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INTORQ BFK468 Series Operating Instructions Manual

Spring-applied brake with electromagnetic release
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Operating Instructions INTORQ BFK468
Spring-applied brake with electromagnetic release
j
setting the standard
www.intorq.de

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Summary of Contents for INTORQ BFK468 Series

  • Page 1 Operating Instructions INTORQ BFK468 Spring-applied brake with electromagnetic release setting the standard www.intorq.de...
  • Page 2 Rostschutzverpackung-Reibfläche fettfrei halten 0Fig. 0Tab. 0 © 2007 INTORQ GmbH & Co KG, Wülmser Weg 5, D-31855 Aerzen No part of this documentation may be reproduced or made accessible to third parties without written consent by INTORQ GmbH & Co KG.

  • Page 3: Table Of Contents

    j | BA 14.0190 - EN | 02/2007 Contents Preface and general information ........How to use these Operating Instructions .

  • Page 4: Preface And General Information

    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.

  • Page 5: Labelling

    – operating faults – disregarding these Operating Instructions 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 6: Safety Instructions

    Do not operate the spring-applied brake unless it is in perfect condition. Retrofittings, modifications and changes of the drive system are generally forbidden. In any case, INTORQ GmbH & Co. KG must be contacted beforehand. The friction lining and the friction surfaces must be carefully protected from oil or grease since even small amounts of lubricants reduce the brake torque considerably.
  • Page 7 – must only be operated under the ambient conditions prescribed in these Operating Instructions. – must not be operated beyond their corresponding power limits. Any other use shall be deemed inappropriate! Possible applications of the INTORQ spring-applied brake No explosive or aggressive atmosphere. Humidity, no restrictions. Ambient temperature -20°C to +40°C.

  • Page 8: Definition Of Notes Used

    j | BA 14.0190 - EN | 02/2007 Safety instructions Definition of 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: Technical Data

    | BA 14.0190 - EN | 02/2007 Technical data Technical data Product description KL 46820-003.iso Fig. 1 Design of the spring-applied brake INTORQ BFK468: basic module E (complete stator) + rotor + hub + flange Armature plate Stator Compression springs Shaft...
  • Page 10 3.1.1 General information The spring-applied brake INTORQ BFK468- is a single-disk brake with two friction surfaces. The brake torque is generated by several compression springs (2) by friction. The brake is released electromagnetically with holding current reduction via an INTORQ bridge/half-wave rectifier.

  • Page 11: Brake Torques

    j | BA 14.0190 - EN | 02/2007 Technical data 3.1.7 Encapsulated design (optional) This design not only avoids the penetration of spray water and dust, but also the spreading of abrasion particles outside the brake. This is achieved by: a cover seal over the armature plate and rotor, a cover in the adjuster nut, a shaft seal in the adjuster nut for continuous shafts (option).

  • Page 12: Rated Data

    55.1 Tab. 3 Rated data - spring-applied brake INTORQ BFK468 The friction lining is designed such that the brake can be adjusted at least 5 times. The screw length depends on the material and the thickness of the customer’s mounting place.
  • Page 13 100 / 408 360 / 180 317.6 205 / 103 79.6 INTORQ BFK468-25 132 / 528 360 / 180 245.5 INTORQ BFK468-31 230 / 920 360 / 180 140.9 Tab. 4 Coil voltage/coil resistance of INTORQ BFK468 Coil power at 20_C...

  • Page 14: Operating Times

    | BA 14.0190 - EN | 02/2007 Technical data Operating times K14.0583 Fig. 3 Operating times of the INTORQ spring-applied brakes Engagement time Reaction delay during engagement Disengagement time (up to M = 0.1 M Rise time of the brake torque...

  • Page 15: Operating Frequency / Friction Work

    j | BA 14.0190 - EN | 02/2007 Technical data Engagement time With switching on the AC side, the engagement times are prolonged approximately by the factor 5, for connection see page 28. Spark suppressors for the rated voltages, which are to be connected in parallel to the contact are available for engagement on the DC side.

  • Page 16: Emission

    Under normal switching conditions with an unfiltered DC voltage via a bridge circuit, the INTORQ spring-applied brake complies with the EMC standard EN50081, part 1. Please note that the entire circuit only complies with the EMC Directive, if it is configured...

  • Page 17: Mechanical Installation

    Nuts/bolts 2kt lever Diameter Wrench size range [Nm] [mm] sleeves [mm] [mm] ” 13 x ” INTORQ BFK468-18 110 - 115 square square 20 - 100 - / 10 INTORQ BFK468-20 135 - 145 ” 17 x ” square square...

  • Page 18: Installation

    j | BA 14.0190 - EN | 02/2007 Mechanical installation 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 KL BFK46825-001-a.iso Fig. 5 Installation of the hub onto the shaft Circlip Endshield 1.
  • Page 19 j | BA 14.0190 - EN | 02/2007 Mechanical installation KL BFK46825-001-b.iso Fig. 6 Brake mounting Rotor Endshield 1. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand (Fig. 6).  Stop! Please note the following for versions with shaft seal in the adjuster nut: 2.
  • Page 20 j | BA 14.0190 - EN | 02/2007 Mechanical installation  KL-BFK46825-010-C.iso Fig. 8 Checking the air gap s Lü  Threaded sleeves Lürated Stator Allen screws 6. Tighten the screws (10) evenly (for torques see table chapter 3.3 and Fig. 8). 7.
  • Page 21 j | BA 14.0190 - EN | 02/2007 Mechanical installation 4.3.3 Assembly of the flange The flange (4) can be screwed onto the endshield (15) with the outer pitch circle (for screw dimensions see chapter 3.3). Flange assembly with additional screws ...
  • Page 22 j | BA 14.0190 - EN | 02/2007 Mechanical installation 4.3.4 Assembly of the cover seal KL BFK46825-001-e.iso Kl BFK46820-002.iso Fig. 11 Assembly of the cover seal Armature plate Stator Cover seal Flange Allen screw 1. Pull the cable through the seal (13). 2.
  • Page 23 j | BA 14.0190 - EN | 02/2007 Mechanical installation 1. Hammer the pins (12.3) into the bore holes of the armature plate (1). (When the brake has already been installed, cushion the impact energy by pressing against the opposite side of the armature plate).
  • Page 24 | BA 14.0190 - EN | 02/2007 Mechanical installation Type (mm) (mm) s + s (mm) Lü Lü INTORQ BFK468-18 INTORQ BFK468-20 INTORQ BFK468-25 Tab. 6 Adjustment setting for manual release  Stop! Dimension ”s” must be observed! Check air gap ”s ”.

  • Page 25: Electrical Installation

    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. After a defined overexcitation time, the bridge/half-wave rectifiers change from bridge rectification to half-wave rectification.
  • Page 26 j | BA 14.0190 - EN | 02/2007 Electrical installation Type Input voltage U Max. current I Overexcitation time t ( ±20%) max. (40 Hz ... 60 Hz) min. rated max. bridge half-wave with U with with U 1min 1max [V ∼...

  • Page 27: Electrical Connection

    j | BA 14.0190 - EN | 02/2007 Electrical installation 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%...
  • Page 28 j | BA 14.0190 - EN | 02/2007 Electrical installation KL-BFKXXX-001.iso Fig. 13 AC switching, delayed engagement  Bridge / half-wave rectifier KL-BFKXXX-002.iso Fig. 14 DC switching, normal engagement  Bridge / half-wave rectifier  Stop! For switching on the DC side the brake must be operated with a spark suppressor to avoid impermissible overvoltages.
  • Page 29 j | BA 14.0190 - EN | 02/2007 Electrical installation KL-BFKXXX-003.iso Fig. 15 With microswitch / release check; connection diagram also valid for star connection  DC voltage depending on coil voltage  Spark suppressor blue sw black KL-BFKXXX-004.iso Fig. 16 With microswitch / wear check addition for all circuits; connection diagram also valid for star connection blue black...
  • Page 30 j | BA 14.0190 - EN | 02/2007 Electrical installation  Tip! During operation according to Fig. 16 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.

  • Page 31: Commissioning And Operation

    j | BA 14.0190 - EN | 02/2007 Commissioning and operation Commissioning and operation  Danger! The live connections and the rotating rotor must not be touched. The motor must not be running when checking the brake. Functional test In the event of failures, refer to the troubleshooting table in chapter 8. If the fault cannot be eliminated, please contact the aftersales service.
  • Page 32 j | BA 14.0190 - EN | 02/2007 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. Connection diagram: ( 29) 1.
  • Page 33 j | BA 14.0190 - EN | 02/2007 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 34 j | BA 14.0190 - EN | 02/2007 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.

  • Page 35: Reducing The Brake Torque

    j | BA 14.0190 - EN | 02/2007 Commissioning and operation Reducing the brake torque Emax KL BFK46825-010-a.iso KL-BFK46820-012.iso Fig. 17 Brake torque adjustment Stator Adjuster nut 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 36: Maintenance/Repair

    j | BA 14.0190 - EN | 02/2007 Maintenance/repair Maintenance/repair Inspection intervals The wear of the friction lining of the rotor depends on the operating conditions. The time until readjustment does not only depend on the friction work. The friction work per operation decreases steadily until readjustment takes place.

  • Page 37: Maintenance Operations

    j | BA 14.0190 - EN | 02/2007 Maintenance/repair 7.2.3 Release / voltage  Danger! The running rotor must not be touched.  Danger! Live connections must not be touched. 1. Observe air gap ”s ” during operation of the drive. Lü...
  • Page 38 j | BA 14.0190 - EN | 02/2007 Maintenance/repair 7.3.2 Rotor replacement  Danger! Disconnect voltage. The brake must be free of residual torque. 1. Loosen connection cable. 2. Loosen the screws evenly and remove them. 3. Completely remove the stator from the endshield. Observe the supply cable. 4.

  • Page 39: Spare-Parts List

    The position numbers are only valid for the standard design. 7.4.1 Brakes BFK468-18 to 31 7 Module N 7 Module E KL-BFK45825-011.cad Fig. 18 Spring-applied brake INTORQ BFK468-18 to 31 Pos. Name Variant Complete rotor Complete rotor, low-noise version Bore...

  • Page 40: Spare-Parts Order

    | BA 14.0190 - EN | 02/2007 Maintenance/repair Spare-parts order INTORQ BFK468- / complete stator Size E (with adjuster nut, sizes 18, 20,25) Design: N (without adjuster nut) 205 V / 103 V (not available for size 31) Voltage...

  • Page 41: Troubleshooting And Fault Elimination

    j | BA 14.0190 - EN | 02/2007 Troubleshooting and fault elimination Troubleshooting and fault elimination If any malfunctions should occur during operation of the drive system, 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 42 j | BA 14.0190 - EN | 02/2007 Troubleshooting and fault elimination Fault Cause Remedy Rotor not thick enough Rotor has not been replaced in time Replace rotor (chapter 7.3.2) Voltage is not zero when checking Incorrect wiring of microswitch Check the wiring of the microswitch and correct it.

  • Page 43: Disposal

    j | BA 14.0190 - EN | 02/2007 Disposal Disposal Protect the environment! Packing material can be recycled. What? Where? Transport material Pallets Return to the manufacturer or forwarder Packing material Cardboard boxes to waste paper Plastics to plastics recycling or waste material Reuse or dispose of wood wool Components...
  • Page 44 INTORQ – sales and service worldwide INTORQ is worldwide and any time available to its customers. Our key account sales representatives take care of key accounts and project business. INTORQ works closely together with Lenze’s worldwide sales organisation. With the Lenze service, you can reach us around the clock via the 24-hour helpline (008000 24 46177).

This manual is also suitable for:

Bfk468-18Q bfk468-20Q bfk468-25Q bfk468-31

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