Kendrion INTORQ BFK457 Quick guide

INTORQ BFK457
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
www.kendrion.com

Document history
Material number Version Description
399720 1.0 09/1997 TD09 First edition for the series
399720 1.1 07/2000 TD09 Address changed, Change of rated data
13053267 2.0 09/2002 TD09
All chapters: Complete editorial revisions. Extension of the oper-
ating manual to cover sizes 10 – 16, sizes 06 and 08 changed to
new design principle with spacer bushings. Change of company
name. Incorporation of the basic and compact versions
13231528 3.0 09/2007 TD09 Change of company name to INTORQ. Completely revised, in-
cluding the sizes 01 and 02
13343901 4.0 07/2010 TD09 Changed values of the braking torques and rotation speeds
13343901 4.1 07/2011 TD09 Updated cover
13343901 4.2 03/2012 TD09
Additions to the Maintenance chapter. Updated the connection di-
agrams in the "Electrical installation" chapter. Changed the tight-
ening torques, brake torques and rotation speeds in the Rated
Data chapter.
13343901 5.0 04/2013 TD09
Added notice for spare parts list. Added the Spare parts ordering
section. Inserted "Size of socket-head cap screws" table. Notice
for mounting the basic version. Notice for shaft-hub connection
13343901 6.0 01/2015 SC Restructured FM. Unified connection diagrams
13343901 7.0 02/2016 SC Update
13343901 8.0 12/2018 SC Migration to ST4
13343901 9.0 01/2022 SC
Change of company name to Kendrion INTORQ
Changes to Chapters 3.1.2 and 5.1
Supplements to Chapters 6.7 and 8.2
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 infor-
mation, illustrations and descriptions.
¾
We do not accept any liability for damage and operating interference caused by:
– inappropriate use
– unauthorized modifications to the product
– improper work on or with the product
– operating errors
– disregarding the documentation
Kendrion INTORQ | BA 14.0164 | 02/2022 2

Warranty
Notice
The warranty conditions can be found in the terms and conditions of Kendrion INTORQ
GmbH.
¾
Warranty claims must be made to Kendrion INTORQ immediately after the defects or faults are de-
tected.
¾
The warranty is void in all cases when liability claims cannot be made.
Product key
Product group: Brakes
Product family: Spring-applied brake
Type: 457
Size: 01, 02, 03, 04, 05, 06, 08, 10, 12, 14, 16
INTORQ B FK
Not coded: Connection voltage, hub bore diameter, options
Checking the delivery
After receipt of the delivery, check immediately whether the items delivered match the accompanying pa-
pers.
Kendrion INTORQ does not accept any liability for deficiencies claimed subsequently.
¾
Claim visible transport damage immediately to the deliverer.
¾
Claim visible defects or incompleteness of the delivery immediately to Kendrion INTORQ.
Kendrion INTORQ | BA 14.0164 | 02/2022 3

Contents
1 General information................................................................................................................................................... 7
1.1 Using these Operating Instructions...................................................................................................................... 7
1.2 Conventions in use............................................................................................................................................... 7
1.3 Safety instructions and notices ............................................................................................................................ 7
1.4 Terminology used................................................................................................................................................. 8
1.5 Abbreviations used............................................................................................................................................... 9
2 Safety instructions................................................................................................................................................... 11
2.1 General safety instructions................................................................................................................................. 11
2.2 Disposal ............................................................................................................................................................. 11
3 Product description ................................................................................................................................................. 12
3.1 Proper and intended usage................................................................................................................................ 12
3.1.1 Standard applications............................................................................................................................ 12
3.2 Layout ................................................................................................................................................................ 12
3.2.1 Basic module......................................................................................................................................... 12
3.2.2 Compact module ................................................................................................................................... 13
3.3 Function ............................................................................................................................................................. 13
3.4 Braking and release ........................................................................................................................................... 14
3.5 Project planning notes........................................................................................................................................ 14
3.6 Optional configuration ........................................................................................................................................ 14
3.6.1 Hand-release (optional)......................................................................................................................... 14
4 Technical specifications.......................................................................................................................................... 15
4.1 Possible applications of the Kendrion INTORQ spring-applied brake................................................................ 15
4.2 Characteristics ................................................................................................................................................... 15
4.3 Switching times .................................................................................................................................................. 19
4.4 Friction work / operating frequency.................................................................................................................... 21
4.5 Electromagnetic compatibility............................................................................................................................. 22
4.6 Emissions........................................................................................................................................................... 22
4.7 Labels on product............................................................................................................................................... 23
Kendrion INTORQ | BA 14.0164 | 02/2022 4

5 Mechanical installation............................................................................................................................................ 25
5.1 Design of end shield and shaft........................................................................................................................... 25
5.2 Tools .................................................................................................................................................................. 26
5.3 Preparing the installation.................................................................................................................................... 26
5.4 Installing the hub onto the shaft ......................................................................................................................... 27
5.5 Mounting the brake ............................................................................................................................................ 28
5.5.1 Mounting the BFK457-06 to 16 – Basic version .................................................................................... 28
5.5.2 Mounting the BFK457-01 to 16 – Compact version............................................................................... 30
6 Electrical installation ............................................................................................................................................... 31
6.1 Electrical connection .......................................................................................................................................... 31
6.1.1 AC switching at the motor – extremely delayed engagement ............................................................... 32
6.1.2 DC switching at the motor – fast engagement....................................................................................... 33
6.1.3 AC switching at mains – delayed engagement...................................................................................... 34
6.1.4 DC switching at mains – fast engagement ............................................................................................ 35
6.2 Minimum bending radius for the brake connection cable................................................................................... 36
6.3 Bridge/half-wave rectifier (optional).................................................................................................................... 36
6.3.1 Assignment: Bridge/half-wave rectifier – brake size.............................................................................. 36
6.3.2 Technical specifications......................................................................................................................... 37
6.3.3 Reduced switch-off times ...................................................................................................................... 38
6.3.4 Permissible current load at ambient temperature.................................................................................. 38
7 Commissioning and operation ............................................................................................................................... 39
7.1 Possible applications of the Kendrion INTORQ spring-applied brake................................................................ 39
7.2 Function checks before initial commissioning .................................................................................................... 40
7.2.1 Function check of the brake .................................................................................................................. 40
7.2.2 Release / voltage control....................................................................................................................... 40
7.2.3 Testing the hand-release functionality................................................................................................... 41
7.3 Commissioning................................................................................................................................................... 41
7.4 Operation ........................................................................................................................................................... 42
Kendrion INTORQ | BA 14.0164 | 02/2022 5

8 Maintenance and repair........................................................................................................................................... 43
8.1 Wear of spring-applied brakes ........................................................................................................................... 43
8.2 Inspections......................................................................................................................................................... 44
8.2.1 Maintenance intervals............................................................................................................................ 44
8.3 Maintenance....................................................................................................................................................... 44
8.3.1 Checking the components..................................................................................................................... 45
8.3.2 Checking the air gap.............................................................................................................................. 45
8.3.3 Release / voltage................................................................................................................................... 46
8.3.4 Replacing the brake (compact version)................................................................................................. 46
8.3.5 Replacing the brake (basic version) ...................................................................................................... 47
8.4 Spare parts list ................................................................................................................................................... 48
9 Troubleshooting and fault elimination................................................................................................................... 50
Kendrion INTORQ | BA 14.0164 | 02/2022 6

General information
Kendrion INTORQ | BA 14.0164 | 02/2022 7
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 Underlined, red _____
Reference to another page with additional
information
For example: Using these Operating In-
structions,Page7
Symbols
Wildcard □
Wildcard (placeholder) for options or selec-
tion details
For example: BFK457-□□ = BFK457-10
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
Kendrion INTORQ | BA 14.0164 | 02/2022 8
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 consequences
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 compo-
nents

General information
Kendrion INTORQ | BA 14.0164 | 02/2022 9
1.5 Abbreviations used
Letter symbol Unit Designation
FRN Rated frictional force
F N Spring 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
M4Nm Torque that can be transmitted without slippage occurring (DIN VDE 0580)
MANm Tightening torque of fastening screws
Mdyn Nm Average torque from initial speed to standstill
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
RNOhms Rated coil resistance at 20 °C
Rzμm Averaged surface roughness
Sh1/h Operating frequency: the number of switching operations evenly distributed
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
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 Mdyn
t3ms Slipping time, operation time of the brake (according to t11) until standstill

General information
Kendrion INTORQ | BA 14.0164 | 02/2022 10
Letter symbol Unit Designation
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 Over-excitation 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
Kendrion INTORQ | BA 14.0164 | 02/2022 11
2 Safety instructions
2.1 General safety instructions
¾
Never operate Kendrion INTORQ components when you notice they are damaged.
¾
Never make any technical changes to Kendrion INTORQ components.
¾
Never operate Kendrion INTORQ components when they are incompletely mounted or incompletely
connected.
¾
Never operate Kendrion INTORQ components without their required covers.
¾
Only use accessories that have been approved by Kendrion 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, Kendrion INTORQ components may have both live (voltage
carrying), moving and rotating parts. Such components require appropriate safety mechanisms.
¾
Surfaces can become hot during operation. Take 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 Kendrion INTORQ components may only be carried out
by qualified 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 Kendrion 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
Kendrion INTORQ | BA 14.0164 | 02/2022 12
3 Product description
3.1 Proper and intended usage
3.1.1 Standard applications
Kendrion INTORQ components are intended for use in machinery and facilities. They may only be used for
purposes as specified in the order and confirmed by Kendrion INTORQ. The Kendrion INTORQ compo-
nents may only be operated under the conditions specified in these Operating Instructions. They may
never be operated beyond their specified performance limits. The technical specifications (refer to Techni-
cal specifications,Page15) must be followed to comply with the proper and intended usage. Any other
usage is consider improper and prohibited.
3.2 Layout
This chapter describes the Basic and Compact variants, layout and functionality of the INTORQ BFK457
spring-applied brake.
3.2.1 Basic module
Fig.1: Design of the INTORQ BFK457 spring-applied brake: Basic module (complete stator) + rotor + flange
AStator BPressure spring CArmature plate
DSocket-head cap screw EElastic band (shipping bracket) FRotor
GHub HCoil ISpacer

Product description
Kendrion INTORQ | BA 14.0164 | 02/2022 13
3.2.2 Compact module
Fig.2: Design of the INTORQ BFK457 spring-applied brake: Compact module (complete stator) + rotor + flange
AStator BPressure spring CArmature plate
DSocket-head cap screw EFlange FRotor
GHub HCoil
3.3 Function
This brake is an electrically releasable spring-applied brake with a rotating brake disk (rotor) that is
equipped on both sides with friction linings. In its de-energized state, the rotor is clamped with braking
force applied by pressure springs between the armature plate and a counter friction surface. This corre-
sponds 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 a service 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
Kendrion INTORQ | BA 14.0164 | 02/2022 14
3.4 Braking and release
During the braking procedure, the pressure springs use the armature plate to press the rotor (which can
be shifted axially on the hub) against the friction surface. 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 energized 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 effects 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
Since the material properties of the friction linings are subject to fluctuations and as a result of different
environmental conditions, deviations from the specified braking torque are possible. This has to be
taken into account by appropriate dimensioning of the tolerances. Increased breakaway torque can oc-
cur in particular as an result of long standstill periods in humid environments with variing temperatures.
¾
If the brake is used as a pure holding brake without dynamic load, the friction lining must be reacti-
vated regularly.
3.6 Optional configuration
3.6.1 Hand-release (optional)
To temporarily release the brake when there is no electricity available, a hand-release version is available
as an option.

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 15
4 Technical specifications
4.1 Possible applications of the Kendrion INTORQ spring-applied brake
¾
Degree of protection:
– Without additional protective measures, this brake complies with protection class IP00. Contact the
Kendrion INTORQ sales department for information about using special protective measure to in-
crease the protection class.
¾
Ambient temperature:
– -20 °C to +40 °C (Standard)
4.2 Characteristics
Size Rated brake torque at
Δn=100 rpm
Air gap Moment of inertia
of rotor
Weight of brake
MKSLN
1) SLmax JRotor Compact Basic
[Nm] [mm] [mm] [kg cm2] [kg] [kg]
01 0.12
0.1 +0.08/-0.05
0.35 0.0025 0.2 -
0.25 0.23 -
02 0.25 0.35 0.010 0.25 -
0.5 0.23 -
03 0.5
0.15 ±0.1
0.4 0.021 0.4 -
1 0.3 -
04 1 0.4 0.058 0.55 -
2 0.3 -
05 2 0.4 0.105 0.8 -
4 0.3 -
06 4
0.2 ±0.1
0.6 0.130 1.1 0.9
6 0.4
08 8 0.6 0.450 1.9 1.5
12 0.45

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 16
Size Rated brake torque at
Δn=100 rpm
Air gap Moment of inertia
of rotor
Weight of brake
MKSLN
1) SLmax JRotor Compact Basic
[Nm] [mm] [mm] [kg cm2] [kg] [kg]
10 16
0.3 ±0.1
0.7 2.000 3.8 3.0
23 0.5
12 32 0.8 4.500 5.7 4.7
46 0.5
14 60 0.8 6.300 8.6 7.1
90 0.5
16 80 0.9 15.000 12.0 10.0
125 0.6
Tab.1: General data
1) The default (as delivered) air gap results from the sum tolerances of the individual components.
Size Outer diameter Screw hole circle Minimum thread depth of
motor end shield
Tightening
torque
Diameter (Ø) Thread1) Basic Compact MA
[mm] [mm] [mm] [mm] [Nm]
01 37 32 2x M2.5 - 40.7
02 47 40 2x M3 -
1.303 56 48 3x M3 -6
04 65 58 -
05 75 66 3x M4 - 7 3.0
06 84 72 11 8
08 102 90 3x M5
14
11 5.9
10 130 112 3x M6 14 10.1
12 150 132
14 165 145 3x M8 16 16 24.6
16 190 170
Tab.2: Mounting data
1) Fastening screws (socket-head cap screws according to DIN EN ISO 4762) are included in the scope of delivery

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 17
CAUTION
Functional incapacity of the brake
It is very important to comply with the minimum thread depth of the end shield (refer to the
Mounting data,Page16 table).
If the required thread depth is not maintained, the fastening screws may run onto the
thread root. This has the effect that the required pre-load force is no longer established –
the brake is no longer securely fastened!
The material of the end shield must have a tensile strength of Rm > 250 N/mm2 !
Size Braking torque at Δn0 [Nm] Max. rotation speed
Δn0max
1500 3000 Max. [rpm]
01 0.11 0.10 0.09
5000
02 0.23 0.21 0.18
03 0.45 0.42 0.35
04 0.89 0.82 0.68
05 1.76 1.62 1.34
06 3.5 3.2 3.0 6000
5.2 4.8 4.4
08 6.8 6.2 5.8 5000
10.2 9.3 8.8
10 13.3 12.2 11.7 4000
19.1 17.5 16.8
12 25.9 23.7 23.4
3600
37.3 34 33.6
14 48 43.8 43.2
72 65.7 64.8
16 63.2 57.6 56.0
98.8 90 87.5
Tab.3: Brake torques

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 18
Size Electrical power
PN
Rated voltage
UN
Rated current
IN
Coil resistance
RN
[W] [V] [A] [Ω] ±8%
01 5
24
205
0.21 115.3
0.02 8413
02 6.6 0.28 87.3
0.03 6372
03 9 0.38 64.0
8.2 0.04 5128
04 11.5 0.48 50.1
10 0.048 4205
05 13 0.54 44.3
0.06 3184.2
06 20 0.83 28.8
0.10 2101
08 25 1.17 20.57
0.12 1681
10 30 1.25 19.2
33 0.16 1273
12 40 1.67 14.4
0.20 1051
14
50
24
42
205
2.08 11.52
53 1.26 33.28
55 0.27 764
16
55 2.29 10.47
55 1.31 32.07
56 0.27 765
Tab.4: Coil data

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 19
4.3 Switching times
The operating times listed here are guide values which apply to DC switching with rated air gap sLN, warm
coil and standard characteristic torque. The given operating times are average values and subject to varia-
tions. The engagement time t1 is approximately 8 to 10 times longer for AC switching.
t
t
M
t2
t12
t11
t1
Mdyn
U
0.1Mdyn
Fig.3: Operating/switching times of the spring-applied brakes
t1Engagement time t11 Delay time during engagement
t2Disengagement time (up to M = 0.1 Mdyn)t12 Rise time of the braking torque
Mdyn Braking torque at a constant speed of rotation UVoltage
Size Rated brake torque at
Δn=100 rpm
MK
1)
QE
1) Shue Operating times 2)
DC-side engagement Disengaging
t11 t12 t1t2
[Nm] [J] [1/h] [ms] [ms] [ms] [ms]
01 0.12 200 160 2 9 11 17
02 0.25 400 125 3 5 8
03 0.5 800 100 5 7.5 12.5 18
04 1 1200 90 9 9 18 23
05 2 1800 80 10 16 26 35
06 4 3000 79 29 19 48 37
08 8 7500 50 60 35 95 42
10 16 12000 40 35 60 100
12 32 24000 30 45 53 98 135
14 60 30000 28 50 57 107 240
16 80 36000 27 71 50 121 275
Tab.5: Switching energy - operating frequency - operating times
1) The maximum permissible friction energy QE relates to the standard friction lining.
2) These operating times are specified for usage of Kendrion INTORQ bridge/half-wave rectifiers and coils with a con-
nection voltage of 205 V DC at sLN and 0.7 IN.

Technical specifications
Kendrion INTORQ | BA 14.0164 | 02/2022 20
Engagement time
The transition from a brake-torque-free state to a holding-braking torque is not free of time lags.
For emergency braking, short engagement times for the brake are absolutely essential. The DC-side
switching in connection with a suitable spark suppressor must therefore be provided.
Engagement time for AC-side switching: The engagement time is significantly longer (approx. 10 times
longer).
NOTICE
Connect the spark suppressors in parallel to the contact. If this is not admissible for safety
reasons (e.g. with hoists and lifts), the spark suppressor can also be connected in parallel
to the brake coil.
¾
If the drive system is operated with a frequency inverter so that the brake will not be de-energized be-
fore the motor is at standstill, AC switching is also possible (not applicable to emergency braking).
¾
The specified engagement times are valid for DC switching with a spark suppressor.
– Circuit proposals: refer to DC switching at mains – fast engagement.
Notice
Spark suppressors are available for the rated voltages.
Disengagement time
The disengagement time is the same for DC-side and AC-side switching. The specified disengagement
times always refer to control using Kendrion INTORQ rectifiers and rated voltage.