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

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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.