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Summary of Contents for INTORQ BFK455
- Page 1 INTORQ BFK455 Electromagnetically released spring-applied brake Operating Instructions www.intorq.com...
- Page 2 BFK455-001.iso/dms BFK455-020.iso/dms Product key Product key INTORQ Legend for the INTORQ BFK455 product key Product group Brakes Product type Spring-applied brake Type Size Not coded: supply voltage, hub bore, options...
- Page 3 Type No. Name Quantity per box Rated voltage Rated torque Packing date Rated power Hub diameter Additional information CE designation BFK455-101.iso/dms Nameplate Example Manufacturer Type (see product key) CE designation Rated voltage Rated power Hub diameter Type No. Rated torque Production date BFK455-002.iso/dms...
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Page 4: Table Of Contents
j | BA 14.0196 | 05/2013 Contents Preface and general information ........About these Operating Instructions . - Page 5 j | BA 14.0196 | 05/2013 Contents Maintenance/repair ..........Wear of spring-applied brakes .
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Page 6: Preface And General Information
j | BA 14.0196 | 05/2013 Preface and general information Preface and general information About these Operating Instructions These Operating Instructions will help you to work safely on and with the spring-applied brake with electromagnetic release. They contain safety instructions that must be followed. -
Page 7: Abbreviations Used
j | BA 14.0196 | 05/2013 Preface and general information Abbreviations used Abbreviation Unit Name Current Holding current at 20 °C and holding voltage Release current at 20 °C and release voltage Rated current at 20 °C and rated voltage Tightening torque of the fixing screws Rated torque of brake, rated value at a relative speed of 100 rpm Maximum speed during the slipping time t3... -
Page 8: Notes Used
j | BA 14.0196 | 05/2013 Preface and general information Notes used The following pictographs and signal words are used in this documentation to indicate dangers and important information: Safety instructions Structure of safety instructions: Danger! Characterises the type and severity of danger Note Describes the danger Possible consequences:... -
Page 9: Scope Of Supply
Scope of supply After receipt of the delivery, check immediately whether it corresponds to the accompanying papers. INTORQ does not grant any warranty for deficiencies claimed subsequently. Claim visible transport damage immediately to the forwarder. Claim visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG. -
Page 10: Legal Regulations
– operating faults – disregarding the documentation Warranty Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG. Warranty claims must be made to INTORQ immediately after detecting defects or faults. The warranty is void in all cases where liability claims cannot be made. -
Page 11: Safety Instructions
This is vital for a safe and trouble-free operation and for achieving the specified product features. Only qualified, skilled personnel are permitted to work on and with INTORQ components. In accordance with IEC 60364 or CENELEC HD 384, qualified, skilled personnel are persons ... -
Page 12: Application As Directed
– ... must not be operated beyond their corresponding power limits. Any other use shall be deemed inappropriate! Possible applications of the INTORQ spring-applied brake Humidity: no restrictions – In case of formation of condensed water and moisture: provide for appropriate ventilation to ensure that all components will dry quickly. -
Page 13: Technical Data
Emergency braking is possible at high speed. The more friction work, the higher the wear, (operating speeds 16). The BFK455 spring-applied brake is a double disc brake with four friction surfaces. The braking torque is generated within two electrically and mechanically separated braking circuits by means of several compression springs (1.2) with friction locking. - Page 14 The stator (1) is designed in temperature class F. The temperature limit of the coils (8) is 155 °C. The BFK455 spring-applied brake is designed for a maximum operating time of 60 % with a reduction of the holding current.
- Page 15 j | BA 14.0196 | 05/2013 Technical data 3.1.6 Project planning notes The brakes are dimensioned in such a way that the given characteristic torques are reached safely after a short run-in process. Due to the fluctuating properties of the organic friction linings used and the alternating environmental conditions, deviations of the given braking torques may occur.
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Page 16: Rated Data
BFK455-28 6 x M16x210 6 x M16x220 22.5 Tab. 1 Dimensions of the BFK455-28 Stop! | The minimum thread depth of the end shield must be observed in any case, Tab. 1 | If the required thread depth is not observed, the fixing screws may run into the thread root. -
Page 17: Rated Data (Selection Data)
BFK455-28 2 x 434 2 x 108.5 2 x 298.6 2 x 1.21 Tab. 2 Coil power ratings of the BFK455-28 Rated data (selection data) BFKXXX-011.iso/dms Fig. 2 Operating times of the spring-applied brakes Engagement time Reaction delay during engagement Disengagement time (up to M = 0.1 M... - Page 18 j | BA 14.0196 | 05/2013 Technical data Engagement time The transition from brake-torque free state to holding braking torque is not free of time lags. Short brake engagement times are vital for emergency braking. DC switching together with a suitable spark suppressor must therefore be provided. The engagement times are valid for DC switching with a spark suppressor.
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Page 19: Friction Work / Operating Frequency
| BA 14.0196 | 05/2013 Technical data Friction work / operating frequency BFK455-003.iso/dms Fig. 3 Switching energy as a function of the operating frequency − p −p ÜìÉ ÜìÉ N − É p Ü ëã~ñ ... -
Page 20: Emission
The user must ensure compliance with EMC Directive 2004/108/EC using appropriate controls and switching devices. If an INTORQ rectifier is used for the DC switching of the spring-applied brake and if the operating frequency exceeds five switching operations per minute, the use of a mains filter is required. -
Page 21: Mechanical Installation
16 EN-GJL-250 Free of grease and oil In case of other materials please consult INTORQ. Tab. 4 Counter friction face design of the end shield The diameter of the shaft shoulder must not be bigger than the tooth root diameter of the hub. -
Page 22: Installation
1. Unpack spring-applied brake. 2. Check for completeness. 3. Check nameplate data, especially rated voltage. 4.3.3 Overview without separate counter friction face with flange BFK455-007.iso/dms BFK455-008.iso/dms Installation Stop! Toothed hub and screws must not be lubricated with grease or oil! ... - Page 23 | BA 14.0196 | 05/2013 Mechanical installation 4.4.1 Brake assembly Mounting the first hub onto the shaft BFK455-009.iso/dms BFK455-010.iso/dms Keyway End shield 1. Insert keyway (4.1) into the shaft. 2. Press the first hub (4) onto the shaft. 3. Secure hub (4) against axial displacement, e.g. by using a circlip (4.2).
- Page 24 | BA 14.0196 | 05/2013 Mechanical installation Assembly of the first rotor BFK455-012.iso/dms Fig. 5 Mounting of the rotor Rotor Flange End shield 6. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand.
- Page 25 | BA 14.0196 | 05/2013 Mechanical installation Assembly of the first stator BFK455-015.iso/dms BFK455-015a.iso/dms Fig. 7 Assembly of the stator Complete stator Flange Complete rotor 4.2 Circlip 15 End shield 10. Push the complete stator onto the shaft. 11. Align the through holes in the complete stator (1) to the threads of the fastening bore holes.
- Page 26 | After the mounting, excessive mounting paste must be removed properly! Note! If a manual release is to be installed, the required worksteps in chapter 4.5.2Step 2 must be carried out now! Assembly of the second stator BFK455-017.iso/dms BFK455-017a.iso/dms Fig. 9 Assembly of the stator Complete stator Flange...
- Page 27 Danger! Disconnect voltage. The brake must be free of residual torque. BFK455-006.iso/dms Fig. 10 Checking the air gap 1. Check the air gap near the screws (10) by means of a feeler gauge and compare the values to the values for ”s ”...
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Page 28: Manual Release
1. Mount first rotor (3), first complete stator (1), and second rotor (3A) according to chapter 4.4.1 steps 1. to 12., 24 and 25. 4.5.1 Components of the hand-release BFK455-023.iso/dms Fig. 12 Manual release 12.1 Manual release lever 12.8 Self-locking nut 12.14 Tension rod... - Page 29 The boards are not symmetrical. The pin with the greater distance to the axis of rotation must point to the outside. The levers also point to the outside. BFK455-021.iso/dms Fig. 14 Installation of the tension rods 3. Assemble four pre-assembled tension rods (12.14) with one spring (12.5) each Carry out steps 4 and 5 separately for each side of every lever.
- Page 30 | BA 14.0196 | 05/2013 Mechanical installation BFK455-006.iso/dms Fig. 15 Assembly parts 5. Attach the clips (12.11) with the bore holes (Ø12 mm) to the tension rods (12.14) and tighten them with the self-locking nuts (12.8), the blind holes (Ø17 mm) pointing in the direction of the stator and the screw heads of the complete manual release levers sinking into the clips (12.11).
- Page 31 11. Switch off power. 4.5.3 Checking the air gap BFK455-007.iso/dms Fig. 17 Checking the air gap 12. Check the air gap by means of a feeler gauge and correct it if necessary = 0.4 +0.05mm), according to Fig. 10 and Fig. 11.
- Page 32 j | BA 14.0196 | 05/2013 Mechanical installation 4.5.4 Setting the hand-release Stop! For setting the manual release, always lock the pre-assembled hexagon nut of the tension rod (12.14) against rotation and rotate the self-locking nuts at the ends of the tension rod only. Carry out steps 13 and 14 separately for each side of every lever 13.
- Page 33 | BA 14.0196 | 05/2013 Mechanical installation BFK455-008.iso/dms Fig. 18 Test dimensions and reference dimensions 16. Check of the correct setting (nominal dimension 1.05...1.15 mm): – For this purpose, position two feeler gauges of the same thickness (e.g. 1.1 mm) for each tension rod between the hexagon nuts and the complete stator and ensure that the feeler gauges can be easily moved.
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Page 34: Assembly Of The Cover Ring
Assembly of the cover ring Stop! Brakes without flange require a groove at the end shield for the lip of the cover seal. BFK455-019.iso Fig. 19 Assembly of the cover ring Complete stator Flange Cover ring 1. Disconnect electrical connection. -
Page 35: Electrical Installation
In this case, the suppressor circuit must be connected in parallel to the brake coil, 36. Stop! | Only operate the brake with holding current reduction to 25 % P | For this purpose, use e.g. INTORQ switching device BEG-561-... -
Page 36: Bridge/Half-Wave Rectifiers (Option)
Bridge/half-wave rectifiers are used for the supply of electromagnetic spring-applied DC brakes which have been released for operation with such rectifiers. Any other use is only permitted with the explicit written approval of INTORQ. Once a set overexcitation time has elapsed, the bridge/half-wave rectifiers switch over from... - Page 37 Rectifier type AC voltage Coil voltage Assigned brake release/holding [V AC] [V DC] ±10% BEG-561-255-130 205 / 103 BFK455-28 (205 V) ±10% BEG-561-440-130 360 / 180 BFK455-28 (360 V) Fig. 21 BEG-561 attachment features 5.2.2 Technical data Rectifier type Bridge/half-wave rectifier Output voltage for bridge rectification 0.9 x U...
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Page 38: Electrical Connection
j | BA 14.0196 | 05/2013 Electrical installation 5.2.3 Permissible current load - ambient temperature BFKXXX-008.iso For screw assembly with metal surface (good heat dissipation) For other assembly (e.g. glue) Electrical connection Danger! The brake must only be electrically connected when no voltage is applied! ... -
Page 39: Commissioning And Operation
j | BA 14.0196 | 05/2013 Commissioning and operation Commissioning and operation Important notes Danger! The live connections and the rotating rotor must not be touched. The drive must not be running when checking the brake. Function checks before commissioning 6.2.1 Operational check Brake with microswitch... -
Page 40: Commissioning
j | BA 14.0196 | 05/2013 Commissioning and operation 9. Open the switching contact for the brake. – The brake is applied. 10. Check the switch position of the microswitch (see Tab. 6). 11. Switch off DC voltage for the brake. 12. -
Page 41: During Operation
j | BA 14.0196 | 05/2013 Commissioning and operation During operation Danger! The running rotor must not be touched. Danger! Live connections must not be touched. Check the brake regularly during operation. Take special care of: – unusual noises or temperatures –... -
Page 42: Maintenance/Repair
Maintenance/repair Wear of spring-applied brakes INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The friction lining and the mechanical brake components are subject to function-related wear. For safe and trouble-free operation, the brake must be checked at regular intervals or, if necessary, be replaced, ... -
Page 43: Inspections
The maintenance operations must be carried out as described in the detailed descriptions. 7.2.1 Maintenance intervals Type Time interval BFK455-28 for service brakes: for holding brakes with emergency stop: according to service life calculation at least every two years or else every six months... -
Page 44: Maintenance Operations
j | BA 14.0196 | 05/2013 Maintenance/repair 7.2.2 Release / voltage 1. Start motor and control system! Danger! The running rotor must not be touched. Danger! Live connections must not be touched. 2. Observe air gap ”s ” during operation of the drive. The air gap must be zero. 3. - Page 45 j | BA 14.0196 | 05/2013 Maintenance/repair 7.3.2 Checking the air gap Danger! The motor must not run during the check. 1. Stop motor and control system! 2. Measure air gap ”s ” near the fixing screws between armature plate and stator using a feeler gauge.
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Page 46: Spare-Parts List
– The item numbers are only valid for the standard design. Please include the following information with the order: – Order number of the brake – Position number of the spare part BFK455-004.iso/dms + BFK455-021.iso/dms Fig. 22 BFK455-28 spring-applied brake Pos. Name Variant Complete stator... -
Page 47: Spare Parts Order
j | BA 14.0196 | 05/2013 Maintenance/repair Spare parts order Complete stator Size Voltage 103 V / 52 V 205 V / 103 V 360 V / 180 V Braking torque ___________ Nm (see torque ranges) Cable length Standard (1000 mm) Armature plate Standard Microswitch... -
Page 48: Troubleshooting And Fault Elimination
j | BA 14.0196 | 05/2013 Troubleshooting and fault elimination Troubleshooting and fault elimination If any malfunctions should occur during operation, please check the possible causes using the following table. If the fault cannot be eliminated by one of the listed measures, please contact the aftersales service. - Page 49 j | BA 14.0196 | 05/2013 Troubleshooting and fault elimination Fault Cause Remedy Rotor not thick enough Rotor has not been replaced in time Replace rotor ( 45) Voltage is not zero during Incorrect microswitch wiring Check microswitch wiring and correct it functional test (6.2.2 or Defective microswitch or incorrect setting Replace the complete stator and return complete defective 6.2.3)
- Page 50 j | BA 14.0196 | 05/2013 Notizen...
- Page 51 j | BA 14.0196 | 05/2013 Notizen...
- Page 52 INTORQ GmbH & Co KG Germany Postfach 1103 D-31849 Aerzen Wülmser Weg 5 D-31855 Aerzen +49 5154 70534-444 +49 5154 70534-200 info@intorq.com INTORQ (SHANGHAI) Co., Ltd China No. 600, Xin Yuan Road Building No. 6 / Zone B Nan Hui District, Lingang Shanghai, China 201306 应拓柯制动器（上海）有限公司...
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