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
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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
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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: