Kendrion INTORQ BFK458-ATEX User manual

INTORQ BFK458-ATEX
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
www.kendrion.com

Document history
Material number Version Description
33007851 1.0 09/2019 SC First edition
33007851 2.0 07/2021 SC Change of name to Kendrion INTORQ
Changes to Chapter 6.1, additions to Chapters 9.2 and 9.3
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
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 detected.
¾
The warranty is void in all cases when liability claims cannot be made.
Kendrion INTORQ | BA 14.0217 | 07/2021 2

Spring-applied brakes of type BFK458-06...25
Design E Design N
Double spring-applied brake
Kendrion INTORQ | BA 14.0217 | 07/2021 3

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
B FKINTORQ
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 14.0217 | 07/2021 4

Contents
Legal regulations ....................................................................................................................................................... 2
Warranty...................................................................................................................................................................... 2
Spring-applied brakes of type BFK458-06...25........................................................................................................ 3
Product key................................................................................................................................................................. 4
Checking the delivery................................................................................................................................................ 4
1 General information................................................................................................................................................... 8
1.1 Using these Operating Instructions...................................................................................................................... 8
1.2 Conventions in use............................................................................................................................................... 8
1.3 Safety instructions and notices ............................................................................................................................ 8
1.4 Terminology used................................................................................................................................................. 9
1.5 Abbreviations used............................................................................................................................................. 10
2 Safety instructions................................................................................................................................................... 12
2.1 General safety instructions................................................................................................................................. 12
2.2 Safety notices for use in potentially explosive areas.......................................................................................... 13
2.3 Disposal ............................................................................................................................................................. 13
3 Product description ................................................................................................................................................. 14
3.1 Proper and intended usage................................................................................................................................ 14
3.1.1 Standard applications............................................................................................................................ 14
3.2 Design................................................................................................................................................................ 15
3.2.1 Spring-applied brake as holding/parking brake ..................................................................................... 15
3.2.2 Spring-applied brake used as a holding brake with emergency-stop function and as a service brake..15
3.2.3 Basic module E...................................................................................................................................... 16
3.2.4 Basic module N ..................................................................................................................................... 17
3.2.5 Basic module L...................................................................................................................................... 17
3.2.6 Double spring-applied brake.................................................................................................................. 18
3.3 Function ............................................................................................................................................................. 18
3.4 Braking and release ........................................................................................................................................... 19
3.5 Brake torque reduction....................................................................................................................................... 19
3.6 Optional configuration ........................................................................................................................................ 19
3.6.1 Hand-release (optional)......................................................................................................................... 19
4 Project planning notes ............................................................................................................................................ 20
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5 Technical specifications.......................................................................................................................................... 21
5.1 General information............................................................................................................................................ 21
5.2 Possible applications of the Kendrion INTORQspring-applied brake................................................................. 21
5.3 Brake torques..................................................................................................................................................... 22
5.4 Characteristics ................................................................................................................................................... 23
5.5 Operating times.................................................................................................................................................. 28
5.6 Friction work / operating frequency.................................................................................................................... 30
5.7 Dust explosive atmosphere (zone 22: non-conductive dusts)............................................................................ 30
5.8 Gas explosive atmosphere (zone 2) .................................................................................................................. 32
5.9 Example calculation for the charts ..................................................................................................................... 35
5.10 Electromagnetic compatibility............................................................................................................................. 35
5.11 Emissions........................................................................................................................................................... 36
5.12 Hand-release...................................................................................................................................................... 36
5.13 Labels on product............................................................................................................................................... 37
5.14 ATEX marking.................................................................................................................................................... 39
6 Mechanical installation............................................................................................................................................ 40
6.1 Design of end shield and shaft........................................................................................................................... 41
6.2 Tools .................................................................................................................................................................. 42
6.3 Preparing the installation.................................................................................................................................... 42
6.4 Installing the hub onto the shaft ......................................................................................................................... 43
6.5 Mounting the brake ............................................................................................................................................ 44
6.6 Installing the friction plate (optional)................................................................................................................... 47
6.7 Mounting the flange............................................................................................................................................ 47
6.7.1 Mounting the flange without additional screws...................................................................................... 47
6.7.2 Installing the flange (variants: size 06 - 16)........................................................................................... 48
6.7.3 Installing the flange (variants: size 18 - 20)........................................................................................... 49
6.7.4 Installing the flange (variants: size 25) .................................................................................................. 50
6.8 Installing the double spring-applied brake.......................................................................................................... 51
6.9 Cover ring assembly .......................................................................................................................................... 52
6.10 Installing the shaft sealing ring........................................................................................................................... 53
6.11 Mounting the hand-release (retrofitting)............................................................................................................. 54
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7 Electrical installation ............................................................................................................................................... 55
7.1 Electrical connection .......................................................................................................................................... 55
7.2 AC switching at the motor – extremely delayed engagement ............................................................................ 56
7.3 DC switching at the motor – fast engagement ................................................................................................... 57
7.4 AC switching at mains – delayed engagement .................................................................................................. 58
7.5 DC switching at mains – fast engagement......................................................................................................... 59
7.6 Minimum bending radius for the brake connection cable................................................................................... 60
7.7 Bridge/half-wave rectifier (optional).................................................................................................................... 60
7.7.1 Assignment: Bridge/half-wave rectifier – brake size.............................................................................. 61
7.7.2 Technical specifications......................................................................................................................... 61
7.7.3 Reduced switch-off times ...................................................................................................................... 62
7.7.4 Permissible current load at ambient temperature.................................................................................. 62
8 Commissioning and operation ............................................................................................................................... 63
8.1 Possible applications of the Kendrion INTORQ spring-applied brake................................................................ 63
8.2 Function checks before initial commissioning .................................................................................................... 64
8.2.1 Function check of the brake .................................................................................................................. 64
8.2.2 Release / voltage control....................................................................................................................... 64
8.2.3 Testing the hand-release functionality................................................................................................... 65
8.3 Commissioning................................................................................................................................................... 66
8.4 Operation ........................................................................................................................................................... 67
8.4.1 Brake torque reduction (for the optional adjustable braking torque)...................................................... 68
8.4.2 Operating procedures............................................................................................................................ 68
9 Maintenance and repair........................................................................................................................................... 69
9.1 Wear of spring-applied brakes ........................................................................................................................... 69
9.2 Inspections......................................................................................................................................................... 70
9.2.1 Maintenance intervals............................................................................................................................ 71
9.3 Maintenance....................................................................................................................................................... 71
9.3.1 Brake testing.......................................................................................................................................... 72
9.3.2 Checking the air gap.............................................................................................................................. 73
9.3.3 Release / voltage................................................................................................................................... 73
9.3.4 Adjusting the air gap.............................................................................................................................. 74
9.3.5 Checking the rotor thickness ................................................................................................................. 74
9.3.6 Replacing the rotor ................................................................................................................................ 74
9.4 Spare parts list ................................................................................................................................................... 76
10 Troubleshooting and fault elimination................................................................................................................... 79
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General information
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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8
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:

General information
Kendrion INTORQ | BA 14.0217 | 07/2021 9
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 14.0217 | 07/2021 10
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