INTORQ BFK458 User manual

INTORQ BFK458
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
setting the standard
www.intorq.com

Document history
Material number Version Description
405520 1.0 08/1998 TD09 First edition for the series
405520 1.1 05/2000 TD09
Address revision
Changed values of brake torques in table 1 and table 3
Added switching times to table 4
460730 2.0 11/2002 TD09
All chapters: Complete editorial revisions, renaming
Changed values of brake torques
Drawing changes to Figures 12, 13, 14, 15 and 16
New: Chapter 7.4 "Spare parts list for double spring-applied
brake"
13040626 2.1 02/2005 TD09 Changed company name to INTORQ
13284675 3.0 12/2008 TD09
Changed the tightening torques
Added to table 5
Revision of Chapter 3.5
Supplemented Chapters 7.1 and 7.2
13284675 3.1 01/2010 TD09 Changed the maintenance intervals for holding brakes with emer-
gency stop
13343893 4.0 07/2010 TD09 Changed values of the braking torques and rotation speeds (Table 3)
13343893 4.1 05/2012 TD09 Changed strength grade of the fastening screws
13343893 5.0 10/2013 TD09 Complete revision
13343893 6.0 09/2015 SC Restructured FM, harmonized connection diagrams, revised graphics
13343893 6.1 11/2015 SC Revision of Chapter 8.4 (Spare parts list)
13343893 7.0 02/2016 SC Update
13343893 8.0 03/2017 SC Update, extension to Project Planning Notes
13343893 8.1 07/2017 SC Added to Safety Brake
13343893 9.0 04/2018 SC Update, ST4 migration
13343893 10.0 05/2018 SC Holding brake in the ATEX zone, added to HFC
13343893 11.0 11/2018 SC Update
INTORQ | BA 14.0168 | 11/2018 2

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.
¾
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.
INTORQ | BA 14.0168 | 11/2018 3

Spring-applied brakes of type BFK458-06...25
Design E Design N
Double spring-applied brake
INTORQ | BA 14.0168 | 11/2018 4

Product key
Product group: Brakes
Product family: Spring-applied brake
Type: 458
Size: 06, 08, 10, 12, 14, 16, 18, 20, 25
Design/type:
E - adjustable (brake torque can be reduced via torque adjustment ring)
N - not adjustable
L – not adjustable, long-life design
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.
¾
Claim visible transport damage immediately to the deliverer.
¾
Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.
NOTICE
Labelling of drive systems and individual components
¾
Drive systems and components are unambiguously designated by the labelling on their
name plates.
¾
The spring-applied INTORQ brake is also delivered in single modules which can then be
put together by the customer according to their requirements. The specifications – particu-
larly the packaging label, name plate and type code – apply to a complete stator.
¾
The labelling is not included when components are delivered individually.
INTORQ | BA 14.0168 | 11/2018 5

Contents
1 General information................................................................................................................................................. 10
1.1 Using these Operating Instructions.................................................................................................................... 10
1.2 Conventions in use............................................................................................................................................. 10
1.3 Safety instructions and notices .......................................................................................................................... 10
1.4 Terminology used............................................................................................................................................... 11
1.5 Abbreviations used............................................................................................................................................. 12
2 Safety instructions................................................................................................................................................... 14
2.1 General safety instructions................................................................................................................................. 14
2.2 Disposal ............................................................................................................................................................. 14
3 Product description ................................................................................................................................................. 15
3.1 Proper and intended usage................................................................................................................................ 15
3.1.1 Standard applications............................................................................................................................ 15
3.1.2 Applications with special safety requirements ("Safety Brake")............................................................. 15
3.2 Layout ................................................................................................................................................................ 16
3.2.1 Basic module E...................................................................................................................................... 16
3.2.2 Basic module N ..................................................................................................................................... 17
3.2.3 Basic module L...................................................................................................................................... 17
3.2.4 Double spring-applied brake.................................................................................................................. 18
3.3 Function ............................................................................................................................................................. 18
3.4 Braking and release ........................................................................................................................................... 19
3.5 Project planning notes........................................................................................................................................ 19
3.6 Brake torque reduction....................................................................................................................................... 19
3.7 Optional configuration ........................................................................................................................................ 19
3.7.1 Hand-release (optional)......................................................................................................................... 19
3.7.2 Optional micro-switch ............................................................................................................................ 19
3.7.3 Optional CCV......................................................................................................................................... 19
INTORQ | BA 14.0168 | 11/2018 6

4 Technical specifications.......................................................................................................................................... 20
4.1 Possible applications of the INTORQ spring-applied brake............................................................................... 20
4.2 Brake torques .................................................................................................................................................... 21
4.3 Rated data.......................................................................................................................................................... 23
4.4 Switching times .................................................................................................................................................. 28
4.5 Switching energy / operating frequency............................................................................................................. 30
4.6 Electromagnetic compatibility............................................................................................................................. 31
4.7 Emissions........................................................................................................................................................... 31
4.8 Hand-release...................................................................................................................................................... 32
4.9 Labels on product............................................................................................................................................... 33
5 Mechanical installation............................................................................................................................................ 35
5.1 Design of end shield and shaft........................................................................................................................... 35
5.2 Tools .................................................................................................................................................................. 36
5.3 Preparing the installation.................................................................................................................................... 36
5.4 Installing the hub onto the shaft ......................................................................................................................... 37
5.5 Mounting the brake ............................................................................................................................................ 38
5.6 Installing the friction plate (optional)................................................................................................................... 41
5.7 Mounting the flange............................................................................................................................................ 41
5.7.1 Mounting the flange without additional screws...................................................................................... 41
5.7.2 Installing the flange (variants: size 06 - 16)........................................................................................... 42
5.7.3 Installing the flange (variants: size 18 - 20)........................................................................................... 43
5.7.4 Installing the flange (variants: size 25) .................................................................................................. 44
5.8 Installing the double spring-applied brake.......................................................................................................... 45
5.9 Cover ring assembly .......................................................................................................................................... 46
5.10 Installing the shaft sealing ring........................................................................................................................... 47
5.11 Installing the hand-release (retrofitting).............................................................................................................. 48
INTORQ | BA 14.0168 | 11/2018 7

6 Electrical installation ............................................................................................................................................... 49
6.1 Electrical connection .......................................................................................................................................... 49
6.2 AC switching at the motor – extremely delayed engagement............................................................................ 50
6.3 DC switching at the motor – fast engagement ................................................................................................... 51
6.4 AC switching at mains – delayed engagement .................................................................................................. 52
6.5 DC switching at mains – fast engagement......................................................................................................... 53
6.6 Minimum bending radius for the brake connection line...................................................................................... 54
6.7 Technical specifications for the micro-switch..................................................................................................... 54
6.8 Bridge/half-wave rectifier (optional).................................................................................................................... 55
6.8.1 Assignment: Bridge/half-wave rectifier – brake size.............................................................................. 55
6.8.2 Technical specifications......................................................................................................................... 55
6.8.3 Reduced switch-off times ...................................................................................................................... 56
6.8.4 Permissible current load at ambient temperature.................................................................................. 56
7 Commissioning and operation ............................................................................................................................... 57
7.1 Protect the electrical connections against any contact or touching.................................................................... 57
7.2 Function checks before initial commissioning.................................................................................................... 58
7.2.1 Function check of the brake .................................................................................................................. 58
7.2.2 Release / voltage control....................................................................................................................... 58
7.2.3 Testing the hand-release functionality................................................................................................... 59
7.3 Commissioning................................................................................................................................................... 60
7.4 Operation ........................................................................................................................................................... 60
7.4.1 Brake torque reduction (for the optional adjustable braking torque)...................................................... 61
8 Maintenance and repair........................................................................................................................................... 62
8.1 Wear of spring-applied brakes ........................................................................................................................... 62
8.2 Inspections......................................................................................................................................................... 63
8.2.1 Maintenance intervals............................................................................................................................ 63
8.3 Maintenance....................................................................................................................................................... 63
8.3.1 Checking the components..................................................................................................................... 64
8.3.2 Check the rotor thickness...................................................................................................................... 64
8.3.3 Checking the air gap.............................................................................................................................. 65
8.3.4 Release / voltage................................................................................................................................... 65
8.3.5 Adjusting the air gap.............................................................................................................................. 66
8.3.6 Replace rotor......................................................................................................................................... 66
8.4 Spare parts list ................................................................................................................................................... 68
9 Troubleshooting and fault elimination................................................................................................................... 71
INTORQ | BA 14.0168 | 11/2018 8

10 Appendix................................................................................................................................................................... 73
10.1 Holding brake for the ATEX zone....................................................................................................................... 73
10.1.1 Proper and intended usage ................................................................................................................... 73
10.1.2 Operating conditions.............................................................................................................................. 73
10.1.3 Labelling ................................................................................................................................................ 73
INTORQ | BA 14.0168 | 11/2018 9

General information
INTORQ | BA 14.0168 | 11/2018 10
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.
¾
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10
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:

General information
INTORQ | BA 14.0168 | 11/2018 11
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
Cold Climate Version (CCV) Version of the spring-applied brake suited for particularly low
temperatures

General information
INTORQ | BA 14.0168 | 11/2018 12
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 14.0168 | 11/2018 13
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
INTORQ | BA 14.0168 | 11/2018 14
2 Safety instructions
2.1 General safety instructions
¾
Never operate INTORQ components when you notice they are damaged.
¾
Never make any technical changes to INTORQ components.
¾
Never operate INTORQ components when they are incompletely mounted or incompletely connected.
¾
Never operate INTORQ components without their required covers.
¾
Only use accessories that have been approved by INTORQ.
¾
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, 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.
¾
Recycle metals and plastics.
¾
Ensure professional disposal of assembled PCBs according to the applicable environmental regula-
tions.

Product description
INTORQ | BA 14.0168 | 11/2018 15
3 Product description
3.1 Proper and intended usage
3.1.1 Standard applications
INTORQ components are intended for use in machinery and facilities. They may only be used for pur-
poses as specified in the order and confirmed by INTORQ. The INTORQ components may only be oper-
ated under the conditions specified in these Operating Instructions. They may never be operated beyond
their specified performance limits. The technical specifications (refer to Technical specifica-
tions,Page20) must be followed to comply with the proper and intended usage. Any other usage is con-
sider 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
INTORQ spring-applied brakes are being used in applications that have special safety requirements. The
BFK458-series brakes are suitable for use as operating brakes, as holding brakes, and as holding brakes
with emergency-stop functionality for safety applications. The safety characteristics of the safety brake ap-
ply 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, comply with the stand-
ard braking torque in order to meet the high safety requirements.
Please note the following conditions:
¾
Proper and intended usage of the brake as described in Standard applications,Page15
¾
Compliance with the installation specifications in these Operating Instructions
¾
Version of the brake with:
– A characteristic torque corresponding to the standard braking torque of that size or higher
– An expected characteristic torque that covers the safety-relevant functionality, even with a drop to
80%
– A noise-reduced rotor with toothed intermediate ring
¾
Compliance with the technical specifications listed in the Technical specifications,Page20 chapter.
– Ambient temperature during operation: -20° to +40° C
¾
The customer is responsible for ensuring that there is a secure connection between the shaft and the
hub.
Observe the following notices:
¾
The extended lower temperature range of the CCV version must not be reached when used as a
safety brake.
¾
The micro-switch option is not covered by the safety certificate.
¾
The service life specification for the long-life version remains valid. When it is being used as a safety
brake, however, the safety characteristic values for the non-long-life design must be used.
¾
The calculation for the safety application does not consider the wear of the friction lining or the load on
the brake due to emergency stops. These points must be checked separately when configuring the
brake.

Product description
INTORQ | BA 14.0168 | 11/2018 16
¾
Furthermore, all specified restrictions apply to the standard and wear-resistant friction linings (e.g. per-
missible operating frequency, permissible friction work, reactivation during operation as a holding
brake, breakaway torque after extended rest, temperature range, etc.).
The classification of the safety function of our brakes is based on the performance levels PL in accordance
with DIN EN ISO 13849-1:2015. This can be used to support the verifications of the functional safety of
drive systems. The safety characteristic data are available on request.
3.2 Layout
This chapter describes the variants, layout and functionality of the INTORQ BFK458 spring-applied brake.
The basic module E is adjustable (the braking torque can be reduced using the torque adjustment ring).
The special feature for basic module L (with an identical design) is the more durable materials (torque sup-
port, guide pins, toothed intermediate ring, friction lining and gear teeth). The double spring-applied brake
design is especially useful in redundant braking applications.
3.2.1 Basic module E
Fig.1: Design of the INTORQ BFK458 spring-applied brake: Basic module E (complete stator) + rotor + hub + flange
ATappet BTorque adjustment ring CStator
DSocket head cap screw EHand-release (optional) FSleeve bolt
GFlange HRotor IHub
JPressure spring KArmature plate

Product description
INTORQ | BA 14.0168 | 11/2018 17
3.2.2 Basic module N
Fig.2: Design of the INTORQ BFK458 spring-applied brake: Basic module N (complete stator) + rotor + hub + flange
AStator BSocket head cap screw CHand-release (optional)
DSleeve bolt ERotor FHub
GPressure spring HArmature plate IFlange
3.2.3 Basic module L
Description of the long-life design:
¾
Armature plate with low backlash and reinforced torque support
¾
Pressure springs with guide pins for protection against shearing forces
¾
Aluminium rotor with toothed intermediate ring: Low-wear friction lining and low-wear gear teeth.
The long-life design can be configured modularly for size 6 to size 12 in combination with the specified
rated torques. The specifications are as follows:
¾
The stator corresponds to the design N.
¾
Rear bores and extensions are not possible.
¾
A micro-switch in the size 12 is not configurable.

Product description
INTORQ | BA 14.0168 | 11/2018 18
3.2.4 Double spring-applied brake
Fig.3: Design of the INTORQ BFK458 spring-applied brake: Basic module N, doubled design with intermediate flange
AStator BSocket head cap screw CScrew for intermediate flange
DIntermediate flange EHand-release (optional) FSleeve bolt
GFlange HHub IRotor
JPressure spring KArmature plate
Notice
A version of the double spring-applied brake using HFC (high-friction coefficient) linings is not
permitted.
3.3 Function
This brake is an electrically releasable spring-applied brake with a rotating brake disc (rotor) that is
equipped on both sides with friction linings. In its de-energised state, the rotor is clamped with braking
force applied by pressure springs between the armature plate and a counter friction surface. This corres-
ponds to a fail-safe functionality.
The brake torque applied to the rotor is transferred to the input shaft via a hub that has axial gear teeth.
The brake can be used as a holding brake, as an operating brake, and as an emergency stop brake for
high speeds.
The asbestos-free friction linings ensure a safe braking torque and low wear.
To release the brake, the armature plate is released electromagnetically from the rotor. The rotor, shifted
axially and balanced by the spring force, can rotate freely.

Product description
INTORQ | BA 14.0168 | 11/2018 19
3.4 Braking and release
During the braking procedure, the inner and outer springs use the armature plate to press the rotor (which
can be shifted axially on the hub) against the friction surface. The asbestos-free friction linings ensure high
braking torque and low wear. The braking torque is transmitted between the hub and the rotor via gear teeth.
When the brakes are applied, an air gap (sL) is present between the stator and the armature plate. To re-
lease the brake, the coil of the stator is energised with the DC voltage provided. 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.
3.5 Project planning notes
¾
When designing a brake for specific applications, torque tolerances, the limiting speeds of the rotors,
the thermal resistance of the brake, and the effect of environmental influences must all be taken into
account.
¾
The brakes are dimensioned in such a way that the specified rated torques are reached safely after a
short run-in process.
¾
However, as the organic friction linings used do not all have identical properties and because environ-
mental conditions can vary, deviations from the specified braking torques are possible. These must be
taken into account in the form of appropriate dimensioning tolerances. Increased breakaway torque is
common in particular after long downtimes in humid environments where temperatures vary.
¾
If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactiv-
ated regularly.
3.6 Brake torque reduction
For the basic module E, the spring force and thus the brake torque can be reduced by unscrewing the
central torque adjustment ring.
3.7 Optional configuration
3.7.1 Hand-release (optional)
To temporarily release the brake when there is no electricity available, a hand-release function is available
as an option. The hand-release function can be retrofitted.
3.7.2 Optional micro-switch
The micro-switch is used for the release monitoring or for wear monitoring. The user is responsible for ar-
ranging the electrical connection for this optional micro-switch.
¾
Usage for the (air) release monitoring: The motor will start only after the brake has been released. This en-
ables the micro-switch to monitor for errors (e.g. when the motor does not start because of a defective rec-
tifier, if there are broken connection cables, defective coils, or an excessive air gap).
¾
Usage for monitoring wear: The brake and motor are not supplied with power when the air gap is too
large.
3.7.3 Optional CCV
The Cold Climate Version (CCV) allows the brake to be operated at lower ambient temperatures.

Technical specifications
INTORQ | BA 14.0168 | 11/2018 20
4 Technical specifications
4.1 Possible applications of the INTORQ spring-applied brake
¾
Degree of protection:
– The brake is designed for operation under the environmental conditions that apply to IP54 protec-
tion. Because of the numerous possibilities of using the brake, it is still necessary to check the func-
tionality of all mechanical components under the corresponding operating conditions.
¾
Ambient temperature:
– -20 °C to +40 °C (Standard)
– -40 °C to +40 °C (Cold Climate Version: CCV)
NOTICE
When using the spring-applied brake as safety brake, the temperature range specified for
the Cold Climate Version (CCV) is not permitted.