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Summary of Contents for INTORQ BFK464-R Series
- Page 1 INTORQ BFK464-□□R Spring-applied brake with electromagnetic release Translation of the Original Operating Instructions www.intorq.com...
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Page 2: Legal Regulations
– disregarding the documentation 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. -
Page 3: Product Key
¾ The spring-applied INTORQ brake is also delivered in single modules which can then be put together by the customer according to their requirements. The specifications – particu- larly the packaging label, name plate and type code – apply to a complete stator. -
Page 4: Table Of Contents
3.6.2 Optional micro-switch .......................... 14 3.6.3 Optional encapsulated design ....................... 14 4 Technical specifications............................ 15 4.1 Possible applications of the INTORQ spring-applied brake ................ 15 4.2 Rated data................................ 15 4.3 Switching times .............................. 18 4.4 Friction work / operating frequency ........................ 20 4.5 Electromagnetic compatibility.......................... - Page 5 8.3.2 Check the rotor thickness ........................ 49 8.3.3 Checking the air gap.......................... 50 8.3.4 Release / voltage........................... 50 8.3.5 Replace rotor ............................ 51 8.4 Spare parts list .............................. 52 9 Troubleshooting and fault elimination........................ 53 INTORQ | BA 14.0214 | 10/2019...
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Page 6: General Information
Important notice about ensuring smooth op- Notice erations or other key information. Safety instructions and notices The following icons and signal words are used in this document to indicate dangers and important safety information: INTORQ | BA 14.0214 | 10/2019... -
Page 7: Terminology Used
Notice about a harmful situation with possible consequences: the product itself or sur- rounding objects could be damaged. Terminology used Term In the following text used for Spring-applied brake Spring-applied brake with electromagnetic release Drive systems with spring-applied brakes and other drive com- Drive system ponents INTORQ | BA 14.0214 | 10/2019... -
Page 8: Abbreviations Used
Minimum air gap Lmin Maximum air gap Lmax Air gap for hand-release Engagement time, sum of the delay time and braking torque: rise time Disengagement time, time from switching the stator until reaching 0.1 M INTORQ | BA 14.0214 | 10/2019... - Page 9 Over-excitation period Voltage V DC Holding voltage, after voltage change-over V DC Release voltage, before voltage change-over Rated coil voltage; in the case of brakes requiring a voltage change-over, V DC equals U INTORQ | BA 14.0214 | 10/2019...
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Page 10: Safety Instructions
These must be followed to maintain safe, trouble-free operations and to achieve the specified product characteristics. ¾ 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: –... -
Page 11: Product Description
3.1.1 Standard applications INTORQ components are intended for use in machinery and facilities. They may only be used for pur- poses as specified in the order and confirmed by INTORQ. The INTORQ components may only be oper- ated under the conditions specified in these Operating Instructions. They may never be operated beyond their specified performance limits. - Page 12 2 x 350 2 x 280 EU-BD 1034 2 x 450 2 x 360 EU-BD 1054 2 x 600 2 x 540 EU-BD 1053 2 x 900 2 x 720 EU-BD 1052 2 x 1200 INTORQ | BA 14.0214 | 10/2019...
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Page 13: Function
¾ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactiv- ated regularly. INTORQ | BA 14.0214 | 10/2019... -
Page 14: Optional Configuration
This design not only prevents the penetration of spray water and dust, but also the spreading of abrasion particles outside the brake. This is achieved by the following enclosures: ¾ A cover ring over the armature plate and rotor. INTORQ | BA 14.0214 | 10/2019... -
Page 15: 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 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 16 The screws for the different brake attachment variants have different strength grades and may have special surface coatings. In order to guarantee a secure screw connec- tion, use ONLY the proper screws from INTORQ! ¾ It is very important to comply with the minimum thread depth of the end shield (refer to Rated data for the screw set for brake mounting, Page 16).
- Page 17 2 x 26 2 x 3.88 Tab. 3: Rated data for coil power Minimum braking torque with run-in friction pairs at Δn = 100 rpm Power at 20 °C Current at 20 °C during brake release INTORQ | BA 14.0214 | 10/2019...
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Page 18: Switching Times
2 x 210 425 1025 68000 2 x 350 2 x 280 350 1100 80000 2 x 450 2 x 360 350 1160 90000 2 x 600 2 x 540 450 1410 120000 2 x 900 INTORQ | BA 14.0214 | 10/2019... - Page 19 Spark suppressors are available for the rated voltages. Disengagement time The disengagement time is the same for DC-side and AC-side switching. The specified disengagement times always refer to control using INTORQ rectifiers and rated voltage. INTORQ | BA 14.0214 | 10/2019...
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Page 20: Friction Work / Operating Frequency
, the permissible amount of heat is Q Smax Notice With high speeds of rotation and switching energy, the wear increases, because very high temperatures occur at the friction surfaces for a short time. INTORQ | BA 14.0214 | 10/2019... -
Page 21: Electromagnetic Compatibility
The user must ensure compliance with EMC Directive 2014/30/EC using appropriate controls and switching devices. NOTICE 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 22: Labels On Product
Rated voltages of both braking circuits 900 NM Rated torque Pieces Qty. per box 540/135 W Rated powers for both braking circuits 28.07.17 Packaging date Anti-rust packaging: keep friction surface free of Addition grease! CE mark INTORQ | BA 14.0214 | 10/2019... - Page 23 Technical specifications Fig. 7: Product traceability sticker BFK464-20-R Type (refer to Product key, Page 3 ) 33005457 ID number G170820000000000 Serial number QR code INTORQ | BA 14.0214 | 10/2019...
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Page 24: Mechanical Installation
The diameter of the shaft shoulder must not be greater than the tooth root diameter of the hub. ¾ 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 25: Tools
Insert for Width across flats bolts hexagonal socket (Allen) screws Measuring Wrench width Width across flats Width across flats range [Nm] [mm] [mm] [mm] 20 to 100 40 to 250 Multimeter Caliper gage Feeler gage INTORQ | BA 14.0214 | 10/2019... -
Page 26: Preparing The Installation
Make sure that the cylindrical dampers on the armature plate are not damaged when you are lifting the brake using an eyebolt. Fig. 8: Lifting mechanism for hooking onto a hoist INTORQ | BA 14.0214 | 10/2019... -
Page 27: Installing The Hub Onto The Shaft
Toothed shaft (optional) 1. Insert the key into the shaft. 2. Press the hub with a moderate amount of force to the shaft. 3. Secure the hub against axial displacement (for example, by using a circlip). INTORQ | BA 14.0214 | 10/2019... -
Page 28: Mounting The Flange (Optional)
1. Hold the flange to the end shield. Place the chamfer at the inner diameter on the side of the end shield. 2. Align the through holes in the flange to the threads of the fastening bore holes. INTORQ | BA 14.0214 | 10/2019... -
Page 29: Brake Mounting
Hub or shaft with teeth (optional) Flange (optional) End shield CAUTION Note the illustration showing the chamfer of the rotor! 1. Push the rotor onto the shaft and check that it can be moved by hand. INTORQ | BA 14.0214 | 10/2019... - Page 30 3. Evenly tighten the brake with the six socket head cap screws included in the scope of supply in sev- eral runs using a torque wrench. 4. Establish the electrical connection and energize the brake (siehe Chapter Electrical connec- tion, Page 38). INTORQ | BA 14.0214 | 10/2019...
- Page 31 6. Use a torque wrench to retighten the supplied fastening screws with the required tightening torque, as shown in the table Rated data for the screw set for brake mounting, Page 16. 7. Switch off the power. INTORQ | BA 14.0214 | 10/2019...
- Page 32 Do not insert feeler gage more than 10 mm between armature plate and stator! Notice If the measured value for "s " is not within the tolerance, then the brake and the motor end shield must be checked! INTORQ | BA 14.0214 | 10/2019...
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Page 33: Cover Ring Assembly
The hand-release is mounted on the spring-applied brake which is already fitted on the motor. During this, the brake is not energized (except for steps 10 through 14). The brake's air gap is less than the maximum permissible value "S ". Lmax INTORQ | BA 14.0214 | 10/2019... - Page 34 Mechanical installation Fig. 16: Assembly of the hand-release BFK464-R Washer Disk spring Thrust washer Sleeve Lever Stud bolt Stator Perforated disk Ball Fig. 17: Assembly of the hand-release BFK464-R INTORQ | BA 14.0214 | 10/2019...
- Page 35 (if the rotor can rotate). If necessary, repeat the configuration as de- scribed in steps 10 to 15. NOTICE Be sure to check the air gap "s " before adjusting the hand-release (siehe Checking the air gap, Page 32). INTORQ | BA 14.0214 | 10/2019...
- Page 36 The brake may fail. If the hand-release is incorrectly adjusted, the brake may fail and cause serious personal injury and damage to property. Protective measure: ¾ Make sure that you comply with the specified turn-back degrees. INTORQ | BA 14.0214 | 10/2019...
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Page 37: Electrical Installation
K1/K3. ¾ The protective circuitry contained in the INTORQ switching device BEG-561- □□□- □□□ is not permitted for use in the lift technology. The protective circuitry must be connected in parallel to the brake coil (refer to the figure ). -
Page 38: Electrical Connection
Braking circuit 2 4-pole 4-pole BEG-14x BEG-14x BEG-24x BEG-24x Observe the Observe the correct polarity! correct polarity! 14.198.00.xx 14.198.00.xx Fig. 20: Switching suggestion for the BFK464-R without holding current reduction BK Black GR Grey BU Blue INTORQ | BA 14.0214 | 10/2019... -
Page 39: Technical Specifications For The Micro-Switch
Switching states (-0.1) Lmax Checking the air gap 1 - 4 1 - 2 1 - 2 Monitoring wear 1 - 4 1 - 4 1 - 2 Tab. 8: Switching states of the mechanical micro-switches INTORQ | BA 14.0214 | 10/2019... -
Page 40: Rectifier
The bridge-half-wave rectifiers are used to supply electromagnetic DC spring-applied brakes which are ap- proved for use with such rectifiers. Other use is only permitted with the approval of INTORQ. Once a set over-excitation period has elapsed, the bridge-half-wave rectifiers switch over from bridge recti- fication to half-wave rectification. -
Page 41: Technical Specifications
Bridge half- at U at U at U 1 min 1 Nom 1 max wave [V~] [V~] [V~] BEG-561-255-130 1,870 1,300 1,170 BEG-561-440-030-1 2,300 1,300 1,200 BEG-142-270 without without without without Tab. 9: Rectifier data INTORQ | BA 14.0214 | 10/2019... -
Page 42: Permissible Current Load At Ambient Temperature
Permissible current load at ambient temperature [°C] Fig. 23: Permissible current load for BEG-561-xxx-xxx If screwed to metal surface (good heat dissipation) For other installations (e.g. with adhesive) [°C] Fig. 24: Permissible current load for BEG-142-270 INTORQ | BA 14.0214 | 10/2019... -
Page 43: Commissioning And Operation
3. Apply DC voltage to the brake. 4. Measure the AC voltage at the motor terminals. The measured level must be zero. 5. Close the switching contact for the brake. – The brake is released. INTORQ | BA 14.0214 | 10/2019... -
Page 44: Checking The Hand-Release
The preparations for commissioning are completed. 7.1.2 Checking the hand-release NOTICE Labeling of drive systems and individual components ¾ The hand-release is designed for activation via a Bowden cable. ¾ An individual brake circuit can only be released electrically. INTORQ | BA 14.0214 | 10/2019... -
Page 45: Commissioning
- The drive must be able to turn freely. A low residual torque is permitted. 2. Release the lever. - A torque must now be built up! Commissioning 1. Switch on drive system. 2. Carry out a braking test. INTORQ | BA 14.0214 | 10/2019... -
Page 46: During Operation
¾ If a fault occurs once, go through the troubleshooting table (siehe the chapter Troubleshooting and fault elimination). If the fault cannot be fixed or eliminated, please contact the customer service depart- ment. INTORQ | BA 14.0214 | 10/2019... -
Page 47: Maintenance And Repair
Maintenance and repair Maintenance and repair INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The fric- tion lining and braking mechanism are subject to operational wear. To ensure safe and trouble-free opera- tions, the brake must be checked at regular intervals and replaced when necessary (refer to the table Maintenance intervals BFK458). -
Page 48: Inspections
After replacing the rotor, the original braking torque will not be reached until the run-in op- eration for the friction surfaces has been completed. After replacing the rotor, the run-in armature plates and the flanges have an increased initial rate of wear. INTORQ | BA 14.0214 | 10/2019... -
Page 49: Checking The Components
4. Compare the measured rotor thickness with the minimum permissible rotor thickness. (Refer to the values in the table Rated data for air gap specifications.) If the measured rotor thickness is insufficient, the rotor must be replaced completely. (Refer to Replace rotor for the description.) INTORQ | BA 14.0214 | 10/2019... -
Page 50: Checking The Air Gap
– Compare the measured voltage to the voltage specified on the name plate. A deviation of up to 10% is permitted. – When using bridge/half-wave rectifiers: After switching to one-way voltage, the measured DC voltage may drop to 45% of the voltage specified on the name plate. INTORQ | BA 14.0214 | 10/2019... -
Page 51: Replace Rotor
9. You can now install and adjust the new rotor and the complete stator. (Refer to Brake mount- ing, Page 29.) 10. Re-connect the connection cables. 11. If necessary, deactivate the mechanical shutdown of the system. INTORQ | BA 14.0214 | 10/2019... -
Page 52: Spare Parts List
Fastening screws Fastening screws ¾ for mounting to the motor ¾ Voltage Complete stator ¾ Rated torques Noise reducer ¾ For brake with hub Complete rotor ¾ For directly toothed shaft Flange Cover ring INTORQ | BA 14.0214 | 10/2019... -
Page 53: Troubleshooting And Fault Elimination
If the rectifier defect occurs again, replace the en- tire spring-applied brake, even if you cannot find any fault between turns or short circuit to ground. The error may only occur on warming up. INTORQ | BA 14.0214 | 10/2019... - Page 54 AC voltage is not mains Incorrect micro-switch wiring Check and correct the wiring of the micro-switch. voltage Micro-switch defective or in- Replace the complete stator and return the defective correctly set complete stator to the manufacturer. INTORQ | BA 14.0214 | 10/2019...
- Page 55 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...
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