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Перейти на сайт официального дистрибьютора >> INTORQ BFK458-ATEX Spring-applied brake with electromagnetic release Translation of the Original Operating Instructions www.intorq.com...
– 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.
INTORQ does not accept any liability for deficiencies claimed subsequently. ¾ Claim visible transport damage immediately to the deliverer. ¾ Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG. INTORQ | BA 14.0217 | 09/2019...
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 14.0217 | 09/2019...
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 14.0217 | 09/2019...
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 t Disengagement time, time from switching the stator until reaching 0.1 M INTORQ | BA 14.0217 | 09/2019...
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Overexcitation 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, U V DC equals U INTORQ | BA 14.0217 | 09/2019...
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: –...
ATEX name plate for the dust zone must be mon- itored on the brake's magnet housing using a suitable temperature measurement mechanism. If there is no available knowledge of the occurring temperatures, then INTORQ is no longer responsible for this ATEX certification.
3.1.1 Standard applications INTORQ components are intended for use in machinery and facilities. They may only be used for purposes as specified in the order and confirmed by INTORQ. The INTORQ components may only be operated under the conditions specified in these Operating Instructions. They may never be operated beyond their specified performance limits.
Layout This chapter describes the variants, layout and functionality of the INTORQ BFK458 spring-applied brake. The basic module E is adjustable (the braking torque can be reduced using the torque adjustment ring).
ID number: Assignment of the cover rings and sealing covers for the basic models N and E 3.2.3 Basic module E Fig. 1: Design of the INTORQ BFK458 spring-applied brake: Basic module E (complete stator) + rotor + hub + flange Tappet Torque adjustment ring Stator...
Optional configuration 3.6.1 Hand-release (optional) To temporarily release the brake when there is no electricity available, a hand-release function is available as an option. The hand-release function can be retrofitted. INTORQ | BA 14.0217 | 09/2019...
This would result in higher temperatures, which would then pose a risk of igni- tion. ¾ Use only original INTORQ friction parts (flange and armature plate) and standard friction linings (ST) for the ATEX brake. ¾ The brake is designed with one free cable end. This cable must be inserted into a suitable terminal box (through a cable gland) in accordance with the ATEX directives.
ATEX name plate for the dust zone must be mon- itored on the brake's magnet housing using a suitable temperature measurement mechanism. If there is no available knowledge of the occurring temperatures, then INTORQ is no longer responsible for this ATEX certification.
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.
Dust explosive atmosphere (zone 22: non-conductive dusts), Page 31 and Gas explosive atmosphere (zone 2), Page 33, shall be applicable. Notice A version of the double spring-applied brake using HFC (high-friction coefficient) linings is not permitted. INTORQ | BA 14.0217 | 09/2019...
0.45 11.5 10.0 13.0 12.0 16.0 1.25 0.75 15.5 20.0 19.5 Tab. 4: Rated data for air gap specifications The friction lining is sized so that the brake can be adjusted at least five times. INTORQ | BA 14.0217 | 09/2019...
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With the double spring-applied brake design, when working with braking torques which are greater than the standard braking torque, you need to check the screws connecting the first brake. Please consult with INTORQ first! INTORQ | BA 14.0217 | 09/2019...
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1.06 262.7 0.647 294.6 0.611 328.2 0.578 382.1 0.536 Tab. 8: Rated data for coil powers Coil power at 20 °C in W, deviation up to +10% is possible depending on the selected connection voltage. INTORQ | BA 14.0217 | 09/2019...
[ms] Tab. 9: Switching energy - operating frequency - switching times These switching times are specified for usage of INTORQ bridge/half-wave rectifiers and coils with a connection voltage of 205 V DC at s and 0.7 I INTORQ | BA 14.0217 | 09/2019...
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Spark suppressors are available for the rated voltages. Notice INTORQ's half-wave and bridge rectifiers and spark suppressors have not been designed for use in potentially explosive atmospheres. If the use of these electrical components is neces- sary, they must be installed within a control cabinet that is outside the explosive atmosphere.
Dust explosive atmosphere (zone 22: non-conductive dusts) 100000 10000 1000 1000 Operating frequency S [h ] Fig. 5: Friction work as a function of the operating frequency BFK-458-ATEX for dust atmospheres INTORQ | BA 14.0217 | 09/2019...
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10986 10799 21329 20317 28727 27237 34117 32181 48216 43233 73755 65483 110150 93224 Tab. 10: Permissible friction work [J], depending on the number of switching operations that is typical for facility ac- ceptance tests INTORQ | BA 14.0217 | 09/2019...
Friction work as a function of the operating frequency for the BFK-458-ATEX, for gas atmospheres, for the speed 800 rpm 100000 10000 1000 1000 Operating frequency S [h ] Fig. 7: Friction work as a function of the operating frequency for the BFK-458-ATEX, for gas atmospheres, for the speed 1500 rpm INTORQ | BA 14.0217 | 09/2019...
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Friction work as a function of the operating frequency for the BFK-458-ATEX, for gas atmospheres, for the speed 1800 rpm 100000 10000 1000 1000 Operating frequency S [h ] Fig. 9: Friction work as a function of the operating frequency for the BFK-458-ATEX, for gas atmospheres, for the speed 2500 rpm INTORQ | BA 14.0217 | 09/2019...
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.
Brake completely installed Stator (not attached to the motor) Fig. 11: Positions of the adjustment dimensions that must be checked +0.1 / -0.05 +0.1 Size [mm] [mm] Tab. 12: Adjustment setting for hand-release INTORQ | BA 14.0217 | 09/2019...
Rated voltage 32 NM Rated torque Pieces Qty. per box 40 W Rated power 25 H7 Hub diameter 1 Jun. 2017 Packaging date Anti-rust packaging: keep friction surface free of Addition grease! CE mark INTORQ | BA 14.0217 | 09/2019...
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205 V DC Rated voltage 40 W Rated power 20 H7 Hub diameter No. 15049627 ID number 32 NM Rated torque 20 Mar. 2018 Date of manufacture Data matrix code CE mark CSA/CUS acceptance UL mark INTORQ | BA 14.0217 | 09/2019...
Name plate ATEX holding brake (an example) Labeling Meaning II 3G Designation label according to ATEX II 3D directive 2014/34/EU Ex nA IIC T4 Gc X Designation label according to Ex tc IIIC 120°C Dc X DIN EN 60079-0 INTORQ | BA 14.0217 | 09/2019...
DANGER Danger of explosion Increased temperatures on the surfaces and in the friction gap can result when the max- imum friction work and operating frequencies specified by INTORQ are exceeded. These can lead to ignition. ¾ Operation is only permitted within the specified specifications.
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.
Caliper gage Feeler gage Preparing the installation 1. Remove the packaging from the spring-applied brake and dispose of it properly. 2. Check the delivery for completeness. 3. Check the name plate specifications (especially rated voltage)! INTORQ | BA 14.0217 | 09/2019...
¾ If you have deviating operating conditions (e.g. additional load spectra with engaged brake), please contact INTORQ for the proper dimensioning of the hub-side key connection. ¾ Secure the hub against axial displacement after you install it (e.g. with a circlip).
Mounting the rotor (without friction plate / without brake flange) Fig. 16: Assembly of the rotor Rotor End shield 1. Push the rotor on the hub. 2. Check if the rotor can be moved manually. INTORQ | BA 14.0217 | 09/2019...
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Rated data: screw kit for brake assembly on separately screwed-on flange, Page 25 ). 4. Remove the terminal clips and dispose of properly. Fig. 18: Tightening the screws with a torque wrench INTORQ | BA 14.0217 | 09/2019...
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7. Use a torque wrench to tighten the socket head cap screws (refer to the Figure Tightening the screws with a torque wrench, Page 46). NOTICE Tightening torques: refer to the table Rated data: screw kit for brake assembly on separ- ately screwed-on flange, Page 25. INTORQ | BA 14.0217 | 09/2019...
2. Align the hole circle along the screw-in holes. 3. Mount the brake using the appropriate set of screws (refer to the figures in the chapters Mounting the brake, Page 45 and Spare parts list, Page 77 ). INTORQ | BA 14.0217 | 09/2019...
Tighten the screws evenly (for tightening torques, refer to the table Rated data: screw kit for brake assembly on separately screwed-on flange, Page 25 ). 3. Use the three screws to screw the flange to the end shield. INTORQ | BA 14.0217 | 09/2019...
Flange mounting for sizes 18 – 20 Screw Flange End shield According to the table Rated data: screw kit for brake assembly on separately screwed-on flange, Page 25 1. Place the flange against the end shield. INTORQ | BA 14.0217 | 09/2019...
Fig. 23: Flange mounting for size 25 Hex screw Flange End shield According to the table Rated data: screw kit for brake assembly on separately screwed-on flange, Page 25 1. Place the flange against the end shield. INTORQ | BA 14.0217 | 09/2019...
Install them using the tightening torque specified in the table for the screw kit for in- termediate flange mounting for double spring-applied brakes as well as the table Rated data: screw kit for brake assembly on separately screwed-on flange, Page 25 (in the column "Screw kit for mounting on flange"). INTORQ | BA 14.0217 | 09/2019...
NOTICE With the double spring-applied brake design, when working with braking torques which are greater than the standard braking torque, you need to check the screws connecting the first brake. Please consult with INTORQ first! Cover ring assembly Fig. 25: Cover ring assembly...
No grease should be allowed to contact the friction surfaces. ¾ When assembling the stator, push the shaft sealing ring carefully over the shaft. The shaft should be located concentrically to the shaft sealing ring INTORQ | BA 14.0217 | 09/2019...
7. Set the gap s evenly using the hex head screws and the feeler gauge. Refer to the table Ad- justment setting for hand-release, Page 37 for the values for the dimension s INTORQ | BA 14.0217 | 09/2019...
The terminal pin sequence shown here does not match the actual order. Notice INTORQ's half-wave and bridge rectifiers and spark suppressors have not been designed for use in potentially explosive atmospheres. If the use of these electrical components is neces- sary, they must be installed within a control cabinet that is outside the explosive atmosphere.
Supply: Phase-phase Bridge rectifier Half-wave rectifiers BEG-1xx: U [V DC] = 0.9 • U [V AC] BEG-2xx: U [V DC] = 0.45 • U [V AC] Not recommended for most regional/national high-voltage mains voltages. INTORQ | BA 14.0217 | 09/2019...
Supply: Phase-phase Bridge rectifier Half-wave rectifiers BEG-1xx: U [V DC] = 0.9 • U [V AC] BEG-2xx: U [V DC] = 0.45 • U [V AC] Not recommended for most regional/national high-voltage mains voltages. INTORQ | BA 14.0217 | 09/2019...
Supply: Phase-phase Bridge rectifier Half-wave rectifiers BEG-1xx: U [V DC] = 0.9 • U [V AC] BEG-2xx: U [V DC] = 0.45 • U [V AC] Not recommended for most regional/national high-voltage mains voltages. INTORQ | BA 14.0217 | 09/2019...
[V AC] BEG-24x: U [V DC] = 0.45 • U [V AC] Spark suppressor: 14.198.00.xx (required once, select position) For most regional/national high-voltage mains voltages, this only makes sense for supplies on L1 and N. INTORQ | BA 14.0217 | 09/2019...
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 overexcitation period has elapsed, the bridge-half-wave rectifiers switch over from bridge recti- fication to half-wave rectification.
Delayed engagement Fast engagement Mains Bridge Coil Mains Coil 7.7.4 Permissible current load at ambient temperature Fig. 37: Permissible current load If screwed to metal surface (good heat dissipation) For other installations (e.g. with adhesive) INTORQ | BA 14.0217 | 09/2019...
Commissioning and operation Commissioning and operation Possible applications of the INTORQ spring-applied brake NOTICE In case of high humidity: If condensed water and moisture are present, provide for the appro- priate ventilation for the brake to ensure that all friction components dry quickly.
. The air gap must be zero and the rotor must rotate freely. 6. Switch off the supply to the motor and brake securely. 7. Connect the bridges to the motor terminals. Remove any extra neutral conductor. INTORQ | BA 14.0217 | 09/2019...
This operational test must also be carried out! Fig. 38: Turning direction of the lever Size Hand force [N] Hand force [N] Standard braking torque Maximum braking torque 250* 330* 350* Tab. 16: Actuating forces * When used with a long lever INTORQ | BA 14.0217 | 09/2019...
If the fault cannot be fixed or eliminated, please contact the customer service department. Commissioning 1. Switch on your drive system. 2. Perform a test braking procedure; if necessary, reduce the braking torque (depending on your spe- cifications and requirements) INTORQ | BA 14.0217 | 09/2019...
The deviation must be less than ± 10%! ¾ 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 14.0217 | 09/2019...
(as delivered) torque value . 8.4.2 Operating procedures Operating procedures DANGER The friction lining and the friction surfaces must never contact oil or grease since even small amounts reduce the braking torque considerably. INTORQ | BA 14.0217 | 09/2019...
DANGER Danger of explosion Increased temperatures on the surfaces and in the friction gap can result when the max- imum friction work and operating frequencies specified by INTORQ are exceeded. These can lead to ignition. ¾ Operation is only permitted within the specified specifications.
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Axial load cycle and shear stress of Reduced spring force or Number of switching op- Springs springs through radial backlash on re- fatigue failure erations of brake versal of armature plate Tab. 17: Causes for wear INTORQ | BA 14.0217 | 09/2019...
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 14.0217 | 09/2019...
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, Page 24.) If the measured rotor thickness is insufficient, the rotor must be replaced completely. (Refer to Replace rotor, Page 75 for the descrip- tion.) INTORQ | BA 14.0217 | 09/2019...
– 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 14.0217 | 09/2019...
In case of strong scoring on the end shield, rework the friction surface. 8. Measure the rotor thickness of the new rotor and the head thickness of the sleeve bolts (use a calliper gauge). INTORQ | BA 14.0217 | 09/2019...
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11. You can now install and adjust the new rotor and the complete stator. (Refer to Mounting the brake, Page 45.) 12. Re-connect the connection cables. 13. If necessary, deactivate mechanical shutdown of the system. INTORQ | BA 14.0217 | 09/2019...
Maintenance and repair Spare parts list Spring-applied brake INTORQ BFK458-06 to 25 Fig. 40: Spring-applied brake INTORQ BFK458-06 to 25 Designation Variant Hand-release with standard lever Mounting kit Basic module N Shaft sealing ring Shaft diameter on request ¾ for mounting to the flange Screw set DIN EN ISO 4762 - 8.8...
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Maintenance and repair Double spring-applied brake INTORQ BFK458-06 to 25 Fig. 41: Double spring-applied brake INTORQ BFK458-06 to 25 Designation Variant Hand-release with standard lever Mounting kit Basic module N Shaft sealing ring Shaft diameter on request ¾ for mounting to the flange Screw set DIN EN ISO 4762 - 8.8...
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Supply Overexcitation Holding current reduction rectifier voltage Coil voltage Size Coil voltage Size [V AC] [V DC] [V DC] BEG-561-255-030 06 – 25 06 – 14 BEG-561-255-130 16 – 25 BEG-561-440-030-1 06 – 25 INTORQ | BA 14.0217 | 09/2019...
If the rectifier defect occurs again, replace the entire spring-ap- plied 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 14.0217 | 09/2019...
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Voltage too low Defective rectifier diode Replace the defective rectifier with a suitable undamaged one. AC voltage is not Fuse is missing or defect- Select a connection with proper fusing. mains voltage INTORQ | BA 14.0217 | 09/2019...
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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 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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