Kendrion INTORQ BFK518 Quick guide

INTORQ BFK518
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
www.intorq.com

Document history
Material number Version Description
33008872 1.0 06/2020 SC First edition ST4
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 drive system
– operating errors
– disregarding the documentation
Warranty
Notice
The warranty conditions can be found in the terms of sale and delivery from INTORQ GmbH &
Co. KG.
¾
Warranty claims must be made to INTORQ immediately after the defects or faults are detected.
¾
The warranty is void in all cases when liability claims cannot be made.
Checking the delivery
After receipt of the delivery, check immediately whether the items delivered match the accompanying pa-
pers.
INTORQ does not accept any liability for deficiencies claimed subsequently.
¾
Claim visible transport damage immediately to the deliverer.
¾
Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG.
INTORQ | BA 14.0222 | 06/2020 2

Contents
1 General information................................................................................................................................................... 5
1.1 Using these Operating Instructions ...................................................................................................................... 5
1.2 Conventions in use............................................................................................................................................... 5
1.3 Safety instructions and notices ............................................................................................................................ 6
1.4 Terminology used................................................................................................................................................. 7
1.5 Abbreviations used............................................................................................................................................... 7
2 Safety instructions..................................................................................................................................................... 9
2.1 General safety instructions................................................................................................................................... 9
2.2 Disposal ............................................................................................................................................................... 9
3 Product description ................................................................................................................................................. 10
3.1 Proper and intended usage................................................................................................................................ 10
3.1.1 Standard applications ............................................................................................................................ 10
3.2 Layout ................................................................................................................................................................ 10
3.2.1 Spring-applied brake BFK518 ............................................................................................................... 10
3.3 Function ............................................................................................................................................................. 11
3.4 Braking and release ........................................................................................................................................... 11
3.5 Project planning notes........................................................................................................................................ 11
4 Technical specifications.......................................................................................................................................... 12
4.1 Possible applications of the INTORQ spring-applied brake ............................................................................... 12
4.2 Rated data.......................................................................................................................................................... 12
4.3 Switching times .................................................................................................................................................. 13
4.4 Electromagnetic compatibility............................................................................................................................. 15
4.5 Emissions........................................................................................................................................................... 15
4.6 Rust film on friction parts.................................................................................................................................... 15
4.7 Labels on product............................................................................................................................................... 16
5 Mechanical installation............................................................................................................................................ 18
5.1 Design of end shield and shaft........................................................................................................................... 18
5.2 Tools .................................................................................................................................................................. 18
5.3 Preparing the installation.................................................................................................................................... 18
5.4 Installing the hub onto the shaft ......................................................................................................................... 19
5.5 Brake mounting .................................................................................................................................................. 20
INTORQ | BA 14.0222 | 06/2020 3

6 Electrical installation ............................................................................................................................................... 23
6.1 Electrical connection .......................................................................................................................................... 23
7 Commissioning and operation ............................................................................................................................... 24
7.1 Function checks before initial commissioning .................................................................................................... 24
7.1.1 Function check of the brake .................................................................................................................. 24
7.2 Commissioning................................................................................................................................................... 24
7.3 Operation ........................................................................................................................................................... 24
8 Maintenance and repair........................................................................................................................................... 25
8.1 Wear of spring-applied brakes ........................................................................................................................... 25
8.2 Inspections ......................................................................................................................................................... 25
8.3 Spare parts list ................................................................................................................................................... 25
9 Troubleshooting and fault elimination................................................................................................................... 26
INTORQ | BA 14.0222 | 06/2020 4

General information
INTORQ | BA 14.0222 | 06/2020 5
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 Underscore, orange _____
Reference to another page with additional
information
For example: Using these Operating In-
structions,Page5
Symbols
Wildcard □
Wildcard (placeholder) for options or selec-
tion details
For example: BFK518-□□ = BFK518-80
Notice Important notice about ensuring smooth op-
erations or other key information.

General information
INTORQ | BA 14.0222 | 06/2020 6
1.3 Safety instructions and notices
The following icons and signal words are used in this document to indicate dangers and important safety
information:
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 causes
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.

General information
INTORQ | BA 14.0222 | 06/2020 7
1.4 Terminology used
Term In the following text used for
Servo brake Electromagnetically released brake
Drive system Drive systems with spring-applied brakes and other drive compo-
nents
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 spread 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

General information
INTORQ | BA 14.0222 | 06/2020 8
Letter symbol Unit Designation
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
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 reaching
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
INTORQ | BA 14.0222 | 06/2020 9
2 Safety instructions
2.1 General safety instructions
¾
Never operate INTORQ components when you notice they are damaged.
¾
Never make any technical changes to INTORQ components.
¾
Never operate INTORQ components when they are incompletely mounted or incompletely connected.
¾
Never operate INTORQ components without their required covers.
¾
Only use accessories that have been approved by 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, INTORQ components may have both live (voltage carrying),
moving and rotating parts. Such components require the appropriate safety mechanisms.
¾
Surfaces can become hot during operation. Take the 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 INTORQ components may only be carried out by quali-
fied 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 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
INTORQ | BA 14.0222 | 06/2020 10
3 Product description
3.1 Proper and intended usage
3.1.1 Standard applications
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 INTORQ. The INTORQ components 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 Technical specifications,Page12) must be fol-
lowed to comply with the proper and intended usage. Any other usage is consider improper and prohibited.
3.2 Layout
This chapter describes the variants, layout and functionality of the BFK518 spring-applied brake.
3.2.1 Spring-applied brake BFK518
A
C
B
F
E
G
D
Fig.1: Structure and layout of an INTORQ BFK518 spring-applied brake
AHub BRotor CCounter friction surface (flange)
DArmature plate ECoil FStator
GPressure spring
Notice
¾
Friction parts: The flange (sheet metal part) and the counter friction surface are not pro-
tected against corrosion.
¾
Rust film may occur under certain circumstances. The functionality of the brake is not af-
fected by this.

Product description
INTORQ | BA 14.0222 | 06/2020 11
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 spring force
applied by pressure springs between the armature plate and a counter friction surface. This corresponds
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 and for emergency stops.
The friction linings designed to be used in servo drives ensure a safe braking torque.
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.
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 friction linings ensure high braking torque
and low wear. 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
The friction linings are specially designed for the typical usage scenario of a servo drive.
¾
When designing a brake for specific applications, torque tolerances, the limiting speeds of the rotors,
the thermal resistance of the brake, and the effect of environmental influences must all be taken into
account.
¾
However, as the organic friction linings used do not all have identical properties and because environ-
mental conditions can vary, deviations from the specified braking torques are possible. These must be
taken into account in the form of appropriate dimensioning tolerances. Increased breakaway torque is
common in particular after long downtimes in humid environments where temperatures vary.

Technical specifications
INTORQ | BA 14.0222 | 06/2020 12
4 Technical specifications
4.1 Possible applications of the INTORQ spring-applied brake
¾
Degree of protection:
– The brake is designed for operation under the operating conditions that apply to IP00 protection.
Because of the numerous possibilities of using the brake, it is still necessary to check the function-
ality of all mechanical components under the corresponding operating conditions.
¾
Ambient temperature:
– +5 °C to 120 °C (Standard)
– -20 °C to 120 °C (non-condensing)
4.2 Rated data
Size Rated braking torque M4
at Δn=100 rpm
Braking torque Mdyn 1)
at Δn0 [rpm]
Max. speed Δn0max
[Nm] [Nm] [rpm]
80 14
11 3000
10 4500
8 6000
100 25 22 3000
20 4500
Tab.1: Rated braking torques as a function of speed
1) Braking torque for dynamic braking, at which braking from the specified max. speed is reduced to 0 rpm.
Size Screw hole circle Screw set for flange attachment
DIN EN ISO 4762 (8.8)1) 2)
Tightening torque
Screws
± 10%
Ø [mm] [Nm]
80 72 4 x M5 5.9
100 90 4 x M5 5.9
Tab.2: Rated data for the brake-mount screws
1) The screw length depends on the material and the thickness of the customer's mounting surface.
2) Ensure that there is sufficient free clamping length (> 5 mm).

Technical specifications
INTORQ | BA 14.0222 | 06/2020 13
Size Electrical power
PN
Coil voltage
U
Coil resistance
RN±8%
Rated current
IN
[W] [V] [Ω] [A]
80 21.5 24 27.5 0.9
100 22 24 26.1 0.92
Tab.3: Rated data for coil power
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.
NOTICE
The release (venting) times can be reduced by over-excitation.
t
t
M
t2
t12
t11
t1
Mdyn
U
0.1Mdyn
Fig.2: 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

Technical specifications
INTORQ | BA 14.0222 | 06/2020 14
Size Brake torque
M4
QEShue
*) Operating times 1)
DC-side engagement Disengaging
t11 t12 t1t2 / t2 at sLmax
[Nm] [J] [1/h] [ms] [ms] [ms] [ms]
80 14 2500 - 18 27 45 120 / 420
100 25 3000 - 20 30 50 165 / 480
Tab.4: Switching energy - operating frequency - operating times
1) The operating times specified refer to the usage of coils with a connection voltage of 24 V DC at sLN and 0.7 IN and
an induction voltage peak of 300 V.
*) There are no data for Shue, since it is a pure holding brake.
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. Therefore, a circuit
without a freewheel branch with an induction voltage peak must be provided. The level of the limited in-
duction voltage is decisive for the engagement time of the brake.
Engagement time with freewheel diode: The engagement time is significantly longer (approx. 10 - 12 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
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 disengagement time in-
creases as the wear increases. Refer to the specifications for the disengagement time at max. air gap.

Technical specifications
INTORQ | BA 14.0222 | 06/2020 15
4.4 Electromagnetic compatibility
Notice
The user must ensure compliance with EMC Directive 2014/30/EC using appropriate controls
and switching devices.
4.5 Emissions
Heat
Since the brake converts kinetic energy and electrical energy into heat, the surface temperature varies
considerably, depending on the operating conditions and possible heat dissipation. A surface temperature
of 130 °C may be reached under unfavorable conditions.
In the servo-motor, heat is dissipated by the thermal coupling of the brake to the motor end shield.
Noise
The loudness of the switching noise during engaging and disengaging depends on the air gap "sL" and the
brake size.
Depending on the natural oscillation after installation, operating conditions and the state of the friction sur-
faces, the brake may squeak during braking.
4.6 Rust film on friction parts
The flange (sheet metal part) and the counter friction surface are not protected against corrosion. Rust film
may occur under certain circumstances. The functionality of the brake is not affected by this.

Technical specifications
INTORQ | BA 14.0222 | 06/2020 16
4.7 Labels on product
There is a packaging label on the package. The name plate is glued to the outer surface of the brake.
Fig.3: Packaging label
INTORQ Manufacturer
33007467 ID number
BFK518-80 Type (refer to Product key )
Bar code
SPRING-APPLIED BRAKE Designation of the product family
24 V DC Rated voltage
14 NM M4 torque
Pieces Qty. per box
21 W Rated power
30 H7 Hub diameter
11.02.20 Packaging date
Anti-rust packaging: keep friction surface free of
grease! Addition
CE mark

Technical specifications
INTORQ | BA 14.0222 | 06/2020 17
Fig.4: Name plate (example)
INTORQ Manufacturer
BFK518-80 Type (refer to Product key )
24 V DC Rated voltage
21 W Rated power
No. 33007467 ID number
14 NM M4 torque
11.02.20 Date of manufacture
Data matrix code
CE mark

Mechanical installation
INTORQ | BA 14.0222 | 06/2020 18
5 Mechanical installation
This chapter provides step-by-step instructions for the installation.
Important notes
NOTICE
The toothed hub and screws must not be lubricated with grease or oil.
5.1 Design of end shield and shaft
¾
Comply with the specified minimum requirements regarding the end shield and the shaft to ensure a
correct function of the brake.
¾
The diameter of the shaft shoulder must not be greater than the tooth root diameter of the hub.
¾
The form and position tolerances apply only to the materials mentioned. Consult with INTORQ before
using other materials; INTORQ's written confirmation is required for such usage.
¾
The brake is screwed on at the rear; the bearing is usually used for the support. Make sure that the
screws are tightened evenly all round to prevent the brake from tilting. Use a torque wrench according
to DIN.
¾
Keep the end shield free from grease or oil.
5.2 Tools
Size Torque wrench
DIN EN ISO 6789 / Type 2
Insert for
hexagonal socket (Allen) screws
Multimeter
Measuring range Wrench width
[Nm] [mm]
80 1 to 12 4
100 4
5.3 Preparing the installation
1. Remove the packaging from the spring-applied brake and dispose of it properly.
2. Check the delivery for completeness.
3. Check the name plate specifications (especially rated voltage)!

Mechanical installation
INTORQ | BA 14.0222 | 06/2020 19
5.4 Installing the hub onto the shaft
NOTICE
When the brake is being used in a servo motor, we recommend attaching the hub with a
shrink fitting (heating it up first). Alternatively, a key may be used to avoid shrinkage.
Notice
Recommended ISO fitting for shaft: Max. Ø 50 mm, according to basic tolerance series
IT6
Recommended roughness of the shaft: Rzmax 4.0
A
B
C
Fig.5: Installing the hub onto the shaft
AHub BShaft CShaft shoulder
Requirement for mounting:
The design of the shaft must be such that the axial position of the hub fits relative to the de-
sign of the brake.
A minimum distance of at least 1.2 mm between the hub and armature plate must be main-
tained!
1. Heat up the hub to the necessary joining temperature of approx. 300 °C.
2. Push the hub into position against the shaft shoulder (refer to illustration).
3. Allow the hub to cool completely before proceeding with the assembly. The full holding force of the
shaft-hub connection is reached after approx. 24 hours.

Mechanical installation
INTORQ | BA 14.0222 | 06/2020 20
5.5 Brake mounting
Notice
Depending on the particular design, the sequence of assembly steps may vary.
A
B
C
D
Fig.6: Mounting the brake
ABrake BFK518 BMotor shaft CEnd shield of hub
DMotor housing (example)
1. Push the brake along with the internal rotor toothing onto the completely cooled hub.
NOTICE
When routing the connecting wire leads, make sure that there is no contact between these
leads and moving parts such as the rotor or armature plate.
Notice
Mount the connecting lead according to the current motor housing being used. Two mounting
options are shown in the illustration:
¾
Mounting the connecting lead in the direction of insertion
¾
Mounting the connecting lead against the insertion direction (This saves space! Refer to
the magnified image.)
2. Route and contact the connecting lead. Pay attention to the following: The connecting lead must be
routed in such a way that the permissible bending radii are observed! Damage caused by sharp edges
must be avoided.