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Summary of Contents for INTORQ BFK557
- Page 1 INTORQ BFK557 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 14.0223 | 04/2022...
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Page 4: Table Of Contents
3.6.2 Optional flange ............................ 14 3.6.3 Optional friction plate.......................... 14 3.6.4 Optional cover ring .......................... 14 4 Technical specifications ............................ 15 4.1 Possible applications of the Kendrion INTORQ spring-applied brake .............. 15 4.2 Characteristics .............................. 15 4.3 Switching times.............................. 18 4.4 Electromagnetic compatibility .......................... 19 4.5 Emissions ................................ 20 4.6 Labels on product ............................... 20... - Page 5 6.3.3 Reduced switch-off times ........................ 36 6.3.4 Permissible current load at ambient temperature................... 37 7 Commissioning and operation .......................... 38 7.1 Possible applications of the Kendrion INTORQ spring-applied brake .............. 38 7.2 Function checks before initial commissioning..................... 39 7.2.1 Function check of the brake ........................ 39 7.2.2 Release / voltage control........................ 39...
- Page 6 8.2.1 Maintenance intervals .......................... 43 8.3 Maintenance ............................... 43 8.3.1 Checking the components........................ 44 8.3.2 Checking the air gap .......................... 44 8.3.3 Release / voltage............................ 44 8.3.4 Brake replacement .......................... 45 8.4 Spare parts list.............................. 46 9 Troubleshooting and fault elimination........................ 48 Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 7: 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: Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 8: Terminology Used
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 compo- Drive system nents Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 9: Abbreviations Used
Rated air gap Minimum air gap Lmin Maximum air gap Lmax Engagement time, sum of the delay time and braking torque: rise time Disengagement time, time from switching the stator until reaching 0.1 M Kendrion INTORQ | BA 14.0223 | 04/2022... - Page 10 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 14.0223 | 04/2022...
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Page 11: 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 12: Product Description
This chapter describes the design and functionality of the INTORQ BFK557 spring-applied brake. 3.2.1 Sizes 06 to 12 Fig. 1: Design of a INTORQ spring-applied brake BFK557-06 to 12: Complete stator + rotor + friction plate Stator Socket-head cap screw Armature plate... -
Page 13: Function
¾ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reacti- vated regularly. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 14: Optional Configuration
A friction plate can be used if there is an available flat surface that is not suitable for use as a friction sur- face. 3.6.4 Optional cover ring The cover ring prevents most dust and moisture from escaping or penetrating into the brake compartment. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 15: Technical Specifications
General data The default (as delivered) air gap results from the sum tolerances of the individual components. These operating times are specified for usage of Kendrion INTORQ bridge/half-wave rectifiers and coils with a connection voltage of 205 V DC at s and 0.7*I... - Page 16 The material of the end shield must have a tensile strength of R > 250 N/mm Size Rated brake torque at Δn=100 rpm Braking torque at Δn Max. rotation speed Δn 0max 1500 3000 Max. [rpm] 6000 5000 4000 3600 Tab. 3: Brake torques Kendrion INTORQ | BA 14.0223 | 04/2022...
- Page 17 24.5 0.12 1715 0.107 2010 23.5 0.094 2660 24.0 0.233 0.197 0.15 1200 0.132 1556 0.116 1849 0.104 2404 1.583 15.2 0.369 0.315 0.211 0.195 1051 0.186 1156 0.160 1563 Tab. 4: Coil data Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 18: Switching Times
The specified engagement times are valid for DC switching with a spark suppressor. – Circuit proposals: refer to DC switching at mains – fast engagement, Page 34. Notice Spark suppressors are available for the rated voltages. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 19: Electromagnetic Compatibility
The maximum permissible friction energy Q relates to the standard friction lining. 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... -
Page 20: Emissions
Rated voltage 16 NM Rated torque 1 pc. Qty. per box 27 W Rated power 20 H7 Hub diameter 14.12.20 Packaging date Anti-rust packaging: keep friction surface free of Addition grease! CE mark Kendrion INTORQ | BA 14.0223 | 04/2022... - Page 21 Type (refer to Product key, Page 3 ) 205 V DC Rated voltage 27 W Rated power 20 H7 Hub diameter No. 33007925 ID number 16 NM Rated torque 14.12.20 Date of manufacture Data matrix code CE mark UL mark Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 22: Mechanical Installation
0.03 0.03 S235JR; C15; < 0.06 EN-GJL-250 0.03 0.05 Tab. 6: 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 14.0223 | 04/2022... -
Page 23: Tools
1 to 12 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 14.0223 | 04/2022... -
Page 24: Installing The Hub Onto 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). NOTICE If you are using the spring-applied brake for reverse operations, glue the hub to the shaft. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 25: Mounting The Brake
End shield Socket-head cap screw for fas- tening the brake 1. Push the spring-applied brake on the hub. 2. Tighten the socket-head cap screws slightly to attach the brake (screws should have just gripped). Kendrion INTORQ | BA 14.0223 | 04/2022... - Page 26 3. Remove the assembly lock (the rubber ring). 4. Screw the spring-applied brake to the end shield using the cap screws. Use a torque wrench (refer to the Mounting data, Page 16 table for the tightening torques). Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 27: Assembly Of The Flange
2. Align the through holes in the flange to the threads of the fastening bore holes in the end shield. 3. The further work steps are identical with the assembly of the brake as described in the chapter Mount- ing the BFK557-06 to -12, Page 25. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 28: Mounting The Cover Ring
Stator Socket-head cap screw Armature plate Sleeve bolt Friction plate End shield Fig. 10: Assembly of the cover ring with flange Cover ring Stator Socket-head cap screw Armature plate Sleeve bolt Flange End shield Kendrion INTORQ | BA 14.0223 | 04/2022... - Page 29 2. Slide the cover ring over the stator. 3. Press the corresponding lips of the cover ring into the groove of the flange. If a friction plate is used, the lip must be pulled over the edging. Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 30: 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 14.0223 | 04/2022... -
Page 31: 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 14.0223 | 04/2022... -
Page 32: 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 14.0223 | 04/2022... -
Page 33: 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 14.0223 | 04/2022... -
Page 34: 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 14.0223 | 04/2022... -
Page 35: Minimum Bending Radius For The Brake Connection Cable
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 Kendrion INTORQ. Once a set overexcitation period has elapsed, the bridge-half-wave rectifiers switch over from bridge recti- fication to half-wave rectification. -
Page 36: Technical Specifications
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 Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 37: Permissible Current Load At Ambient Temperature
Electrical installation 6.3.4 Permissible current load at ambient temperature Fig. 20: Permissible current load If screwed to metal surface (good heat dissipation) For other installations (e.g. with adhesive) Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 38: 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 39: Function Checks Before Initial Commissioning
DANGER Danger: rotating parts! Your system should be mechanically immobilized in the event that it could start moving when the brake is released. 3. Switch the power on. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 40: Testing The Hand-Release Functionality
– A sufficient torque must build up immediately! Notice If faults occur, refer to the error search table (Troubleshooting and fault elimina- tion, Page 48). If the fault cannot be fixed or eliminated, please contact the customer service department. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 41: Commissioning
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. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 42: Maintenance And Repair
Axial load cycle and shear stress Reduced spring force or fa- Number of switching opera- Springs of springs through radial backlash tigue failure tions of brake on reversal of armature plate Tab. 9: Causes for wear Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 43: Inspections
Contamination by oils and greases should be removed using brake cleaner, or the brake should be replaced after determining the cause. Dirt and particles in the air gap between the stator and the armature plate endanger the function and should be removed. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 44: Checking The Components
3. Replace the brake if necessary. 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. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 45: Brake Replacement
10. If necessary, deactivate the mechanical shutdown of the system. Notice After replacing the brake, the original braking torque will not be reached until the run-in opera- tion for the friction surfaces has been completed. Kendrion INTORQ | BA 14.0223 | 04/2022... -
Page 46: Spare Parts List
Maintenance and repair Spare parts list Sizes 06 to 12 Fig. 21: Spring-applied brake INTORQ BFK557 - sizes 06 to 12 Designation Variant ¾ Hand-release Size ¾ Size ¾ Brake torque ¾ Voltage ¾ Complete brake with hand-release ¾ without hand-release ¾... - Page 47 Maintenance and repair Electrical accessories Rectifier type Supply voltage Over-excitation Holding current reduc- Size tion Coil voltage Coil voltage [V AC] [V DC] [V DC] BEG-561-255-030 BEG-561-255-130 06 to 12 BEG-561-440-030-1 Kendrion INTORQ | BA 14.0223 | 04/2022...
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Page 48: Troubleshooting And Fault Elimination
The error may only occur on warming up. ¾ Brake cannot be re- For spring-applied brake Kendrion INTORQ Air gap too big leased, air gap is not zero BFK557-06 ... 12, replace the brake. Kendrion INTORQ | BA 14.0223 | 04/2022... - Page 49 The brake has not been re- For spring-applied brake Kendrion INTORQ Rotor is too thin placed in time BFK557-06 ... 12, replace the brake. Brake voltage does not match Voltage too high Adjust rectifier and brake voltage to each other.
- Page 50 (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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