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
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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
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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