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Summary of Contents for INTORQ BFK455-28
- Page 1 INTORQ BFK455-28 Electromagnetically Released Spring-Applied Brake Translation of the Original Operating Instructions www.intorq.com www.intorq.com...
- Page 2 This documentation applies to the: Product key INTORQ Legend for the product key INTORQ BFK455 Product group Brakes Product type Spring-applied brake Type Size Not coded: Supply voltage, hub bore, options INTORQ | BA 14.0196 | 04/2016...
- Page 3 EN: Do not re-adjust the air-gap after the first installation! Haltespannung: FR: Ne plus regler l‘entrefer après la première installa- Holding voltage: 103 V DC tion! Nur mit BEG-561-255-130 betreiben! Only use with BEG-561-255-130! Nr./No. 33000224 INTORQ | BA 14.0196 | 04/2016...
- Page 4 Values for characteristic torque 2x2065 Nm added to “Dimensions” table 33002468 01/2015 SC Restructured FM 33002468 11/2015 SC Changing the model identification test numbers 33002468 04/2016 SC Updates Changing the model identification test numbers INTORQ | BA 14.0196 | 04/2016...
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Page 5: Table Of Contents
During operation ............................41 Maintenance and repair ............................42 Wear of spring-applied brakes ........................42 Inspections ..............................43 Maintenance ............................... 44 Spare-parts list ............................46 Ordering spare parts ..........................47 Troubleshooting and fault elimination ......................48 INTORQ | BA 14.0196 | 04/2016... -
Page 6: Preface And General Information
Reference to another page with additional Symbols information For example: 16 = refer to page 16 Wildcard Wildcard for options, selections For example: BFK458- = BFK458-10 Note Important notice about ensuring smooth operations or other key information. INTORQ | BA 14.0196 | 04/2016... -
Page 7: Abbreviations Used
Engagement time, sum of the delay time and braking torque - rise time Disengagement time, time from switching the stator until reaching 0.1 M Slipping time, operation time of the brake (according to t ) until standstill INTORQ | BA 14.0196 | 04/2016... -
Page 8: Safety Instructions And Notices
Characterizes the type and severity of danger Note Describes the danger Possible consequences ❚ List of possible consequences if the safety instructions are disregarded Protective measure ❚ List of protective measures to avoid the danger INTORQ | BA 14.0196 | 04/2016... -
Page 9: Scope Of Delivery
INTORQ does not accept any liability for deficiencies claimed subsequently. ❚ Claim visible transport damage immediately to the deliverer. ❚ Claim visible deficiencies or incomplete deliveries immediately to INTORQ GmbH & Co. KG. Disposal The spring-applied brake consists of different types of material. ❚... -
Page 10: Drive Systems
Manufacturer: INTORQ GmbH & Co. KG, Wülmser Weg 5, D-31855 Aerzen, Germany ❚ 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 – particularly the packaging label, nameplate and type code –... -
Page 11: Safety Instructions
❚ Only qualified, skilled personnel are permitted to work on and with INTORQ components. According to IEC 60364 or CENELEC HD 384, qualified, skilled personnel are persons: ... who are familiar with the installation, mounting, commissioning, and operation of the product. -
Page 12: Application As Directed
... must only be operated under the ambient conditions prescribed in these Operating Instructions..must not be operated beyond their corresponding power limits. Any other use or excessive usage is considered improper! Usage conditions for the INTORQ spring-applied brake ❚ Humidity: no restrictions In the event of condensation or moisture formation: provide for appropriate ventilation to ensure that all components will dry quickly. -
Page 13: Technical Specifications
Technical specifications Technical specifications Product description Versions Basic module Fig. 1 Design of a BFK455 spring-applied brake 1.1 Stator Complete rotor Flange 1.2 Pressure springs Coil Armature plate Shaft 13 Cover ring INTORQ | BA 14.0196 | 04/2016... - Page 14 (which can be shifted axially on the hub (4)) against the friction surface. The asbestos-free friction linings ensure high braking torque and low wear. The braking torque is transmitted between the hub (4) and the rotor (3) via gear teeth. INTORQ | BA 14.0196 | 04/2016...
- Page 15 ❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactivated regularly. INTORQ | BA 14.0196 | 04/2016...
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Page 16: Rated Data
❚ If the required thread depth is not maintained, the fixing screws may run onto the root. This has the effect that the required pre-load force is no longer established – the brake is no longer securely fastened! INTORQ | BA 14.0196 | 04/2016... -
Page 17: Rated Data (Design Data)
2 x 108.5 2 x 97 2 x 2.12 2 x 298.6 2 x 1.21 Tab. 2: Coil power ratings of the BFK455-28 Rated data (design data) Fig. 2 Operating/switching times of the spring-applied brakes Engagement time Reaction delay of engagement Disengagement time (up to M = 0.1 M... - Page 18 If the brake is using AC-side switching, the engagement times increase approximately by a fac- tor of 5 (refer to 35 for connection). Disengagement time The disengagement time is the same for DC and AC switching. The specified disengagement times always refer to control using over-excitation. INTORQ | BA 14.0196 | 04/2016...
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Page 19: Switching Energy / Switching Frequency
, the permissible amount of heat is Q Smax With high speeds of rotation and switching energy, the wear increases strongly, because very high temper- atures occur at the friction surfaces for a short time. INTORQ | BA 14.0196 | 04/2016... -
Page 20: Emissions
The user must ensure compliance with EMC Directive 2014/30/EU using appropriate controls and switching devices. If an INTORQ rectifier is used for the DC switching of the spring-applied brake: If the switching frequency exceeds five switching operations per minute, the use of a mains filter is required. -
Page 21: Mechanical Installation
The toothed hub and screws must not be lubricated with grease or oil. Necessary tools Type Torque wrench Open-jawed spanner Bit for hexagon socket screws Measuring range [Nm] Wrench width [mm] Adjustment tubes - wrench size [mm] BFK455-28 40 - 400 Multi-meter Caliper gauge Feeler gauge INTORQ | BA 14.0196 | 04/2016... -
Page 22: Assembly
❚ Free of grease and oil Tab. 4: Counter friction face design of the end shield For other materials, please consult with INTORQ. The diameter of the shaft shoulder must not be greater than the tooth root diameter of the hub. 4.3.2 Preparation 1. -
Page 23: Installation
2. Press the first hub (4) onto the shaft. 3. Secure the hub (4) against axial displacement (for example, by using a circlip (4.2)). NOTICE For reverse operations, we recommend also glueing the hub to the shaft. INTORQ | BA 14.0196 | 04/2016... - Page 24 Assembly of the first rotor Fig. 6 Mounting of the rotor Rotor Flange 15 End shield 6. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand. INTORQ | BA 14.0196 | 04/2016...
- Page 25 4.1 Key 7. Insert second key (4.1) into the shaft (5) if required. 8. Press second hub (4) onto the shaft (5). 9. Secure hub (4) against axial displacement, e.g. by using a circlip (4.2). INTORQ | BA 14.0196 | 04/2016...
- Page 26 Assembly of the second rotor Fig. 9 Mounting of the rotor Stator, complete 15 End shield Complete rotor Flange 12. Push the complete rotor (3) onto the hub (4) and check whether it can be moved by hand. INTORQ | BA 14.0196 | 04/2016...
- Page 27 16. Establish the electrical connection and energize the brake ( 35). 17. Use a torque key to re-tighten the supplied fixing screws (10) with the required tightening torque 16). 18. Switch off the power. INTORQ | BA 14.0196 | 04/2016...
- Page 28 First correctly adjust the air gap with every 2nd bolt (10) / sleeve bolt (9)! The other three sleeve bolts should be screwed into the stator so that they do not touch the flange or the bearing shield. Then repeat the process with the other three bolts (10). INTORQ | BA 14.0196 | 04/2016...
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Page 29: Manual Release
1 through 12 ( 23 and 26). 4.5.1 Components of the manual release 12.8A 12.5 12.14 12.8 12.11 12.1 Fig. 13 Manual release 12.1 Manual release lever 12.8 Lock nut 12.14 Tension rod 12.5 Pressure spring 12.11Clip INTORQ | BA 14.0196 | 04/2016... - Page 30 12.5 12.14 Fig. 15 Installation of the tension rods 3. Assemble four pre-assembled tension rods (12.14) with one spring (12.5) each Carry out steps 4 and 5 separately for each side of every lever. INTORQ | BA 14.0196 | 04/2016...
- Page 31 (12.14) up to the point where the back side of the lock nut aligns with the top of the tension rod. 8. Evenly tighten the brake with the six socket head cap screws (10) included in the scope of supply in sev- eral runs using a torque key (as shown in Figure 17). INTORQ | BA 14.0196 | 04/2016...
- Page 32 (1) (tangible resistance). 15. Loosen the lock nuts (12.8) at the clips (12.11) by a ¾ revolution (270°). Carry out steps 16 and 17 separately for each side of every lever. INTORQ | BA 14.0196 | 04/2016...
- Page 33 19. Connect the Bowden cable (not included in this delivery) and pull until the motor shaft can be freely ro- tated. NOTICE The actuation force between the Bowden cable's hanging points is approximately 900 N. The actual pull force required may be higher depending on the characteristics and position of the cable. INTORQ | BA 14.0196 | 04/2016...
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Page 34: Cover Ring Assembly
5. Press the lips of the second cover ring into the groove of the first and second complete stator (1). 6. Re-establish the electrical connection. NOTICE Cover ring with condensation drain hole: Attach the cover ring so that condensation can drain through the hole. INTORQ | BA 14.0196 | 04/2016... -
Page 35: Electrical Installation
For a new over-energizing during switch-on, it is also necessary to open switches K1/K3. ❚ The protective circuitry contained in the INTORQ switching device BEG-561- (terminals 3 and 4) is not permitted for use in the lift system. The protective circuitry must be connected parallel to the brake coil ( 36). -
Page 36: Bridge/Half-Wave Rectifier (Optional)
The bridge/half-wave rectifiers are used to supply electromagnetic DC spring-applied brakes which are ap- proved for the use with such rectifiers. Other use is only permitted with the approval of INTORQ. Once a set over-excitation time has elapsed, the bridge/half-wave rectifiers switch over from bridge rectifi- cation to half-wave rectification. - Page 37 U Min. Rated max. Bridge half-wave 1 min 1 Nom 1 max [V ~] [V ~] [V ~] BEG-561-255-130 1.870 1.300 1.170 BEG-561-440-130 2.300 1.300 1.200 Tab. 5: Data for bridge/half-wave rectifier type BEG-561 INTORQ | BA 14.0196 | 04/2016...
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Page 38: Electrical Connection
There is a risk of injury by electrical shock! The brake must only be electrically connected when no voltage is applied! NOTICE Compare the coil voltage of the stator to the DC voltage of the installed rectifier. INTORQ | BA 14.0196 | 04/2016... -
Page 39: 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 14.0196 | 04/2016... -
Page 40: Commissioning
/ grey NO contact black / blue Tab. 6: Switching status of the micro-switch The preparations for commissioning are completed. Commissioning 1. Switch on the drive system. 2. Carry out a braking test. INTORQ | BA 14.0196 | 04/2016... -
Page 41: During Operation
(see table 5). A deviation of ±10 % is permissible. ❚ If faults occur once, go through the troubleshooting table in chapter 8. If the fault cannot be fixed or elim- inated, please contact your customer service. INTORQ | BA 14.0196 | 04/2016... -
Page 42: Maintenance And Repair
Maintenance and repair Wear of spring-applied brakes INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The friction lining and braking mechanism are subject to operational wear. For safe and trouble-free operation, the brake must be checked at regular intervals or replaced, if necessary... -
Page 43: Inspections
❚ Check the armature plate and of the armature plates or flange or bearing shield flange (dark-blue - Levelness < 0.1 mm tarnishing) - Max. run-in depth = rated air gap for the size INTORQ | BA 14.0196 | 04/2016... -
Page 44: Maintenance
2. Remove the motor cover and remove the cover ring, if present. 3. Measure the rotor thickness using a caliper gauge. 4. Compare the measured rotor thickness with the minimally permissible rotor thickness, 5. If required, replace the rotor completely ( 45). INTORQ | BA 14.0196 | 04/2016... - Page 45 11. Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is reached. 12. Install and adjust the new complete rotor and stator ( 23). 13. Reconnect the connection cable. INTORQ | BA 14.0196 | 04/2016...
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Page 46: Spare-Parts List
Stator, complete Voltage Complete rotor Rotor, complete noise-reduced Bore diameter Flange Fixing screws for mounting to the motor Socket head cap screw set, DIN912 for flange with through hole Complete manual release Cover ring INTORQ | BA 14.0196 | 04/2016... -
Page 47: Ordering Spare Parts
(for hole diameter, see dimensions) For mounting Fixing screw set For mounting with flange Flange Counter friction face Cover ring Seal Complete manual release Electrical accessories Rectifier type: Selection see chapter 5.2.1 BEG-561-255-130 Rectifier BEG-561-440-130 INTORQ | BA 14.0196 | 04/2016... -
Page 48: Troubleshooting And Fault Elimination
Brake cannot be Air gap “s ” is too large ❚ For adjustable brakes: released, air gap is - Readjust air gap. not zero ❚ For non-adjustable brakes: - Replace all rotors. INTORQ | BA 14.0196 | 04/2016... - Page 49 Select a connection with proper fusing. mains voltage defective Incorrect micro-switch Check and correct the wiring of the micro-switch. wiring Micro-switch defective Replace the complete stator and return the defective complete stator to or incorrectly set the manufacturer. INTORQ | BA 14.0196 | 04/2016...
- Page 50 Notes Notes INTORQ | BA 14.0196 | 04/2016...
- Page 51 INTORQ GmbH & Co KG Germany PO Box 1103 D-31849 Aerzen Wülmser Weg 5 D-31855 Aerzen +49 5154 70534-444 +49 5154 70534-200 info@intorq.com INTORQ (Shanghai) Co., Ltd. No. 600, Xin Yuan Nan Road, Building No. 6 / Zone B...
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