INTORQ BFK468 User manual

INTORQ BFK468
j
setting the standard
Operating Instructions
www.intorq.com
Electromagnetically released spring−applied brake

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This documentation applies to ...
BFK468
BFK46825−002.iso/dms
Product key
Product key INTORQ B FK LLL −LL L





Legend for INTORQ BFK468 product key
Product group Brakes
Product family Spring−applied brake
Type 468
Size 18, 20, 25, 31
Design E − adjustable (brake torque can be reduced via adjuster nut)
N − not adjustable
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 Rated torque Quantity per box
Release/holding voltage Release/holding power Packing date
Additional information CE designation
BFK458−002.iso/dms
Nameplate Example
Manufacturer CE designation
Type (see product key)
Rated voltage Rated power Hub diameter
Type No. Rated torque Production date
BFK468−001.iso/dms
Document history
Material number Version Description
13190474 1.0 01/2007 TD09 First edition
33002357 2.0 11/2012 TD09 Complete revision
0Fig. 0Tab. 0

Contentsi
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1 Preface and general information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 About these Operating Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Terminology used 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Conventions used 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Abbreviations used 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Notes used 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Scope of supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Disposal 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Drive systems 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Legal regulations 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety information 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Application as directed 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Brake torques 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Rated data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Operating times 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Operating frequency / friction work 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Emission 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Necessary tools 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mounting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Bridge/half−wave rectifiers (option) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical connection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Functional test 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Reducing the brake torque 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 During operation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance/repair 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Wear of spring−applied brakes 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Inspections 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Spare−parts list 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Spare parts order 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Troubleshooting and fault elimination 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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
IN[A] Rated current at 20 °C and rated voltage
MA[Nm] Tightening torque of the fixing screws
MN[Nm] Characteristic torque of the brake / clutch
nmax [r/min] Maximum speed during the slipping time t3
PN[W] Rated coil power at rated voltage and at 20 °C
Q [J] Quantity of heat/energy
QE[J] Maximally permissible friction energy for one−time switching
QR[J] Braking energy, friction energy
QSmax [J] Maximally permissible friction energy for cyclic switching
RN[Ohm] Rated coil resistance at 20 °C
Sh[1/h] Operating frequency, i.e. the number of periodical switching opera-
tions
Shue [1/h] Transition operating frequency for thermal characteristic of the
brake / clutch
Shmax [1/h] Maximally permissible operating frequency, depending on the fric-
tion energy per switching operation
sL[mm] Air gap, i.e. lift of the armature plate while the brake is switched, or
lift of the armature part when the clutch is switched
sLN [mm] Rated air gap
sLmin [mm] Minimum air gap
sLmax [mm] Maximum air gap
t1[s] Engagement time, i.e. sum of the delay time and the braking torque
exit time t1= t11 + t12
t2[s] Disengagement time, i.e. time between switching the stator and
reaching 0.1 MK
t11 [s] Slipping time, i.e. engagement time of the brake (after t11) until
standstill
t11 [m] Delay during engagement, i.e. time from switching off the supply
voltage to the beginning of the torque rise
t12 [m] Rise time of the braking torque, i.e. time from the start of the torque
rise until reaching the braking torque
U [V] Voltage
UN[V] Rated coil voltage

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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

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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 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.
| 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.