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Kendrion INTORQ BFK470 Translation Of The Original Operating Instructions

Spring-applied brake with electromagnetic release
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INTORQ BFK470
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
www.intorq.com

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Summary of Contents for Kendrion INTORQ BFK470

  • Page 1 INTORQ BFK470 Spring-applied brake with electromagnetic release Translation of the Original Operating Instructions www.intorq.com...
  • Page 2 Document history Material number Version Description 33001439 01/2012 TD09 First edition 33001439 03/2012 TD09 Supplemented the technical data Added to the "Brake assembly" chapter 33001439 10/2012 TD09 Updated the "Abbreviations used" table Supplemented the characteristics, rated data and switching times Degree of protection changed Note with regard to the end shield characteristics included 33001439...
  • Page 3 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. Product key INTORQ Product group: Brakes...

  • Page 4: Table Of Contents

    Inhalt 1 General information .............................. 6 1.1 Using these Operating Instructions ........................ 6 1.2 Conventions in use...............................  6 1.3 Safety instructions and notices .......................... 6 1.4 Terminology used.............................. 7 1.5 Abbreviations used...............................  8 2 Safety instructions.............................. 10 2.1 General safety instructions.......................... 10 2.2 Disposal ................................
  • Page 5 6 Electrical installation ...............................  32 6.1 Electrical connection ............................ 32 6.1.1 AC switching at the motor – extremely delayed engagement ...............  33 6.1.2 DC switching at the motor – fast engagement.................. 34 6.1.3 AC switching at mains – delayed engagement.................. 35 6.1.4 DC switching at mains –...

  • Page 6: General Information

    General information General information 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.

  • Page 7: Terminology Used

    General 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.

  • Page 8: Abbreviations Used

    General information Abbreviations used Letter symbol Unit Designation Rated frictional force Spring force 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 Torque that can be transmitted without slippage occurring (DIN VDE 0580) Tightening torque of fastening screws Average torque from initial speed to standstill Rated torque of the brake, rated value at a relative speed of rotation of...
  • Page 9 General information Letter symbol Unit Designation Slipping time, operation time of the brake (according to t ) until standstill Delay during engagement (time from switching off the supply voltage to the beginning of the torque rise) Rise time of the braking torque, time from the start of torque rise until reach- ing the braking torque Over-excitation period Voltage...

  • Page 10: Safety Instructions

    Safety instructions Safety instructions 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...

  • Page 11: Product Description

    Any other usage is con- sider improper and prohibited. Layout Fig. 1: Design of the INTORQ BFK470 spring-applied brake: Complete stator + rotor + flange Stator Bore holes (optional) Socket-head cap screw...

  • Page 12: Function

    Product description 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 braking force applied by pressure springs between the armature plate and a counter friction surface. This corre- sponds to a fail-safe functionality.

  • Page 13: Technical Specifications

    Technical specifications Technical specifications 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 IP66 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.
  • Page 14 Technical specifications Size Air gap Rotor thickness Min. New state Lmax Operating brake Holding brake Operating brake Holding brake [mm] [mm] [mm] [mm] [mm] [mm] +0.08 / -0.05 -0.05 5.73 5.93 +0.08 / -0.05 -0.05 6.73 6.93 +0.13 / -0.05 -0.1 0.35 8.73...
  • Page 15 Technical specifications CAUTION Functional incapacity of the brake It is very important to comply with the minimum thread depth of the end shield (refer to the Mounting data, Page 14 table). If the required thread depth is not maintained, the fastening screws may run onto the thread root.
  • Page 16 Technical specifications Size Electrical power Rated voltage Rated current Coil resistance [Ω] ±8% 1.667 1.000 20.0 0.833 28.8 0.625 51.2 0.476 88.2 0.286 245.0 0.208 460.8 0.194 530.5 0.158 806.0 0.140 1071.0 0.118 1445.0 0.111 1620.0 0.105 1805.0 0.098 2101.0 0.093 2311.0 0.089...
  • Page 17 Technical specifications Size Electrical power Rated voltage Rated current Coil resistance [Ω] ±8% 2.083 5.76 1.250 16.0 0.833 28.8 0.781 40.96 0.595 70.56 0.357 196.0 0.260 368.6 0.194 530.5 0.213 597.4 0.167 900.0 0.147 1156.0 0.111 1620.0 0.132 1444.0 0.098 2101.0 0.116 1849.0...
  • Page 18 Technical specifications Size Electrical power Rated voltage Rated current Coil resistance [Ω] ±8% 2.500 1.500 13.33 1.250 19.2 0.938 34.1 0.714 58.8 0.429 163.3 0.323 297.3 0.311 331.5 0.236 537.6 0.200 750.0 0.176 963.3 0.178 1013.0 0.158 1203.0 0.161 1273.0 0.140 1540.83 0.142...
  • Page 19 Technical specifications Size Electrical power Rated voltage Rated current Coil resistance [Ω] ±8% 2.542 9.443 0.583 176.817 0.333 540.0 0.307 667.063 0.219 1316.571 0.203 1525.4 2.833 8.471 0.660 156.015 0.378 476.471 0.332 618.015 0.236 1219.765 3.542 6.776 0.825 124.8 0.472 381.176 0.415 494.412...

  • Page 20: Switching Times

    Technical specifications Switching times The operating times listed here are guide values which apply to DC switching with rated air gap s , warm coil and standard characteristic torque. The operating times given are mean values and subject to varia- tions.
  • Page 21 Technical specifications 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. The DC-side switching in connection with a suitable spark suppressor must therefore be provided. Engagement time for AC-side switching: The engagement time is significantly longer (approx.

  • Page 22: Friction Work / Operating Frequency

    Technical specifications Friction work / operating frequency Sizes Operating frequency S [h ] Fig. 3: Friction work as a function of the operating frequency –S –S hmax – e hmax – 1 The permissible operating frequency S depends on the friction work Q (refer to Figure Friction work / hmax operating frequency, Page 22).

  • Page 23: Emissions

    Technical specifications 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. Noise The loudness of the switching noise during engaging and disengaging depends on the air gap "s "...
  • Page 24 Technical specifications Fig. 5: Packaging label INTORQ Manufacturer 35006069 ID number BFK470-10 Type (refer to Product key ) Bar code SPRING-APPLIED BRAKE Designation of the product family 24 V DC Rated voltage 16 NM Rated torque 1 pc. Qty. per box 30 W Rated power 20 H7...

  • Page 25: Mechanical Installation

    Mechanical installation Mechanical installation This chapter provides step-by-step instructions for the installation. Important notices and information NOTICE The toothed hub and screws must not be lubricated with grease or oil. 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.

  • Page 26: Tools

    Mechanical installation Tools Size Torque wrench Insert for hexagonal socket (Allen) screws Measuring range Wrench width [Nm] [mm] 1 to 12 20 to 100 Multimeter Caliper gage Feeler gage Preparing the installation 1. Remove the packaging from the spring-applied brake and dispose of it properly. 2.

  • Page 27: Installing The Hub Onto The Shaft

    Mechanical installation Installing the hub onto the shaft Notice The customer is responsible for dimensioning the shaft-hub connection. Make sure that the length of the key (shape A) is identical to the length of the hub. Fig. 6: Installing the hub onto the shaft Circlip End shield 1.

  • Page 28: Mounting The Brake

    Mechanical installation Mounting the brake Fig. 7: Mounting the flange and rotor Rotor O-ring End shield Flange 1. Optional: Slide the flange onto the shaft. Note the following: – The chamfer on the flange must point towards the brake so that the O-ring is positioned at the mo- tor end shield.
  • Page 29 Mechanical installation Fig. 8: Mounting the complete stator Socket-head cap screw Complete stator Rotor Flange End shield 3. Slide the brake onto the shaft. 4. Align the supplied cap screws with the mounting holes on the end shield. NOTICE When using a shaft sealing ring, the brake has to be mounted so that it is centerd properly! The shaft diameter must be implemented in accordance with ISO tolerance h11, with a radial eccentricity tolerance according to IT8 and an averaged surface roughness of R ≤...
  • Page 30 Mechanical installation Fig. 9: Tightening the screws with a torque wrench Socket-head cap screw Complete stator Rotor Flange End shield Fig. 10: Measure the air gap (for sizes 12 to 18) Socket-head cap screw Hand-release Dummy plug Feeler gage INTORQ | BA 14.0199 | 10/2020...
  • Page 31 Mechanical installation Notice ¾ Do not push the feeler gage in more than 10 mm between the armature plate and the stator! ¾ The customer must seal the brake in this position himself if no shaft sealing ring or sealing cover is in use.

  • Page 32: Electrical Installation

    Electrical installation Electrical installation Important notes DANGER There is a risk of injury by electrical shock! ¾ The electrical connections may only be made by trained electricians! ¾ Make sure that you switch off the electricity before working on the connections! There is a risk of unintended start-ups or electric shock.

  • Page 33: Ac Switching At The Motor - Extremely Delayed Engagement

    Electrical installation 6.1.1 AC switching at the motor – extremely delayed engagement L1 L2 L3 4-pole BEG-14x BEG-24x 6-pole BEG-16x BEG-26x Brake 3x 39V Inductive proximity sensor Fig. 11: Supply: Phase-neutral Bridge rectifiers Half-wave rectifier BEG-1xx: U [V DC] = 0.9 • [V AC] BEG-2xx: U [V DC] = 0.45 •...

  • Page 34: Dc Switching At The Motor - Fast Engagement

    Electrical installation 6.1.2 DC switching at the motor – fast engagement L1 L2 L3 6-pole BEG-16x BEG-26x Brake 3x 39V Inductive proximity sensor Fig. 13: Supply: Phase-neutral Bridge rectifiers Half-wave rectifier BEG-1xx: U [V DC] = 0.9 • [V AC] BEG-2xx: U [V DC] = 0.45 •...

  • Page 35: Ac Switching At Mains - Delayed Engagement

    Electrical installation 6.1.3 AC switching at mains – delayed engagement 4-pole BEG-14x BEG-24x 6-pole BEG-16x BEG-26x Brake 3x 39V Inductive proximity sensor Fig. 15: Supply: Phase-N Bridge rectifiers Half-wave rectifier BEG-1xx: U [V DC] = 0.9 • U [V AC] BEG-2xx: U [V DC] = 0.45 •...

  • Page 36: Dc Switching At Mains - Fast Engagement

    Electrical installation 6.1.4 DC switching at mains – fast engagement L1 L2 4-pole BEG-14x BEG-24x 14.198.00.xx Inductive proximity sensor 3x 39V Brake Fig. 17: Supply: Phase-phase or phase-N via 6-pole rectifier Bridge rectifier Half-wave rectifier BEG-16x: U [V DC] = 0.9 • U [V AC] BEG-26x: U [V DC] = 0.45 •...

  • Page 37: Technical Data For Inductive Proximity Sensors

    Electrical installation Technical data for inductive proximity sensors Design PNP, N/O contact Operating voltage 10 to 30 VDC Permitted residual ripple 20% U No-load current Max. 10 mA Output current Max. 200 mA Voltage drop at outputs Max. 2.0 V at 200 mA Short circuit protection integrated Reverse polarity protection...

  • Page 38: Minimum Bending Radius For The Brake Connection Cable

    Electrical installation Minimum bending radius for the brake connection cable Size Wire cross-section Minimum bending radius 28 mm AWG 20 46 mm Tab. 9: Minimum bending radius for the brake connection cable Bridge/half-wave rectifier (optional) BEG-561-□□□-□□□ The bridge-half-wave rectifiers are used to supply electromagnetic DC spring-applied brakes which are ap- proved for use with such rectifiers.

  • Page 39: Technical Specifications

    Electrical installation Fig. 19: BEG-561 fastening options 6.4.2 Technical specifications Rectifier type Bridge / half-wave rectifier Output voltage for bridge rectification 0.9 x U Output voltage for half-wave rectification 0.45 x U Ambient temperature (storage/operation) [°C] -25 – +70 input voltage (40 – 60 Hz) Type Input voltage U Max.

  • Page 40: Reduced Switch-Off Times

    Electrical installation 6.4.3 Reduced switch-off times AC switching must also be carried out for the mains supply side switching (fast engagement)! Otherwise, there will be no overexcitation when it is switched back on. Delayed engagement Fast engagement Mains Bridge Coil Mains Coil 6.4.4...

  • Page 41: Commissioning And Operation

    Commissioning and operation Commissioning and operation Possible applications of the INTORQ spring-applied brake Important notes DANGER Danger: rotating parts! ¾ The brake must be free of residual torque. ¾ The drive must not be running when checking the brake. DANGER There is a risk of injury by electrical shock! The live connections must not be touched.

  • Page 42: Function Checks Before Initial Commissioning

    Commissioning and operation Function checks before initial commissioning DANGER Danger: rotating parts! ¾ The brake must be free of residual torque. ¾ The drive must not be running when checking the brake. DANGER There is a risk of injury by electrical shock! The live connections must not be touched.

  • Page 43: Checking A Brake With Proximity Switch

    Commissioning and operation 7.2.3 Checking a brake with proximity switch 1. Switch off the supply to the motor and brake securely. 2. When switching on the brake supply, make sure that the motor DOES NOT start up (e.g. remove the two bridges on the motor terminals).

  • Page 44: Testing The Hand-Release Functionality

    Commissioning and operation 7.2.4 Testing the hand-release functionality NOTICE This operational test must also be carried out! 1. Make sure that the motor and brake are de-energized. 2. Pull (with some force) on the lever until the force increases sharply. –...

  • Page 45: Operation

    Commissioning and operation Operation DANGER Danger: rotating parts! ¾ The running rotor must not be touched. ¾ Take structural design measures on your final product and implement organizational safety rules to ensure that nobody can touch a rotor. DANGER There is a risk of injury by electrical shock! ¾...

  • Page 46: Maintenance And Repair

    Maintenance and repair Maintenance and repair Wear of spring-applied brakes WARNING Braking torque reduction The system must not be allowed to continue operations after the maximum air gap s Lmax has been exceeded. Exceeding the maximum air gap can cause a major reduction in the braking torque! The table below shows the different causes of wear and their impact on the components of the spring-ap- plied brake.

  • Page 47: Inspections

    Maintenance and repair Inspections To ensure safe and trouble-free operations, the spring-applied brakes must be checked at regular intervals and, if necessary, replaced. Servicing at the facility will be easier if the brakes are made accessible. This must be considered when installing the drives in the plant. Primarily, the required maintenance intervals for industrial brakes result from their load during operation.

  • Page 48: Checking The Components

    Maintenance and repair 8.3.1 Checking the components ¾ Check release function and control Refer to Release / voltage, Page 49 ¾ Refer to Checking the air Possible with the components sized 12 to gap, Page 48 18: Measure the air gap With mounted ¾ Measure the rotor thickness (replace ro- brake Refer to Brake replacement, Page 49...

  • Page 49: Release / Voltage

    Maintenance and repair 8.3.3 Release / voltage DANGER Danger: rotating parts! The running rotor must not be touched. DANGER There is a risk of injury by electrical shock! The live connections must not be touched. 1. Check the brake functionality when the drive is running: The armature plate must be tightened and the rotor must move without residual torque.

  • Page 50: Spare Parts List

    After replacing the rotor, the run-in armature plates and the flanges have an increased initial rate of wear. Spare parts list Spring-applied brake INTORQ BFK470-06 to 18 Fig. 21: Spring-applied brake INTORQ BFK470-06 to 18...

  • Page 51: Troubleshooting And Fault Elimination

    Troubleshooting and fault elimination Troubleshooting and fault elimination If any malfunctions should occur during operations, please check for possible causes based on the follow- ing table. If the fault cannot be fixed or eliminated by one of the listed steps, please contact customer ser- vice.
  • Page 52 Troubleshooting and fault elimination Fault Cause Remedy Air gap too big Brake does not re- lease ¾ Rotor is too thin Replace rotor. Refer to Replacing the rotor. Brake voltage does not match Voltage too high Adjust rectifier and brake voltage to each other. the rectifier Brake voltage does not match Adjust rectifier and brake voltage to each other.
  • Page 53 INTORQ GmbH & Co KG Germany PO Box 1103 D-31849 Aerzen, Germany Wülmser Weg 5 D-31855 Aerzen, Germany +49 5154 70534-0 (Headquarters) +49 5154 70534-222 (Sales) Ê +49 5154 70534-200 š info@intorq.com 应拓柯制动器（上海）有限责任公司 INTORQ (Shanghai) Co., Ltd. 上海市浦东新区泥城镇新元南路600 号6 号楼一楼B 座 No.

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