INTORQ BFK466-80 User manual

INTORQ BFK466−80
Electromagnetically released spring−applied brake
j
setting the standard
www.intorq.com
Operating Instructions

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This documentation applies to ...
BFK466−80
BFK46680−003.iso/dms
Product key
Product key INTORQ B FK 466 −LL
0
1
2
3
Legend for the INTORQ BFK466 product key
0Product group Brakes
1Product family Spring−applied brake
2Type 466
3Size 80
Not coded: supply voltage, hub bore, options

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Identification
Package label Example
Manufacturer Bar code
Name Type No.
Type (see product key) Quantity per box
Rated voltage Rated power Rated torque Packing date
Model identification Desired customer no.
Additional information CE designation
BFK46680_001.iso/dms
Nameplate Example
Manufacturer CE designation
Type (see product key) Model identification
Rated voltage Rated power Desired customer no.
Type No. Rated torque Production date
BFK46680_002.iso/dms
Document history
Material number Version Description
33001612 1.0 02/2012 TD09 First edition
0Fig. 0Tab. 0
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 Scope of supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Disposal 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Drive systems 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Legal regulations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety information 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Application as directed 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Notes used 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Rated data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operating times 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Operating frequency / friction work 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Emission 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Important notes 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Necessary tools 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mounting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important notes 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical connection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Microswitch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Function checks before commissioning 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Commissioning 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 During operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance/repair 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Wear of spring−applied brakes 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Inspections 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Spare parts order 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contentsi
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8 Troubleshooting and fault elimination 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 multi−pole
spring−applied brake. They contain safety instructions that must be followed.
| All persons working on or with the multi−pole spring−applied brake must have these
Operating Instructions available and observe the information and notes relevant for
their work.
| 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 Multi−pole spring−applied brake
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: ,software manual

Preface and general information1
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1.4 Abbreviations used
Abbreviation Unit Name
I [A] Current
Irated [A] Rated current
Ma[Nm] Tightening torque
nmax [rpm] Maximum speed
P20 [kW] Electrical power at 20°C
Q [J] Calculated friction work per operation
Qperm [J] Max. permissible friction work per operation
R20 [Ohm] Coil resistance at 20°C
Sh[h−1]Operating frequency, i.e. the number of periodical brakings
sLü [mm] Rated air gap
Shü [h−1]Transition operating frequency, i.e. the maximally permissible
number of brakings per unit time
t1[ms] Engagement time, t1= t11 + t12
t2[ms] Disengagement time (time from the beginning of the torque drop to
reaching 0.1 MK)
t11 [ms] Delay during engagement (time from switching off the supply voltage
to the beginning of the torque rise)
t12 [ms] Torque rise time
U [V] Voltage
1.5 Scope of supply
| The spring−applied brakes are delivered preassembled, the brake disc is not included
in the scope of supply.
| After receipt of the delivery, check immediately whether the items delivered match the
accompanying papers. INTORQ does not accept any liability for deficiencies claimed
subsequently. Claim
– visible transport damage immediately to the forwarder.
– visible deficiencies / incompleteness immediately to INTORQ GmbH & Co. KG.
1.6 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.

Preface and general information1
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1.7 Drive systems
1.7.1 Labelling
Drive systems and drive components are clearly labelled and defined by the indications on the
nameplates.
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D−31855 Aerzen
1.8 Legal regulations
Liability
| The information, data and notes in these Operating Instructions met the state of the
art at the time of printing. Claims referring to drive systems 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 drive system
– improper working on and with the drive system
– operating faults
– disregarding these Operating Instructions
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 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.
| Observe all specifications given in the attached documentation.
– This is the prerequisite for 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.
| Risk of burns!
– 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
| Drive systems
– 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
| Ambient temperature:
– −5°C to +40°C (standard)
| At high humidity and low temperature:
– Take measures to protect friction surfaces from freezing.
| Protect electrical connections against contact.

Safety instructions2
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2.3 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
ITip! Useful tip for simple handling
,Reference to another documentation

Technical data3
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3 Technical data
3.1 Product description
3.1.1 Structure and function
BFK46685−004.iso
Fig. 1 Design of a BFK466−80 spring−applied brake
1 Stator 6 Cheese head screw 11 Friction lining
2 Brake disk 7 Guide sleeve 12 Support of friction lining
3 Flange 8 Cheese head screw 13 Manual release lever
(detachable)
4 Armature plate 9 Microswitch (release
monitoring)
14 Microswitch (wear
monitoring)
5 Compression spring 10 Terminal box
3.1.2 General information
This spring−applied brake is designed as a floating caliper brake for mounting on direct
drive motors. The brake disk (2) is not included in the scope of supply. By using two or
more spring−applied brakes on one brake disk, the demand for redundancy can be fulfilled
for special applications such as lift and stage technology.
The braking torque is generated by the pressure of several compression springs (5) via
friction locking between the two friction linings (11) of the friction lining support (12) and
the flange (3) and the brake disc (2). The brake is released electromagnetically. For this,
an overexcitation voltage is applied to the brake for approx. 1...2 seconds. Then, the
voltage is decreased to 50%. Thus, the medium electrical brake power is reduced.
The BFK466 spring−applied brake is designed for converting mechanical work and kinetic
energy into heat energy. Thanks to the static breakaway torque, loads can be held at
standstill.
Emergency braking at higher speeds is possible. Here, the maximally permissible speed
must not be exceeded. (¶15).

Technical data3
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The stator (1) is designed to be of thermal class F. The limit temperature of the coils is
155°C.
The spring−applied brake is designed for a maximum operating time of 60%.
3.1.3 Braking
During braking, the support of the friction lining (12) and the affixed friction lining (11) are
pressed against the axially fixed brake disc (2). Nearly at the same time, the caliper moves
on the guide sleeves (7) in the opposite direction, so that the friction lining (11) on the
flange (3) is pressed against the brake disc, too. The braking torque is supported by the
mounting flange via the guide sleeves (7). The asbestos−free friction linings ensure a high
braking torque with low wear.
3.1.4 Brake release
When the brake is applied, there is an air gap sLü" between the armature plate (4) and the
pole faces of the stator (1). To release the brake, the respective switching device supplies
the coils of the stator (1) with the overexcitation voltage. The resulting magnetic force
draws the armature plate (4) against the spring force towards the pole faces of the stator
(1). Now, the spring force is taken from the support of the friction lining (12). The caliper
can move on the guide sleeves (7) until the brake disk (2) is relieved and can rotate freely.
After approx. 1...2 seconds, the supply voltage is decreased to 50%.
3.1.5 Release monitoring
The INTORQ BFK466 spring−applied brake is equipped with a microswitch (changeover
contact) which monitors the switching status. During brake release, the microswitch (9)
changes over. This must exclude drive operation against the applied brake.
3.1.6 Wear monitoring
An additional microswitch (14) is used to monitor the wear status of this spring−applied
brake. The microswitches can be used as NC contacts (series connection) or as NO
contacts (parallel connection).
3.1.7 Emergency release option
An optional manual release is available for short−time release of the brake. This allows for
lowering the load in case of a power failure.

Technical data3
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3.1.8 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.
| Check the braking torque if the brake is inserted on the customer’s friction surfaces.
| If the brake is used as a pure holding brake without dynamic load, the friction lining
must be reactivated regularly.
(Stop!
Stable properties of the organic friction lining are only achieved in the case of
continuous use. The readiness for operation of the brake has to be ensured with
a braking energy that is equivalent to one emergency stop per week. Unplanned
emergency stops occurring at a sufficient frequency have the same effect.

Technical data3
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3.2 Rated data
Type Friction
force
Brake disk
radius
Max. sliding
speed
Voltage 1) Power 2) Coil
resistance
Max.
current
Overexcit
ation
time
FR[N] Ra[mm]
min. / max.
Vmax. [m/s] U ±10%
[V] DC
P20 [W] R20±5%
[W]
Imax. [A] sec.
BFK466−80 8015 300 / 600 16.4
90/45
110/55
205/103
522/130.5
522/130.5
550/137.5
15.52
23.18
76.41
5.8
4.75
2.68
1...2
Type Air gap Max. air gap Fixing screws Tightening
torque
Max. perm.
switching
energy
Transition
operating
frequency
Weight
(without brake
disk)
sLü [mm] sLü max. [mm] Ma[Nm] QE[J] Sfo [h−1]m [kg]
BFK466−80 0.4±0.1 0.7 2 x M16 195 250000 24 45
1) Voltage for releasing / holding
2) Coil power at 20°C when releasing / holding
3.3 Operating times
BFKXXX−011.iso/dms
Fig. 2 Operating times of the spring−applied brakes
t1Engagement time t11 Delay time during engagement
t2Disengagement time (up to M = 0.1 Mr)t
12 Rise time of the brake torque
Mrated Braking torque U Voltage
Type Operating times [ms] at sLürated
Engage Disengage
t11 t12 t1t2
BFK466−80 28 152 180 380
Tab. 1 Switching energy − operating frequency − operating times

Technical data3
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Disengagement time
The disengagement time is not affected by DC or AC switching. The indicated disengagement
time applies to an air gap of 0.4 mm. When the air gap is larger (as a result of wear), the
disengagement time increases.
Engagement time
Short brake engagement times are vital for emergency braking. DC switching together with
a suitable spark suppressor must therefore be provided.
If the drive system includes a frequency inverter so that the brake is deenergised only
when the motor is at standstill, switching on the AC side is also possible (not valid for
emergency braking). In this case, engagement times will be 5 times longer.
3.4 Operating frequency / friction work
Sh[h−1]
Q [J]
1 10 100 1000
1
10
100
1000
10000
100000
1000000
KL 466−85−XXX.tiff
Fig. 3 Switching energy as a function of the operating frequency
0Switching energy 1Operating frequency
Sfperm +*Sfo
lnǒ1*Q
QEǓQperm +QEǒ1*e
*Sfo
SfǓ
The permissible operating frequency "Sfperm" depends on the friction work "Q" (see Fig. 3).
At a preset operating frequency "Sf", the permissible friction work is "Qperm".
For "Sfo" and "QE", please see chapter 3.2.

Technical data3
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3.5 Emission
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.
}Danger!
Risk of burns on brake and brake disc!
Noise
The switching noise during engagement and disengagement varies depending on the air gap
"sair" and the brake size. It is between approx. 55 and 60 dB [A].
Others
Abrasion due to braking occurs in the form of dust.
In case of high load, the friction face will become so hot that odours may occur.

Mechanical installation4
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4 Mechanical installation
4.1 Important notes
(Stop!
| Do not lubricate the screws with oil or grease.
4.2 Necessary tools
Type Torque key Insert for hexagon
socket screws
Transport screw Crosstip screwdriver
Measuring range [Nm] Wrench size [mm] Wrench size [mm] Crosstip size
BFK466−80 250 14 x 1/2" square 6 x 1/4" square 2
Feeler gauge Caliper gauge Multimeter

Mechanical installation4
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4.3 Mounting
4.3.1 Preparation
1. Unpack spring−applied brake.
2. Check for completeness.
3. Check nameplate data, especially rated voltage.
4.4 Installation
The brake is delivered preassembled with two transport safety bolts (17).
1. Fit the guide sleeve (19) on the drive and tighten it lightly with the fixing screw (21).
2. Use a through−hole and push the brake onto the guide sleeve until the friction faces
are in alignment with the brake disc (20).
3. Turn the brake around the guide sleeve (19) and position the brake radially over the
brake disc (20).
4. Push the second guide sleeve (19) into the second through−hole of the brake and
tighten it with the fixing screw (21).
(Stop!
The sum total of the distances measured must not exceed "sLü max"!
5. Tighten both fixing screws (21) with the given torque (^15).
6. Remove the transport safety bolts (17)!
7. Switch the current on and off several times, checking the movability of the brake on
the guide sleeves.
8. Check the clearance of the brake disc and the air gap "sLü" between the two friction
linings (3.2) and the brake disc (20) with a feeler gauge (24).
sLü/2
sLü/2
BFK46685−005.iso
Fig. 4 Installation of the BFK466−80 spring−applied brake

Electrical installation5
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5 Electrical installation
5.1 Important notes
{Danger!
| Electrical connection must only be carried out by skilled personnel!
| Connections must only be made when the equipment is de−energised! Danger
through unintended starts or electric shocks.
(Stop!
| It must be ensured that the supply voltage corresponds to the nameplate
data.
| Voltages must be adapted to the local environment!
(Stop!
| If emergency switching off is carried out without the required suppressor
circuit, the control unit may be destroyed.
| Observe the correct polarity of the suppressor circuit!
5.2 Electrical connection
Earthing
Use the PE screw in the terminal box (Fig. 6 and Fig. 8) for PE connection.
PE connection via the fixing screws on the motor is not permitted because there is no
electrically conductive connection between the brake and the guide sleeves!
Temperature sensor connection (optional)
The spring−applied brake can be delivered with PTC sensors according to DIN 44082 for
temperature monitoring (reference temperature 130°C). The signal is evaluated via a PTC
thermistor tripping device provided by the customer.
Connection: AWG 26 blue/blue