INTORQ BFK458 Translation Of The Original Operating Instructions
Spring-applied brake with electromagnetic release
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- Original operating instructions (74 pages) ,
- Operating instructions manual (57 pages) ,
- Manual (32 pages)
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Summary of Contents for INTORQ BFK458
- Page 1 INTORQ BFK458 for NORD Drivesystems Spring-applied brake with electromagnetic release Translation of the Original Operating Instructions www.kendrion.com...
- Page 2 The warranty conditions can be found in the terms and conditions of Kendrion INTORQ GmbH. ¾ Warranty claims must be made to Kendrion INTORQ immediately after the defects or faults are de- tected. ¾ The warranty is void in all cases when liability claims cannot be made.
- Page 3 Kendrion INTORQ does not accept any liability for deficiencies claimed subsequently. ¾ Claim visible transport damage immediately to the deliverer. ¾ Claim visible defects or incompleteness of the delivery immediately to Kendrion INTORQ. Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 4: Table Of Contents
3.6 Brake torque reduction ............................ 14 3.7 Optional configuration............................ 14 3.7.1 Hand-release (optional).......................... 14 4 Technical specifications ............................ 15 4.1 operating range for the Kendrion INTORQ spring-applied brake ............... 15 4.2 Brake torques .............................. 16 4.3 Characteristics .............................. 17 4.4 Switching times.............................. 20 4.5 Friction work / operating frequency........................ 22 4.6 Electromagnetic compatibility .......................... 23... - Page 5 6.5 DC switching at mains – fast engagement ...................... 39 6.6 Minimum bending radius for the brake connection cable ................... 40 7 Commissioning and operation .......................... 41 7.1 Possible applications of the Kendrion INTORQ spring-applied brake .............. 41 7.2 Function checks before initial commissioning..................... 42 7.2.1 Function check of the brake ........................ 42 7.2.2 Release / voltage control........................ 42...
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Page 6: General Information
Characterizes the type and severity of danger. Notice text Describes the danger. Possible consequences List of possible consequences if the safety notices are disregarded. Protective measures List of protective measures required to avoid the danger. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 7: Terminology Used
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 100 rpm Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 8 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 Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 9: Safety Instructions
Only use original spare parts from the manufacturer. Keep the following in mind during the initial commissioning and during operation: ¾ Depending on the degree of protection, Kendrion INTORQ components may have both live (voltage carrying), moving and rotating parts. Such components require appropriate safety mechanisms. ¾... -
Page 10: Product Description
Kendrion INTORQ spring-applied brakes are being used in applications that have special safety require- ments. The BFK458-series brakes are suitable for use as service brakes, as holding brakes, and as hold- ing brakes with emergency-stop functionality for safety applications. The safety characteristics of the safety brake apply to systems that are designed so that 80% of the characteristic torque of the brake is sufficient for the safety function. - Page 11 The classification of the safety function of our brakes is based on the performance levels PL in accordance with DIN EN ISO 13849-1:2015. This can be used to support the verifications of the functional safety of drive systems. The safety characteristic data are available on request. Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 12: Design
The basic module E is adjustable (the braking torque can be reduced using the torque adjustment ring). 3.2.1 Basic module E Fig. 1: Design of a INTORQ BFK458 spring-applied brake Basic module E (complete stator) + rotor + hub + flange / friction plate Tappet Torque adjustment ring... -
Page 13: Basic Module N
Product description 3.2.2 Basic module N Fig. 2: Design of a INTORQ BFK458 spring-applied brake Basic module N (complete stator) + rotor + hub + flange / friction plate Stator Socket-head cap screw Hand-release (optional) Sleeve bolt Rotor Pressure spring Armature plate... -
Page 14: Braking And Release
Systems by removing certain pressure springs. Optional configuration 3.7.1 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 also be retrofitted. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 15: Technical Specifications
– -20 °C to +40 °C (Standard) Notice The Kendrion INTORQ BFK458 size 06 to 10 spring-applied brakes described in these operat- ing instructions may be used in normal operation in areas where there is not expected to be any explosive atmosphere due to gases, vapors, mist or swirling dust – but if they neverthe- less did occur, then only rarely and for a short period of time within the meaning of the ATEX Directive 2014/34/EU –... -
Page 16: Brake Torques
The standard friction lining (ST) is suitable both for pure holding brake applications and for service brake applications with dynamic loads. Progressive wear should be expected under dynamic load. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 17: Characteristics
3 x M4x40 3 x M5x45 3 x M6x50 10.1 Tab. 6: Rated data: Screw set for brake mounted on motor / friction plate Possible screw-in depth = protruding screw plus adjustment reserve for the rotor Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 18 11/12/14/15/20 3xM6 Size 4xM4 37.7 3x4.4 4xM5 3x5.5 56.1 76.5 4xM6 3x6.6 66.1 Tab. 7: Technical specifications Pre-drilled without groove Standard keyway according to DIN 6885/1 P9, select shaft diameter depending on load type Kendrion INTORQ | BA 14.0225 | 05/2022...
- Page 19 Cpl. incl. hand-release [kg] [kg] [kg] [kgcm 36.3 15.8 42.8 16.3 48.4 27.4 Tab. 9: Characteristics masses Size Electrical power Coil voltage Coil resistance Rated current ±8% [Ω] 28.8 0.83 530.5 0.194 1620 0.111 2101 0.098 Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 20: Switching Times
Operating/switching times of the spring-applied brakes Engagement time Delay time during engagement Disengagement time (up to M = 0.1 M Rise time of the braking torque Braking torque at a constant speed of rotation Voltage Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 21 7500 12000 Tab. 11: Switching energy - operating frequency - operating times These operating times are specified for usage of Kendrion INTORQ bridge/half-wave rectifiers and coils with a con- nection voltage of 205 V DC at s and 0.7 I For rectifiers from the manufacturer Nord Drive Systems, the same operating times can be applied.
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Page 22: Friction Work / Operating Frequency
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 Kendrion INTORQ rectifiers and rated voltage. Friction work / operating frequency 1000000... -
Page 23: Electromagnetic Compatibility
The user must ensure compliance with EMC Directive 2014/30/EC using appropriate controls and switching devices. NOTICE If a Kendrion INTORQ rectifier is used for the DC switching of the spring-applied brake and if the switching frequency exceeds five switching operations per minute, the use of a mains filter is required. -
Page 24: Hand-Release
Fig. 8: Packaging label Kendrion INTORQ Manufacturer 33009714 / NORD: 4093190100 ID number BFK458-06N Type (refer to Product key, Page 3 ) Bar code SPRING-APPLIED BRAKE Designation of the product family 24 V DC Rated voltage Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 25 Rated power No. 33009714 / NORD: 4093190100 ID number 5 NM Rated torque 23.08.21 Date of manufacture Data matrix code CE mark CSA/CUS acceptance Fig. 10: UL marking (example) UL marking of the insulation system Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 26: Mechanical Installation
[mm] [mm] [N/mm S235JR; C15; 0.03 < 0.06 EN-GJL-250 Tab. 13: End shield as counter friction surface Consult with Kendrion INTORQ before using other materials. When no brake flange or friction plate is used. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 27: Tools
Feeler gauge 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 the rated voltage)! Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 28: Installing The Hub Onto The Shaft
¾ If you have deviating operating conditions (e.g. additional load spectra with engaged brake), please contact Kendrion 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). -
Page 29: Mounting The Brake
Mounting the rotor (without friction plate / without brake flange) Fig. 12: Assembly of the rotor Rotor End shield 1. Push the rotor on the hub. 2. Check if the rotor can be moved manually. Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 30 Rated data: Screw set for brake mounted on motor / friction plate, Page 17 ). 4. Remove the terminal clips and dispose of properly. Fig. 14: Tightening the screws with a torque wrench Kendrion INTORQ | BA 14.0225 | 05/2022...
- Page 31 7. Use a torque wrench to tighten the socket head cap screws (refer to the Figure Tightening the screws with a torque wrench, Page 30). NOTICE Tightening torques: refer to the table Rated data: Screw set for brake mounted on motor / friction plate, Page 17. Kendrion INTORQ | BA 14.0225 | 05/2022...
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Page 32: Installing The Friction Plate (Optional)
Rotor Friction plate End shield 1. Place the friction plate against the end shield. The lip edging of the friction plate must remain visible! 2. Align the hole circle along the screw-in holes. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 33: Cover Ring Assembly
2. Slide the cover ring over the stator. 3. Press the respective lips of the cover ring into the groove of the stator. Then, pull the lip over the flared edge of the friction plate. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 34: Mounting The Hand-Release (Retrofitting)
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 24 for the values for the dimension s Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 35: Electrical Installation
NOTICE Make sure that the supply voltage matches the voltage specification on the name plate. Electrical connection Switching suggestions NOTICE The terminal pin sequence shown here does not match the actual order. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 36: Ac Switching At The Motor - Extremely Delayed Engagement
Supply: Phase-phase Bridge rectifier Half-wave rectifier 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. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 37: Dc Switching At The Motor - Fast Engagement
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. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 38: Ac Switching At Mains - Delayed Engagement
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. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 39: Dc Switching At Mains - Fast Engagement
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. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 40: 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 AWG 20 27.5 mm Tab. 14: Minimum bending radius for the brake connection cable Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 41: Commissioning And Operation
Commissioning and operation Commissioning and operation Possible applications of the Kendrion INTORQ spring-applied brake NOTICE In case of high humidity: If condensed water and moisture are present, provide for an ap- propriate ventilation for the brake to ensure that all friction components dry quickly. -
Page 42: Function Checks Before Initial Commissioning
6. Switch off the supply to the motor and brake securely. 7. Connect the bridges to the motor terminals. Remove any extra neutral conductor. 8. Adjust the air gap to s 9. If necessary, deactivate the mechanical shutdown of the system. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 43: Testing The Hand-Release Functionality
Do not use auxiliary tools (e.g. extension pipes) to facilitate the air release. Auxiliary tools are not permitted and are not considered as proper and intended usage. 3. Release the lever. – A sufficient torque must build up immediately! Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 44: Commissioning
¾ Checks must be carried out regularly. Pay special attention to: – unusual noises or temperatures – loose fixing/attachment elements – the condition of the electrical cables. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 45: Brake Torque Reduction (For The Optional Adjustable Braking Torque)
Do not change the hand-release setting for designs with hand-release. Increasing the braking torque by screwing in the torque adjustment ring is only permitted up to the default (as delivered) torque value . Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 46: Maintenance And Repair
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. 16: Causes for wear Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 47: Inspections
¾ or else every six months after 1 million cycles at the latest BFK458-□□ E / N ¾ Plan shorter intervals for frequent ¾ after 4000 operating hours at the latest emergency stops. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 48: Maintenance
2. Compare the measured air gap with the value for the max. permissible air gap s . (Refer to the Lmax Characteristics for air gap specifications, Page 17 table for the values.) 3. Adjust the air gap to s . (Refer to Adjusting the air gap). Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 49: Release / Voltage
3. Tighten the screws. (Refer to table Rated data: Screw set for brake mounted on motor / friction plate, Page 17 for the torque values.) 4. Check the value of s near the screws using a feeler gauge. (Refer to table Characteristics for air gap specifications, Page 17.) Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 50: Checking The Rotor Thickness
11. You can now install and adjust the new rotor and the complete stator. (Refer to Mounting the brake, Page 29.) 12. Re-connect the connection cables. 13. If necessary, deactivate the mechanical shutdown of the system. Kendrion INTORQ | BA 14.0225 | 05/2022... -
Page 51: Spare Parts List
Maintenance and repair Spare parts list INTORQ spring-applied brake BFK458-06 to 10 Fig. 29: INTORQ spring-applied brake BFK458-06 to 10 Designation Variant Hand-release with standard lever Mounting kit Basic module N Screw set DIN EN ISO 4762 - 8.8 for mounting to the motor / friction plate... -
Page 52: Troubleshooting And Fault Elimination
If the rectifier defect occurs again, replace the entire 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. Kendrion INTORQ | BA 14.0225 | 05/2022... - Page 53 Voltage too low Defective rectifier Replace the defective rectifier with a suitable undamaged one. diode AC voltage is not Fuse is missing or Select a connection with a proper fuse. mains voltage defective Kendrion INTORQ | BA 14.0225 | 05/2022...
- Page 54 (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. 600, Xin Yuan Nan Road, Building No. 6 / Zone B Nicheng town, Pudong 201306 Shanghai +86 21 20363-810 Ê...
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