Related Manuals for INTORQ BFK458-06...25
Summary of Contents for INTORQ BFK458-06...25
- Page 1 INTORQ BFK458 Electromagnetically Released Spring-Applied Brake Translation of the Original Operating Instructions www.intorq.com www.intorq.com...
- Page 2 ❚ We do not accept any liability for damage and operating interference caused by: inappropriate use unauthorised modifications to the product improper work on or with the drive system operating errors disregarding the documentation INTORQ | BA 14.0168 | 09/2015...
- Page 3 Warranty NOTICE The warranty conditions can be found in the terms and conditions of INTORQ GmbH & Co. KG. ❚ Warranty claims must be made to INTORQ immediately after the defects or faults are detected. ❚ The warranty is void in all cases when liability claims cannot be made.
- Page 4 ❚ Drive systems and components are unambiguously designated by the labelling on their nameplates. ❚ The INTORQ spring-applied brake is also delivered in single modules which can then be put together by the customer according to their requirements. The specifications – particularly the packaging label, nameplate and type code –...
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Page 5: Table Of Contents
5.6.3 Installing the flange (variants: sizes 18 – 20) ...................36 5.6.4 Installing the flange (variants: size 25) .....................37 Installing the double-rotor brake........................38 Cover ring assembly ............................39 Installing the shaft seal..........................40 5.10 Installing the manual release (retrofitting) ....................41 INTORQ | BA 14.0168 | 09/2015... - Page 6 8.3.2 Check the rotor thickness ........................59 8.3.3 Check the air gap ..........................59 8.3.4 Release / voltage ..........................60 8.3.5 Adjusting the air gap ........................60 8.3.6 Replacing the rotor ...........................61 Spare-parts list .............................62 Troubleshooting and fault elimination ........................64 INTORQ | BA 14.0168 | 09/2015...
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Page 7: General Information
Reference to another page with additional information For example: 16 = refer to page 16 Wildcard Wildcard for options, selections Symbols For example: BFK458- = BFK458-10 Note Important notice about ensuring smooth operations or other key information. INTORQ | BA 14.0168 | 09/2015... -
Page 8: Safety Instructions And Notices
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or mod- erate injury. NOTICE Notice about a harmful situation with possible consequences: the product itself or surrounding objects could be damaged. INTORQ | BA 14.0168 | 09/2015... -
Page 9: Terminology Used
Transition switching frequency, thermal parameter of the brake Maximum permissible switching frequency, depending on the friction energy hmax per switching operation Air gap: the lift of the armature plate while the brake is switched Rated air gap Minimum air gap Lmin INTORQ | BA 14.0168 | 09/2015... - Page 10 Over-excitation time Voltage V DC Holding voltage, after voltage change-over V DC Release voltage, before voltage change-over V DC Rated coil voltage; in the case of brakes requiring a voltage change-over, equals U INTORQ | BA 14.0168 | 09/2015...
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Page 11: Safety Instructions
These must be followed to maintain safe, trouble-free operations and to achieve the speci- fied product characteristics. ❚ 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 prod- uct. -
Page 12: Product Description
The double-brake version is especially useful in redundant braking applications. 3.2.1 Basic module E Fig. 1 Design of the INTORQ BFK458 spring-applied brake: Basic module E (complete stator) + rotor + hub + flange Compression piece Torque adjustment ring Stator ... -
Page 13: Basic Module N
Product description 3.2.2 Basic module N Fig. 2 Design of the INTORQ BFK458 spring-applied brake: Basic module N (complete stator) + rotor + hub + flange Stator Socket head cap screw Manual release (optional) Sleeve bolt Rotor ... -
Page 14: Basic Module N, Doubled Design
Product description 3.2.4 Basic module N, doubled design Fig. 3 Design of the INTORQ BFK458 spring-applied brake: Basic module N, doubled design with intermediate flange Stator Socket head cap screw Screw for intermediate flange Intermediate flange Manual release (optional) Sleeve bolts ... -
Page 15: Optional Configuration
A cover ring over the armature plate and rotor. ❚ Cover plate ❚ Shaft seal (can be supplied for continuous shaft). 3.3.4 Optional CCV The Cold Climate Version (CCV) allows the brake to be operated at lower ambient temperatures. INTORQ | BA 14.0168 | 09/2015... -
Page 16: Technical Specifications
Technical specifications Technical specifications Usage conditions for the INTORQ spring-applied brake ❚ Degree of protection: The brake is designed for operation under the environmental conditions that apply to IP54 protec- tion. Because of the numerous possibilities of using the brake, it is still necessary to check the func- tionality of all mechanical components under the corresponding operating conditions. -
Page 17: Rated Data
11.5 10.0 13.0 12.0 16.0 1.25 0.75 15.5 20.0 19.5 Tab. 3: Rated data for air gap specifications The friction lining is designed so that the brake can be adjusted at least 5 times. INTORQ | BA 14.0168 | 09/2015... - Page 18 3 x M8x80 3 x M8x90 6 x M8x80 6 x M8x90 6 x M10x90 6 x M10x100 6 x M10x100 6 x M10x110 Tab. 5: Rated data for the screw set for brake mounting INTORQ | BA 14.0168 | 09/2015...
- Page 19 [] 28.8 0.83 460.8 0.21 530.5 0.194 1445 0.114 1620 0.111 1805 0.105 2101 0.098 1.04 0.26 424.4 0.242 1156 0.147 1296 0.138 1444 0.131 1681 0.121 Tab. 7: Rated data for coil power INTORQ | BA 14.0168 | 09/2015...
- Page 20 0.195 11.5 2.08 184.3 0.52 200.2 0.514 0.294 611.3 0.294 0.263 792.9 0.258 10.5 2.29 167.6 0.573 189.5 0.543 525.5 0.323 589.1 0.305 601.7 0.315 750.5 0.292 Tab. 7: Rated data for coil power INTORQ | BA 14.0168 | 09/2015...
- Page 21 106.1 0.970 0.588 0.55 328.2 0.578 420.3 0.487 5.24 4.58 83.8 1.14 96.5 1.06 262.7 0.647 294.6 0.611 328.2 0.578 382.1 0.536 Tab. 7: Rated data for coil power Coil power at 20 °C INTORQ | BA 14.0168 | 09/2015...
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Page 22: Switching Times
Switching energy - switching frequency - switching times The maximum permissible friction energy Q relates to the standard friction lining. These switching times are specified for the usage of INTORQ bridge/half-wave rectifiers and coils with a supply voltage of 205 V DC at s and 0.7 I... - Page 23 Spark suppressors are available for the rated voltages. Disengagement time The disengagement time is the same for DC and AC switching. The specified disengagement times always refer to control using INTORQ rectifiers and rated voltage. INTORQ | BA 14.0168 | 09/2015...
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Page 24: Switching Energy / Switching Frequency
, the permissible amount of heat is Q Smax NOTICE With high speeds of rotation and switching energy, the wear increases strongly, because very high temperatures occur at the friction surfaces for a short time. INTORQ | BA 14.0168 | 09/2015... -
Page 25: Electromagnetic Compatibility
The user must ensure compliance with EMC Directive 2004/108/EC using appropriate controls and switching devices. NOTICE If an INTORQ rectifier is used for the DC switching of the spring-applied brake: If the switch- ing frequency exceeds five switching operations per minute, the use of a mains filter is required. -
Page 26: Manual Release
" in order to function; this is factory-set prior to delivery. Check for the dimen- sion "s " after the installation. +0.1 +0.1 Size -0.05 (mm) (mm) Tab. 9: Adjustment setting for manual release INTORQ | BA 14.0168 | 09/2015... -
Page 27: Labels On Product
Rated torque 1 St. (1 piece) Quantity per box CSA_CUS approval Rated power 20 H7 Hub diameter 02.06.15 Packaging date Rostschutzverpackung-Reibfläche fettfrei halten! Addition (Anti-rust packaging: keep friction surface free of grease!) CE mark INTORQ | BA 14.0168 | 09/2015... - Page 28 Ambient temperature BFK458-25E Type (see product key) Class F Insulation class 180 V DC Rated voltage 110 W Rated power Nr. (No.) 15049627 Type number 350 NM Rated torque 30/07/2015 Date of manufacture CE mark INTORQ | BA 14.0168 | 09/2015...
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Page 29: Mechanical Installation
The diameter of the shaft shoulder must not be greater than the tooth-base diameter of the hub. ❚ 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. -
Page 30: Tools
Calliper gauge Feeler gauge 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 nameplate specifications (especially rated voltage)! INTORQ | BA 14.0168 | 09/2015... -
Page 31: Installing The Hub Onto The Shaft
NOTICE Check the tensile strength of the hub material: When operating with high torque, consult with INTORQ and use a steel hub with a higher tensile strength. Fig. 8 Installing the hub onto the shaft... -
Page 32: Installing The Brake
Socket head cap screw Stator, complete Terminal clip Rotor End shield 3. Screw the complete stator to the end shield Use the supplied set of screws and a torque wrench. INTORQ | BA 14.0168 | 09/2015... - Page 33 ", readjust this dimension. Loosen the socket head cap screws slightly and adjust the air gap (turn the sleeve bolts using a wrench). 7. Use a torque wrench to tighten the socket head cap screws (refer to Figure 11). INTORQ | BA 14.0168 | 09/2015...
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Page 34: Installing The Friction Plate (Optional)
1. Place the flange against the end shield. 2. Check the pitch circle and the threads of the bore holes. 3. Use the proper screw set ( 32 and 62) to mount the brake. INTORQ | BA 14.0168 | 09/2015... -
Page 35: Installing The Flange (Variants: Size 06)
4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thick- ness. Use screws according to the table NOTICE When mounting the flange, the various size classes must be distinguished: sizes 06 - 16, 18 - 20 and 25 are mounted differently. INTORQ | BA 14.0168 | 09/2015... -
Page 36: Installing The Flange (Variants: Sizes 18 - 20)
3. Use the four screws to screw the flange to the end shield. 4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thick- ness. Use screws according to the table INTORQ | BA 14.0168 | 09/2015... -
Page 37: Installing The Flange (Variants: Size 25)
3. Use the six screws to screw the flange to the end shield. 4. Check the height of the screw heads. The screw heads must not be higher than the minimum rotor thick- ness. Use screws according to the table INTORQ | BA 14.0168 | 09/2015... -
Page 38: Installing The Double-Rotor Brake
Required: The front hub has to be mounted on the shaft! 1. Mount the intermediate flange with the four screws in the threads of the rear magnet housing. All other steps for mounting the front brake are carried out as described in Chapter 5.4. INTORQ | BA 14.0168 | 09/2015... -
Page 39: Cover Ring Assembly
3. Press the corresponding lips of the cover ring in the groove of the stator and in the groove of the flange. If a friction plate is used, the lip must be pulled over the edging. INTORQ | BA 14.0168 | 09/2015... -
Page 40: Installing The Shaft Seal
❚ No grease should be allowed to contact the friction surfaces. ❚ When assembling the stator, push the shaft sealing ring carefully over the shaft. The shaft should be located concentrically to the shaft seal. INTORQ | BA 14.0168 | 09/2015... -
Page 41: Installing The Manual Release (Retrofitting)
" evenly using the hex head screws and the feeler gauge. Refer to Tab. 11 for the values for the dimension "s ". +0.1 +0.1 Size -0.05 (mm) (mm) Tab. 11: Adjustment setting for manual release INTORQ | BA 14.0168 | 09/2015... -
Page 42: Electrical Installation
NOTICE ❚ Make sure that the supply voltage matches the voltage specification on the nameplate. Electrical connection Circuit suggestions NOTICE The terminal pin sequence shown here does not match the actual order. INTORQ | BA 14.0168 | 09/2015... -
Page 43: Ac Switching At The Motor - Extremely Delayed Engagement
4-pole BEG-14x BEG-24x 6-pole BEG-16x BEG-26x Fig. 22 Supply: Phase-phase Bridge rectifier Half-wave rectifier BEG-1xx: U [VDC]=0.9 • U [VAC] BEG-2xx: U [VDC]=0.45 • U [VAC] Not recommended for most regional/national high-voltage mains systems INTORQ | BA 14.0168 | 09/2015... -
Page 44: Dc Switching At The Motor - Fast Engagement
L1 L1 L2 L2 L3 L3 6-pole BEG-16x BEG-26x Fig. 24 Supply: Phase-phase Bridge rectifier Half-wave rectifier BEG-1xx: U [VDC]=0.9 • U [VAC] BEG-2xx: U [VDC]=0.45 • U [VAC] Not recommended for most regional/national high-voltage mains systems INTORQ | BA 14.0168 | 09/2015... -
Page 45: Ac Switching At Mains - Delayed Engagement
4-pole BEG-14x BEG-24x 6-pole BEG-16x BEG-26x Fig. 26 Supply: Phase-phase Bridge rectifier Half-wave rectifier BEG-1xx: U [VDC]=0.9 • U [VAC] BEG-2xx: U [VDC]=0.45 • U [VAC] Not recommended for most regional/national high-voltage mains systems INTORQ | BA 14.0168 | 09/2015... -
Page 46: Dc Switching At Mains - Fast Engagement
BEG-14x: U [VDC]=0.9 • U [VAC] BEG-24x: U [VDC]=0.45 • U [VAC] Spark suppressor: 14.198.00.xx (required once, select position) For most regional/national high-voltage mains systems, this only makes sense for supplies on L1 and N. INTORQ | BA 14.0168 | 09/2015... -
Page 47: Technical Specifications For The Microswitch
The bridge/half-wave rectifiers are used to supply electromagnetic DC spring-applied brakes which are ap- proved for the use with such rectifiers. Other use is only permitted with the approval of INTORQ. Once a set over-excitation time has elapsed, the bridge/half-wave rectifiers switch over from bridge rectifi- cation to half-wave rectification. -
Page 48: Assignment: Bridge/Half-Wave Rectifier - Brake Size
Coil voltage Size Coil voltage Size [V AC] [V DC] [V DC] BEG-561-255-030 06 ... 16 06 ... 14 BEG-561-255-130 – 16 ... 25 BEG-561-440-030-1 06 ... 25 – – Fig. 29 BEG-561 attachment options INTORQ | BA 14.0168 | 09/2015... -
Page 49: Technical Specifications
Reduced switch-off times AC switching must also be carried out for DC switching (fast engagement)! Otherwise, there will be no over- excitation when it is switched back on. Delayed engagement Fast engagement Mains Bridge Coil INTORQ | BA 14.0168 | 09/2015... -
Page 50: Permissible Current Load At Ambient Temperature
Permissible current load at ambient temperature I max. -20 0 20 40 60 80 100 ϑ u [°C] 1 For screw assembly with metal surface (good heat dissipation) 2 For other assembly (e.g. adhesive) INTORQ | BA 14.0168 | 09/2015... -
Page 51: Commissioning And Operation
Commissioning and operation Commissioning and operation Usage conditions for the INTORQ spring-applied brake NOTICE In case of high humidity: If condensed water and moisture are present, provide for the appro- priate ventilation for the brake to ensure that all friction components dry quickly. -
Page 52: Function Checks Before Commissioning
3. Turn on the DC voltage for the brake. 4. Measure the AC voltage at the motor terminal. The AC voltage must be zero. 5. Close the switching contact for the brake. The brake is released. INTORQ | BA 14.0168 | 09/2015... -
Page 53: Microswitch - Checking For Wear
". The air gap must be zero and the rotor must rotate freely. 11. Switch off the brake current. 12. Screw the bridges back onto the motor terminals. 13. Remove the additional neutral conductor again. INTORQ | BA 14.0168 | 09/2015... -
Page 54: Test That The Manual Release Functions
The preparations for commissioning are completed. NOTICE If faults or malfunctions occur, refer to the the error search table ( 64). If the fault cannot be fixed or eliminated, please contact your customer service. INTORQ | BA 14.0168 | 09/2015... -
Page 55: Commissioning
Make sure that the armature plate is tightly attached and the drive moves without residual torque. ❚ Measure the DC voltage at the brake. Compare the measured DC voltage with the voltage indicated on the nameplate. The deviation must be less than ± 10%! INTORQ | BA 14.0168 | 09/2015... -
Page 56: Brake Torque Reduction
Do not change the manual release setting for models with manual release. Operating procedures The friction lining and the friction surfaces must never contact oil or grease since even small amounts reduce the braking torque considerably. INTORQ | BA 14.0168 | 09/2015... -
Page 57: Maintenance And Repair
Axial load cycle and shear stress of springs Reduced spring force or Number of switching through radial backlash on reversal of arma- fatigue failure operations of brake ture plate Tab. 15: Causes for wear INTORQ | BA 14.0168 | 09/2015... -
Page 58: Inspections
❚ After replacing the rotor, the original braking torque will not be reached until the run-in oper- ation for the friction surfaces has been completed. After replacing the rotor, the run-in arma- ture plates and the flanges have an increased initial rate of wear. INTORQ | BA 14.0168 | 09/2015... -
Page 59: Checking The Component Parts
" between the armature plate and the stator near the fixing screws using a feeler gauge (values: 17). 2. Compare the measured air gap to the value for the max. permissible air gap "s " (values: 17). Lmax 3. Adjust the air gap to "s " ( 60). INTORQ | BA 14.0168 | 09/2015... -
Page 60: Release / Voltage
2. Screw the sleeve bolts (using a wrench) further into the stator. A 1/6 turn will decrease the air gap by approximately 0.15 mm. 3. Re-tighten the screws (torque: 18). 4. Check the "s " near the screws using a feeler gauge (s 17). INTORQ | BA 14.0168 | 09/2015... -
Page 61: Replacing The Rotor
10. Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is reached. 11. You can now install and adjust the new rotor and the complete stator ( 32). 12. Re-connect the connecting cables. INTORQ | BA 14.0168 | 09/2015... -
Page 62: Spare-Parts List
Maintenance and repair Spare-parts list Spring-applied brake INTORQ BFK458-06 to 25 Designation Variant Complete stator, module E Voltage / braking torque Complete stator, module N Complete rotor Aluminium rotor Aluminium rotor with sleeve - Low-noise version Hole diameter [mm] slot according to DIN 6885/1... - Page 63 Maintenance and repair Double spring-operated brake INTORQ BFK458-06 to 25 Designation Variant Complete stator, module N Voltage / braking torque - Optionally with rear threads Complete rotor Aluminium rotor Aluminium rotor with sleeve - Low-noise version Hub with standard bore...
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Page 64: Troubleshooting And Fault Elimination
Micro-switch incorrectly set Replace the complete stator and make a complaint about the setting of the microswitch to the manufacturer. Air gap "s " is too large Adjust the air gap: INTORQ | BA 14.0168 | 09/2015... - Page 65 Adjust rectifier and brake voltage to each other. the rectifier Defective rectifier diode Replace defective rectifier with a suitable undamaged one. AC voltage is not mains Fuse is missing or defective Select a connection with proper fusing. voltage INTORQ | BA 14.0168 | 09/2015...
- Page 66 Notes Notes INTORQ | BA 14.0168 | 09/2015...
- Page 68 INTORQ GmbH & Co KG Germany PO Box 1103 D-31849 Aerzen, Germany Wülmser Weg 5 D-31855 Aerzen, Germany +49 5154 70534-444 +49 5154 70534-200 info@intorq.com INTORQ (SHANGHAI) Co., Ltd China No. 600, Xin Yuan Road Building No.