1) and the armature plate (2). To
release the brake, the coil of the stator (1) is excited with the DC voltage provided. The
magnetic force generated attracts the armature plate (2) towards the stator (1) against the
spring force. The rotor (3) is then released and can rotate freely.
3.1.4 Release monitoring
The spring-applied brake is equipped with one microswitch (16) each per braking circuit
for monitoring the switching status. When the braking circuits are released, the
microswitches (16) change over. This means that the operation of the drive against the
applied brake can be excluded. The microswitches can be connected both as NO and NC
contacts.
For checking the correct functioning of the microswitches, we recommend to check the
switching status (see Tab. 6) both when the brake is released and when the brake is
applied.
3.1.5 Encapsulated design (optional)
This design not only avoids the penetration of spray water and dust, but also the spreading
of abrasion particles outside the brake. This is achieved by:
| a cover seal over the armature plate and rotor.

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3.1.6 Project planning notes
| The brakes are dimensioned in such a way that the given characteristic torques are
reached safely after a short run-in process.
| Due to the fluctuating properties of the organic friction linings used and the alternating
environmental conditions, deviations of the given braking torques may occur. These
must be considered by corresponding safety measures in the dimensioning process.
Especially with humidity and alternating temperatures, an increased breakaway torque
may occur after a long downtime.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.

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3.2 Rated data
3.2.1 Dimensions
BFK455-006.iso/dms
Type Character
istic
torque
Air gap Perm. wear Rotor thickness Mass
of 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
+1.0 mm
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
Stop!
| The minimum thread depth of the end shield must be observed in any case,
Tab. 1
| If the required thread depth is not observed, the fixing screws may run into
the thread root. As a result, the required preload force will no longer be built
up and the brake will no longer be fixed securely!

Technical data3
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3.2.2 Electrical data
Type Voltage Power Coil
resistance
Current
Release ±10% Holding ±10% Release Holding
UL[V] DC UH[V] DC PN[W] PH[W] RN±5% [Ω] IL[A]
BFK455-28
103 52 2 x 434 2 x 108.5 2 x 24.5 2 x 4.21
205 103 2 x 434 2 x 108.5 2x97 2 x 2.12
360 180 2 x 434 2 x 108.5 2 x 298.6 2 x 1.21
Tab. 2 Coil power ratings of the BFK455-28
3.3 Rated data (selection data)
BFKXXX-011.iso/dms
Fig. 2 Operating times of the spring-applied brakes
t1Engagement time t11 Reaction delay during engagement
t2Disengagement time (up to M = 0.1 Mr)t
12 Rise time of the brake torque
MKCharacteristic torque U Voltage
Type Rated torque 1) Max. perm.
switching
energy
Transition
operating
frequency
Operating times [ms] 2)
at sLN and 0.7 IN
Max. speed 3)
MKQE Shue DC engagement 4) Disengage
[Nm] [J] [h-1]
t11 t12 t1t2nmax.
[rpm]
BFK455-28
2 x 1100
360000 7
80
220
300
370
455
2 x 1200 60 280
2 x 1700
20 240 480
2 x 1800
2 x 2065 30 250 460
1) Minimum brake torque when all components are run in with Δn=100 rpm
2) Typical values
3) Max. speed according to EC type-examination certificate (for higher speeds contact the manufacturer)
4) Measured with induced voltage limitation -800 V DC
Tab. 3 Switching energy - operating frequency - operating times

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Engagement time
The transition from brake-torque free state to holding braking torque is not free of time lags.
Short brake engagement times are vital for emergency braking. DC switching together with
a suitable spark suppressor must therefore be provided.
| The engagement times are valid 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 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
deenergised before the motor is at standstill, AC switching is also possible (not
applicable to emergency braking).
Note!
If the drive system is equipped with a frequency inverter, the engagement times
are greater by a factor of 5, approximately, connection 35.
Disengagement time
The disengagement time is the same for DC and AC switching. The disengagement times
specified always refer to the control with overexcitation.

Technical data3
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3.4 Friction work / operating frequency
BFK455-003.iso/dms
Fig. 3 Switching energy as a function of the operating frequency
pÜã~ñ =−pÜìÉ
äå N−no
nbnëã~ñ =nbN−É
−pÜìÉ
pÜ
The permissible operating frequency Shmax depends on the quantity of heat QR(see Fig. 3).
If the operating frequency Shis specified, the permissible quantity of heat Qsmax will result.
With high speed and friction work, the wear increases strongly, because very high
temperatures occur at the friction faces for a short time.

Technical data3
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3.5 Emission
Electromagnetic compatibility
Note!
The user must ensure compliance with EMC Directive 2004/108/EC using
appropriate controls and switching devices.
If an INTORQ rectifier is used for the DC switching of the spring-applied brake and if the
operating frequency exceeds five switching operations per minute, the use of a mains filter
is required.
If the spring-applied brake uses a rectifier of another manufacturer for the switching, it
may become necessary 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. Under unfavourable conditions, the surface temperature can reach
130 _C.
Noise
The switching noise during engagement and disengagement varies depending on the air gap
”sL” and the brake size.
Depending on the natural oscillation after installation, operating conditions and state of the
friction faces, the brake may squeak during braking.
Others
The abrasion of the friction parts produces dust.