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INTORQ BFK455-25, Translation Of The Original Operating Instructions

The INTORQ BFK455-25 is a high-quality industrial brake with exceptional performance. For detailed instructions on operating this product, download the free manual with a Translation Of The Original Operating Instructions from manualshive.com. This user-friendly guide will assist you in maximizing the efficiency and effectiveness of your brake system.

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Mechanical installation

INTORQ | BA 14.0215 | 07/2019

23

5.2

Tools

Size

Torque wrench

Insert for 

hexagonal socket (Allen) screws

Measuring range

Wrench width

[Nm]

[mm]

25

40 to 400

10

Multimeter

Caliper gauge

Feeler gauge

5.3

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)!

Summary of Contents for BFK455-25

Page 1: ...INTORQ BFK455 25 Spring applied brake with electromagnetic release Translation of the Original Operating Instructions setting the standard www intorq com...

Page 2: ...d descriptions We do not accept any liability for damage and operating interference caused by inappropriate use unauthorised modifications to the product improper work on or with the drive system oper...

Page 3: ...ion voltage hub bore hole options Checking the delivery After receipt of the delivery check immediately whether the items delivered match the accompanying pa pers INTORQ does not accept any liability...

Page 4: ...age 11 3 1 1 Standard applications 11 3 2 Layout 11 3 2 1 Basic module 12 3 3 Function 12 3 4 Braking and release 13 3 5 Release monitoring 13 3 6 Project planning notes 13 3 7 Optional configuration...

Page 5: ...9 6 2 2 Technical specifications 40 6 2 3 Permissible current load at ambient temperature 40 7 Commissioning and operation 41 7 1 Function checks before initial commissioning 41 7 1 1 Brake with micro...

Page 6: ...e and perfectly readable condition 1 2 Conventions in use This document uses the following styles to distinguish between different types of information Spelling of numbers Decimal separator Point The...

Page 7: ...which if not avoided will result in death or seri ous injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION in...

Page 8: ...energy QE J Max permissible friction energy for one time switching thermal parameter of the brake QR J Braking energy friction energy QSmax J Maximally permissible friction energy for cyclic switchin...

Page 9: ...hing off the supply voltage to the beginning of the torque rise t12 ms Rise time of the braking torque time from the start of torque rise until reach ing the braking torque tue s Overexcitation period...

Page 10: ...ropriate safety measures to ensure contact touch protection Follow all specifications and information found in the Operating Instructions and the corresponding documentation These must be followed to...

Page 11: ...rly suitable for applications such as lift systems and stage platform technology The brake can be selected based on the rated torque for one brake circuit The second brake circuit meets the requiremen...

Page 12: ...ipped on both sides with friction linings In its de energized state the rotor is clamped with braking force applied by pressure springs between the armature plate and a counter friction surface This c...

Page 13: ...to table 6 in both the released and applied braking states 3 6 Project planning notes When designing a brake for specific applications torque tolerances the limiting speeds of the rotors the thermal...

Page 14: ...0 C Standard Humidity no restrictions In the event of condensation or moisture formation provide for appropriate ventilation of the brakes to ensure that the friction pairs will dry quickly Ambient te...

Page 15: ...ecial surface coatings In order to guarantee a secure screw connec tion use ONLY the proper screws from INTORQ It is very important to comply with the minimum thread depth of the end shield refer to R...

Page 16: ...torque Max perm switch ing en ergy Transitional operating frequency Switching times Max speed Engaging Disengaging MK QE Shue t10 1 t90 1 t11 AC 2 t1 AC 2 t2ab sLN 3 t2ab sLmax 3 nmax 5 Nm J 1 h ms ms...

Page 17: ...lifts the spark suppressor can also be connected in parallel to the brake coil If the drive system is operated with a frequency inverter so that the brake will not be de energized be fore the motor is...

Page 18: ...ing frequency The permissible operating frequency Shmax depends on the amount of heat QR refer to Figure Friction work operating frequency Page 18 At a pre set operating frequency Sh the permissible a...

Page 19: ...uppressor in parallel with the AC voltage Spark suppressors are available on request depending on the coil voltage 4 6 Emissions Heat Since the brake converts kinetic energy as well as mechanical and...

Page 20: ...duct family 205 205 V DC Rated voltages of both braking circuits 1500 1500 NM Rated torque Pieces Qty per box 425 425 W Rated powers for both braking circuits 26 04 18 Packaging date Anti rust packagi...

Page 21: ...Technical specifications INTORQ BA 14 0215 07 2019 21 Fig 7 Product traceability sticker BFK455 25 Type refer to Product key Page 3 33006670 ID number G1804260000000000 Serial number QR code...

Page 22: ...ld and the shaft to ensure a correct function of the brake The diameter of the shaft shoulder must not be greater than the tooth root diameter of the hub The form and position tolerances apply only to...

Page 23: ...len screws Measuring range Wrench width Nm mm 25 40 to 400 10 Multimeter Caliper gauge Feeler gauge 5 3 Preparing the installation 1 Remove the packaging from the spring applied brake and dispose of i...

Page 24: ...h flange 5 4 Installing the hub onto the shaft Notice The customer is responsible for dimensioning the shaft hub connection Make sure that the supporting length of the key is identical to the length o...

Page 25: ...the shaft 3 Secure the hub against axial displacement for example by using a circlip 5 5 Brake mounting Notice Here the mounting of the brake is shown in the version with the optional flange and toot...

Page 26: ...e first rotor A Rotor B Toothed shaft C Flange D End shield 1 Push the rotor onto the shaft and check that it can be moved by hand Fig 10 Mounting the first stator A Complete stator B Toothed shaft C...

Page 27: ...oles Fig 11 Mounting the second rotor A Rotor B Toothed shaft C Complete stator D Flange E End shield 4 Push the complete rotor onto the shaft and check that it can be moved by hand Notice If a hand r...

Page 28: ...he complete stator onto the shaft 6 Align the through holes in the complete stator to the threads of the fastening bore holes in the first stator 7 Evenly tighten the brake with the six socket head ca...

Page 29: ...End shield 9 Use a torque wrench to retighten the supplied fastening screws with the required tightening torque as shown in the table Rated data screw kit for brake assembly onto flange Page 15 10 Swi...

Page 30: ...lip of the cover ring Fig 15 Cover ring assembly A Cover ring B Complete stator C Flange 1 Disconnect electrical connection 2 Pull the cable through the cover rings 3 Push the cover rings over the co...

Page 31: ...ded An individual brake circuit can only be released electrically The hand release is mounted when the double spring applied brake is installed No power is applied to the brake Fig 16 Components of th...

Page 32: ...omplete stator E End shield 2 Put both levers completely onto the second complete stator To do this push in the plates pins into the corresponding holes of the stator using a suitable tool Notice The...

Page 33: ...ble the four pre assembled tension rods with one spring each Notice Carry out steps 4 and 5 separately for each side of every lever 4 From the armature plate end plug one pair of pre assembled tension...

Page 34: ...with the bore holes 9 mm to the tension rods and tighten them with the lock nuts The blind holes 17 mm are now pointing in the direction of the stator and the screw heads of the hand release levers ar...

Page 35: ...here 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 included in the scope of supply in sev eral runs using a torque...

Page 36: ...econd complete stator C First complete stator D End shield 12 Check the air gap using a feeler gauge sLN refer to table Rated data Page 14 as shown in the Fig ure Checking the air gap Page 29 13 Conne...

Page 37: ...red suppressor circuit the control unit may be destroyed Observe the correct polarity of the suppressor circuit NOTICE To functionally test the individual brake circuits the power supply must be able...

Page 38: ...tective circuitry Brake Braking circuit 1 Braking circuit 2 Fig 22 Switching suggestions for the BFK455 25 Switching on K2 K4 must be switched on before or at the same time as K1 K3 Switching off Norm...

Page 39: ...switch over from bridge recti fication to half wave rectification Terminals 3 and 4 are in the DC circuit of the brake The induction voltage peak for DC switching refer to the circuit diagram DC switc...

Page 40: ...rrent Imax Overexcitation period tue 20 Min Rated Max Bridge half wave at U1 min at U1 Nom at U1 max V V V A A s s s BEG 561 255 030 160 230 255 3 0 1 5 0 430 0 300 0 270 BEG 561 255 130 1 870 1 300 1...

Page 41: ...the brake is connected via the neutral point of the motor this connection must also be used for connecting the neutral conductor 3 Apply DC voltage to the brake 4 Measure the AC voltage at the motor...

Page 42: ...he drive must not be running when checking the brake DANGER There is a risk of injury by electrical shock The live connections must not be touched Checks must be carried out regularly Pay special atte...

Page 43: ...g and the oper ating frequency If several of the causes of friction lining wear occur in an application at the same time the effects should be added together when the amount of wear is calculated Comp...

Page 44: ...or every application For the spring applied brakes the maintenance intervals and mainten ance operations listed in the table below must be followed The maintenance operations must be carried out as de...

Page 45: ...er excitation time the measured DC voltage must correspond to the holding voltage refer to Assignment Bridge half wave rectifier brake size Page 39 Deviations up to 10 are permissible 8 3 2 Checking t...

Page 46: ...the description at Replacing the ro tor Page 46 8 3 4 Replacing the rotor DANGER Danger rotating parts Switch off the voltage The brake must be free of residual torque 1 Remove the connection cables 2...

Page 47: ...esign Please include the following information with the order Order number of the brake Position number of the spare part Fig 25 Spring applied brake 455 25 Designation Variant A Fastening screws Sock...

Page 48: ...alues If resistance is too low replace the complete stator Check the coil for short to ground using a multimeter If there is a short to ground replace the complete spring applied brake Check the brake...

Page 49: ...unctional test refer to the chapter Function checks be fore initial commission ing Page 41 Incorrect micro switch wir ing Check and correct the wiring of the micro switch Micro switch defective or in...

Page 50: ...om F INTORQ Shanghai Co Ltd 600 6 B No 600 Xin Yuan Nan Road Building No 6 Zone B Nicheng town Pudong 201306 Shanghai 86 21 20363 810 86 21 20363 805 info cn intorq com F INTORQ US Inc USA 300 Lake Ri...

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