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Summary of Contents for INTORQ BFK468
- Page 1 INTORQ BFK468 Electromagnetically released spring−applied brake Operating Instructions www.intorq.com...
- Page 2 | BA 14.0190 | 11/2012 This documentation applies to ... BFK468 BFK46825−002.iso/dms Product key − Product key INTORQ Legend for INTORQ BFK468 product key Product group Brakes Product family Spring−applied brake Type Size 18, 20, 25, 31 Design E − adjustable (brake torque can be reduced via adjuster nut) N −...
- Page 3 CE designation BFK458−002.iso/dms Nameplate Example Manufacturer CE designation Type (see product key) Rated voltage Rated power Hub diameter Type No. Rated torque Production date BFK468−001.iso/dms Document history Material number Version Description 13190474 01/2007 TD09 First edition 33002357 11/2012 TD09 Complete revision...
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Page 4: Table Of Contents
j | BA 14.0190 | 11/2012 Contents Preface and general information ........About these Operating Instructions . -
Page 5: Preface And General Information
j | BA 14.0190 | 11/2012 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 6: Abbreviations Used
j | BA 14.0190 | 11/2012 Preface and general information Abbreviations used Abbreviation Unit Name Current Rated current at 20 °C and rated voltage [Nm] Tightening torque of the fixing screws [Nm] Characteristic torque of the brake / clutch [r/min] Maximum speed during the slipping time t3 Rated coil power at rated voltage and at 20 °C Quantity of heat/energy... -
Page 7: Notes Used
j | BA 14.0190 | 11/2012 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 8: Scope Of Supply
Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D−31855 Aerzen The spring−applied INTORQ brake is also delivered in single modules and individually combined to its modular design. The data − package labels, nameplate, and type code in particular − apply to one complete stator. -
Page 9: 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 10: 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 11: 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 12: Technical Data
| BA 14.0190 | 11/2012 Technical data Technical data Product description BFK46820−003.iso/dms Fig. 1 Design of the BFK468 spring−applied brake: basic module E (complete stator) + rotor + hub + flange Complete stator Complete rotor Flange Compression springs Sleeve bolts... - Page 13 The BFK468−LLL spring−applied brake is a single−disk brake with two friction surfaces. Several compression springs (1.2) generate the braking torque by friction locking. The brake is released electromagnetically by a reduction of the holding current via an INTORQ bridge half−wave rectifier.
- Page 14 j | BA 14.0190 | 11/2012 Technical data 3.1.6 Microswitch (optional) The manufacturer offers the microswitch for air−gap or wear monitoring. The user must provide the corresponding electrical connection (^ 31et seqq.). When air−gap monitoring, the motor does not start before the brake has been released. With this set−up, all possible faults are monitored.
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Page 15: Brake Torques
j | BA 14.0190 | 11/2012 Technical data Brake torques Stop! Please observe that engagement times and disengagement times change depending on the brake torque. Size Characterist Torque Characterist Torque Characterist Torque Characterist ic torque reduction E ic torque reduction E ic torque reduction E ic torque... -
Page 16: Rated Data
Tightening torque Weight of complete stator [mm] Thread Screws [Nm] Complete [kg] lever [Nm] BFK468−18 6 x M8 36.1 13.4 BFK468−20 20.0 6 x M10 BFK468−25 31.0 BFK468−31 8 x M16 −−−−− 55.1 Tab. 3 Characteristics of BFK468 spring−applied brake... - Page 17 360 / 180 140.9 Coil power at 20 _C Tab. 4 Coil voltage/coil resistance of BFK468 3.3.1 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.
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Page 18: Operating Times
Operating times [ms] at s Dn = 100 rpm friction work per operating operation only frequency DC engagement Disengage −1 [Nm] BFK468−18 60000 BFK468−20 80000 BFK468−25 120000 BFK468−31 1200 300000 Minimum braking torque when all components are run in Tab. 5 Switching energy −... -
Page 19: Operating Frequency / Friction Work
Friction work / operating frequency Q [J] 1000000 100000 10000 1000 S [h ] 1000 10000 BFK468−003.des/dms Fig. 4 Switching energy as a function of the operating frequency Switching energy Q Operating frequency s *S hue 1 * e smax hmax ln 1 * The permissible operating frequency "S... -
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
Nuts / bolts 2kt lever Diameter Wrench size range [Nm] [mm] [mm] [mm] " 13 x " 110 − 115 BFK468−18 square square 20 − 100 − / 10 135 − 145 BFK468−20 " 17 x " square square 155 − 165 BFK468−25... -
Page 22: Mounting
j | BA 14.0190 | 11/2012 Mechanical installation Mounting 4.2.1 Preparation 1. Unpack spring−applied brake. 2. Check for completeness. 3. Check nameplate data, especially rated voltage. Installation When you have ordered a version with manual release or flange, attach these units first. 4.3.1 Installation of the hub onto the shaft Stop! - Page 23 Installation of the brake Stop! | Minimum requirement of the end shield (15): – Material S235 JR or C15 (other materials after consultation with INTORQ), – Levelness 0.10 mm, – Axial runout 0.10 mm, – Roughness Rz 10 to Rz 16 | When dimensioning the thread depth in the end shield (15), the permissible wear distance must be taken into consideration, ¶...
- Page 24 j | BA 14.0190 | 11/2012 Mechanical installation BFK46825−008.iso/dms Fig. 7 Mounting the brake Complete rotor Flange End shield 1. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand (Fig. 7). Stop! Please note the following for the version "brake with shaft sealing ring in torque adjustment ring": 2.
- Page 25 j | BA 14.0190 | 11/2012 Mechanical installation BFK46825−003.iso Fig. 8 Mounting of the complete stator Complete stator Connector block Cheese head screw End shield 4. Screw the complete stator (1) onto the end shield (15) using the set of screws (10) provided and a torque key.
- Page 26 j | BA 14.0190 | 11/2012 Mechanical installation BFK46825−006.iso Fig. 10 Adjusting the air gap Stator Cheese head screw Threaded sleeves Please adjust if the value for "s " is outside the tolerance of "s ": 4.3.3 Assembly of the cover seal BFK46825−007.iso/dms BFK46820−008.iso/dms Fig.
- Page 27 j | BA 14.0190 | 11/2012 Mechanical installation 4.3.4 Assembly of the manual release sizes 18 to 25 BFK46825−009.iso Fig. 12 Assembly of the manual release for brake sizes 18−25 Stator (here: design E) 12.1 Manual release lever with control 12.10 Pin button Armature plate...
- Page 28 11. If necessary, screw the lever (12.1) into the shackle (12.2). BFK46820−006.iso Type (mm) (mm) s + s (mm) BFK468−18 BFK468−20 BFK468−25 Tab. 6 Adjustment setting for manual release Stop! Dimension "s" must be observed! Check air gap "s ".
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Page 29: Electrical Installation
j | BA 14.0190 | 11/2012 Electrical installation Electrical installation Bridge/half−wave rectifiers (option) BEG−561 After a defined overexcitation time, the bridge/half−wave rectifiers change from bridge rectification to half−wave rectification. Depending on the dimensioning of the load, the switching performance can thus be improved or the power can be derated. Fig. - Page 30 For screw assembly with metal surface (good heat dissipation) For other assembly (e.g. glue) 5.1.4 Assignment: Bridge/half−wave rectifier − brake size Rectifier type AC voltage Coil voltage Assigned brake release/holding [V AC] [V DC] BFK468−18 BEG−561−255−030 ±10% BFK468−20 205 / 103 BEG−561−255−130 BFK468−25 BFK468−18 BEG−561−440−030−1 BFK468−20 ±10% 360 / 180 BFK468−25...
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Page 31: Electrical Connection
j | BA 14.0190 | 11/2012 Electrical installation Electrical connection Danger! The brake must only be electrically connected when no voltage is applied! 5.2.1 Circuit proposals BFKXXX−007.iso Fig. 14 AC switching, delayed engagement Bridge rectifier/half−wave rectifier BFKXXX−002.iso Fig. 15 DC switching, normal engagement Bridge rectifier/half−wave rectifier Stop! For switching on the DC side the brake must be operated with a spark... - Page 32 j | BA 14.0190 | 11/2012 Electrical installation KL−BFKXXX−003.iso Fig. 16 With microswitch (release check); connection diagram also valid for star connection DC voltage depending on coil voltage Spark suppressor KL−BFKXXX−004.iso Fig. 17 With microswitch / wear check addition for all circuits; connection diagram also valid for star connection...
- Page 33 j | BA 14.0190 | 11/2012 Electrical installation Tip! During operation according to Fig. 17 the air gap is only monitored when no voltage is applied to the brake. This makes sense because it is possible that when the current flows only one side of the armature plate is attracted at first.
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Page 34: Commissioning And Operation
j | BA 14.0190 | 11/2012 Commissioning and operation Commissioning and operation Danger! The live connections and the rotating rotor must not be touched. The drive must not be running when checking the brake. Functional test In the event of failures, refer to the troubleshooting table, ¶ 46. If the fault cannot be eliminated, please contact the aftersales service. - Page 35 j | BA 14.0190 | 11/2012 Commissioning and operation 6.1.2 Microswitch − release check Danger! The brake must be free of residual torque. The motor must not rotate. Danger! Live connections must not be touched. 1. The switching contact for the brake must be open. 2.
- Page 36 j | BA 14.0190 | 11/2012 Commissioning and operation 6.1.3 Microswitch − wear check Danger! The brake must be free of residual torque. The motor must not rotate. Danger! Live connections must not be touched. 1. Remove two bridges from the motor terminals. Do not switch off the DC voltage for the brake.
- Page 37 j | BA 14.0190 | 11/2012 Commissioning and operation 6.1.4 Manual release Stop! This operational test is to be carried out additionally! Danger! The brake must be free of residual torque. The motor must not rotate. 1. Pull the lever (Fig. 18) with approx. 250 N until the resistance increases strongly. Stop! Additional tools to facilitate brake release are not allowed! (e.g.
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Page 38: Reducing The Brake Torque
j | BA 14.0190 | 11/2012 Commissioning and operation Reducing the brake torque M− BFK46825−010−a.iso BFK46820−012.iso Fig. 18 Braking torque adjustment Stator Torque adjustment ring 1. Turn the adjuster nut (8) counterclockwise using the hook wrench. – Observe the notches. Positions between notches are impermissible. (Values for the brake torque reduction see chapter 3.2.1). -
Page 39: During Operation
j | BA 14.0190 | 11/2012 Commissioning and operation During operation Check the brake regularly during operation. Take special care of: – unusual noises or temperatures – loose fixing elements – the condition of the electrical cables. The armature plate must be attracted and the drive must move without residual torque. -
Page 40: Maintenance/Repair
j | BA 14.0190 | 11/2012 Maintenance/repair Maintenance/repair Wear of spring−applied brakes The following table describes the different causes of wear and their effects on the components of the spring−applied brake. The important influencing factors must be quantified so that the service life of the rotor and brake can be calculated and that the maintenance intervals to be prescribed can be specified precisely. -
Page 41: Inspections
j | BA 14.0190 | 11/2012 Maintenance/repair Inspections 7.2.1 Important notes To ensure safe and trouble−free operation, spring−applied brakes must be checked and maintained at regular intervals. Servicing can be made easier if good accessibility of the brakes is provided in the plant. This must be considered when installing the drives in the plant. Primarily, the necessary maintenance intervals for industrial brakes result from the load during operation. -
Page 42: Maintenance Operations
j | BA 14.0190 | 11/2012 Maintenance/repair 7.2.4 Release / voltage Danger! The running rotor must not be touched. Danger! Live connections must not be touched. Maintenance operations 7.3.1 Adjusting the air gap Danger! The brake must be free of residual torque. Stop! Please observe when mounting the flange with additional screws: Behind the threaded holes for the screws in the flange there must be clearing... - Page 43 j | BA 14.0190 | 11/2012 Maintenance/repair 7.3.2 Rotor replacement Danger! The brake must be free of residual torque. 1. Switch off voltage! 2. Disconnect the supply cable. 3. Loosen the screws evenly and remove them completely. 4. Remove the complete stator from the end shield. Observe the supply cable. 5.
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Page 44: Spare−Parts List
Please include the following information with the order: – Order number of the brake – Position number of the spare part 7.4.1 Brakes BFK468−18 to 31 BFK45825−011.iso/dms Fig. 19 BFK468−18 spring−applied brake to 31 Pos. Name Variant Complete stator, module E Voltage / braking torque... -
Page 45: Spare Parts Order
| BA 14.0190 | 11/2012 Maintenance/repair Spare parts order INTORQ BFK468−LLL / complete stator \ 18 \ 20 \ 25 \ 31 Size \ E (with adjuster nut, sizes 18, 20,25) Design: \ N (without adjuster nut) \ 205 V / 103 V (not available for size 31) -
Page 46: Troubleshooting And Fault Elimination
j | BA 14.0190 | 11/2012 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 47 j | BA 14.0190 | 11/2012 Troubleshooting and fault elimination Fault Cause Remedy Rotor not thick enough Rotor has not been replaced in time Replace rotor (^ 43) Voltage is not zero during functional Incorrect wiring of microswitch Check and correct the microswitch wiring. test (chapter 6.1) Defective microswitch or incorrect Replace the entire stator and send the defective...
- Page 48 F INTORQ GmbH & Co KG Germany Postfach 1103 D−31849 Aerzen Wülmser Weg 5 D−31855 Aerzen ( +49 5154 70534−444 Ê +49 5154 70534−200 š info@intorq.com F INTORQ (SHANGHAI) Co., Ltd China No. 600, Xin Yuan Road Building No. 6 / Zone B...
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