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INTORQ BFK455, Operating Instructions Manual

The INTORQ BFK455 is a reliable and high-quality brake designed for industrial applications. Ensure optimal performance by following the Operating Instructions Manual, available for free download from our website. The manual provides clear and detailed guidance on installation, maintenance, and troubleshooting. Keep your equipment running smoothly with the INTORQ BFK455.

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INTORQ BFK455

j

setting the standard

Operating Instructions

www.intorq.com

Electromagnetically released spring-applied brake

Summary of Contents for BFK455

Page 1: ...INTORQ BFK455 j setting the standard Operating Instructions www intorq com Electromagnetically released spring applied brake...

Page 2: ...455 28 double disk version BFK455 001 iso dms BFK455 020 iso dms Product key Product key INTORQ B FK Legend for the INTORQ BFK455 product key Product group Brakes Product type Spring applied brake Typ...

Page 3: ...setting Document history Material number Version Description 33000803 1 0 05 2011 TD09 First edition 33000803 1 1 05 2012 TD09 Change in telephone and fax number Front and back page new Addition of th...

Page 4: ...data 13 3 1 Product description 13 3 2 Rated data 16 3 3 Rated data selection data 17 3 4 Friction work operating frequency 19 3 5 Emission 20 4 Mechanical installation 21 4 1 Important notes 21 4 2 N...

Page 5: ...4 0196 05 2013 5 7 Maintenance repair 42 7 1 Wear of spring applied brakes 42 7 2 Inspections 43 7 3 Maintenance operations 44 7 4 Spare parts list 46 7 5 Spare parts order 47 8 Troubleshooting and fa...

Page 6: ...ete and perfectly readable condition 1 2 Terminology used Term In the following text used for Spring applied brake Spring applied brake with electromagnetic release Drive system Drive systems with spr...

Page 7: ...1 h Operating frequency the number of repeated operations per unit time Shue 1 h Transitional operating frequency thermal rating of the brake Shmax 1 h Maximum permissible operating frequency dependin...

Page 8: ...ng Danger Danger of personal injury through dangerous electrical voltage Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken...

Page 9: ...brake consists of different types of material Recycle metals and plastics Ensure professional disposal of assembled PCBs according to applicable environmental regulations 1 8 Drive systems Labelling D...

Page 10: ...llustrations and descriptions We do not accept any liability for damage and operating interference caused by inappropriate use unauthorised modifications to the product improper working on and with th...

Page 11: ...s Only qualified skilled personnel are permitted to work on and with INTORQ components In accordance with IEC 60364 or CENELEC HD 384 qualified skilled personnel are persons who are familiar with the...

Page 12: ...t be operated beyond their corresponding power limits Any other use shall be deemed inappropriate Possible applications of the INTORQ spring applied brake Humidity no restrictions In case of formation...

Page 13: ...iscbrake withfour frictionsurfaces Thebraking torque is generated within two electrically and mechanically separated braking circuits by means of several compression springs 1 2 with friction locking...

Page 14: ...transmitted between hub 4 and rotor 3 via the splines 3 1 3 Brake release In braked state there is an air gap sL between the stator 1 and the armature plate 2 To release the brake the coil of the stat...

Page 15: ...rganic friction linings used and the alternating environmental conditions deviations of the given braking torques may occur These must be considered by corresponding safety measures in the dimensionin...

Page 16: ...IN 912 Minimum thread depth 1 0 mm Tightening torque without flange with flange without flange with flange without flange with flange mm Thread mm mm mm mm MA Nm MA Nm BFK455 28 314 M16 6 x M16x210 6...

Page 17: ...ent t2 Disengagement time up to M 0 1 Mr t12 Rise time of the brake torque MK Characteristic torque U Voltage Type Rated torque 1 Max perm switching energy Transition operating frequency Operating tim...

Page 18: ...ontact If this is not admissible for safety reasons e g with hoists and lifts the spark suppressor can also be connected in parallel to the brake coil Circuit proposals 36 If the drive system is opera...

Page 19: ...frequency p p N no nb n nb N p p The permissible operating frequency Shmax depends on the quantity of heat QR see Fig 3 If the operating frequency Sh is specified the permissible quantity of heat Qsm...

Page 20: ...park suppressor in parallel with the AC voltage Spark suppressors are available on request depending on the coil voltage Heat Since the brake converts kinetic energy as well as mechanical and electric...

Page 21: ...m BFK455 28 40 250 14 24 Feeler gauge Caliper gauge Multimeter 4 3 Mounting 4 3 1 Important notes Brake size Minimum requirements for the counter friction face Material 1 Evenness Axial runout Roughne...

Page 22: ...pecially rated voltage 4 3 3 Overview without separate counter friction face with flange BFK455 007 iso dms BFK455 008 iso dms 4 4 Installation Stop Toothed hub and screws must not be lubricated with...

Page 23: ...st axial displacement e g by using a circlip 4 2 Stop In reverse operation it is recommended to additionally glue the hub to the shaft Assembly of the counter friction faces Flange option BFK455 011 i...

Page 24: ...teeth Remove cover films from both front ends of the rotor Protect friction surfaces against contact with mounting paste After the mounting excessive mounting paste must be removed properly Installati...

Page 25: ...otor 4 2 Circlip 15 End shield 10 Push the complete stator onto the shaft 11 Align the through holes in the complete stator 1 to the threads of the fastening bore holes Assembly of the second rotor BF...

Page 26: ...bly of the second stator BFK455 017 iso dms BFK455 017a iso dms Fig 9 Assembly of the stator 1 Complete stator 6 Flange 15 End shield 3 Complete rotor 10 Fixing screws 13 Push the complete stator onto...

Page 27: ...auge more than 10 mm between armature plate 2 and stator 1 1 If the measured value sL is outside the tolerance of sLrated set the dimension BFK455 018 iso dms Fig 11 Adjusting the air gap during the i...

Page 28: ...djustment 4 5 Manual release Note The manual release is designed for activation via a Bowden cable For activation without a Bowden cable the lever has to be extended The individual braking circuits ca...

Page 29: ...in with the greater distance to the axis of rotation must point to the outside The levers also point to the outside BFK455 021 iso dms Fig 14 Installation of the tension rods 3 Assemble four pre assem...

Page 30: ...the pre assembled tension rods 12 14 into the through holes 12 mm of the first complete stator 1 in the process Stop Tension rods must not be bent BFK455 008 iso dms Fig 16 Preassembly of the brake w...

Page 31: ...the supplied fixing screws 10 with the required tightening torque 16 11 Switch off power 4 5 3 Checking the air gap BFK455 007 iso dms Fig 17 Checking the air gap 12 Check the air gap by means of a fe...

Page 32: ...rallel alignment of the clips 12 11 with the back side of the complete stator 1A check by means of a caliper gauge In the case of deviations X 0 1mm Fig 18 correct the setting by loosening the self lo...

Page 33: ...the hexagon nuts and the complete stator and ensure that the feeler gauges can be easily moved 17 Correct the setting if necessary until both feeler gauges can be moved by the same force 18 Check the...

Page 34: ...ct electrical connection 2 Pull cables through the cover rings 13 3 Push cover rings 13 over the complete stators 1 4 Press the lips of the first cover ring 13 into the groove of the complete stator 1...

Page 35: ...ied out without the required suppressor circuit the control unit may be destroyed Observe the correct polarity of the suppressor circuit Stop For checking the individual braking circuits it must be po...

Page 36: ...microswitches DC current 10 mA 100 mA at 12 V AC current 10 mA 5 A at 12 V max 250 V Suppressor circuit the limit voltage impacts the operating times 17 5 2 Bridge half wave rectifiers option BEG 561...

Page 37: ...ctifier type Bridge half wave rectifier Output voltage for bridge rectification 0 9 x U1 Output voltage for half wave rectification 0 45 x U1 Ambient temperature storage operation C 25 70 Type Input v...

Page 38: ...BFKXXX 008 iso 1 For screw assembly with metal surface good heat dissipation 2 For other assembly e g glue 5 3 Electrical connection Danger The brake must only be electrically connected when no voltag...

Page 39: ...dges from the motor terminals to deenergise the motor Do not switch off the DC brake supply Stop If the brake is connected to the star point of the motor the neutral conductor must also be connected t...

Page 40: ...or the brake 12 Bolt bridges to the motor terminals 13 If necessary remove neutral conductor from star point step 2 Contact type Connection Brake released Microswitch closed NC contact black grey yes...

Page 41: ...ments the condition of the electrical cables The armature plate must be attracted and the rotor must move without residual torque Measure the DC voltage at the brake The DC voltage measured after the...

Page 42: ...several of the causes of friction lining wear occur in an application at the same time the influencing factors are to be added together when the amount of wear is calculated Component Cause Effect In...

Page 43: ...t adapted to the particular operating conditions and brake loads must be defined for every application For the spring applied brakes the maintenanceintervalsandmaintenanceoperationslistedinthebelowtab...

Page 44: ...ks Remove oil and grease linked impurities using brake cleaning agents if necessary replace brake after identifying the cause of the contamination Dirt deposits in the air gap between stator and armat...

Page 45: ...remove them completely 4 Remove the complete stator from the end shield Observe the supply cable 5 Pull the complete rotor off the hub 6 Check hub teeth 7 Replace the hub as well if worn 8 Check the f...

Page 46: ...th the order Order number of the brake Position number of the spare part BFK455 004 iso dms BFK455 021 iso dms Fig 22 BFK455 28 spring applied brake Pos Name Variant 1 Complete stator Voltage 3 Comple...

Page 47: ...re plate Standard Microswitch Monitoring of the switching function Component parts Rotor Aluminium Noise reduced rotor with sleeve Hub _________ mm for hole diameter see dimensions Fixing screw set fo...

Page 48: ...too low Wiring incorrect or defective Check and correct wiring Check cable continuity using a multimeter Replace defective cable Rectifier defective or wrong Measure rectifier DC voltage using a multi...

Page 49: ...o the manufacturer Voltage too high Brake voltage does not match the rectifier Adapt rectifier and brake voltage to each other Voltage too low Brake voltage does not match the rectifier Adapt rectifie...

Page 50: ...Notizen j BA 14 0196 05 2013 50...

Page 51: ...Notizen i j BA 14 0196 05 2013 51...

Page 52: ...Co Ltd China No 600 Xin Yuan Road Building No 6 Zone B Nan Hui District Lingang Shanghai China 201306 600 6 1 B 201306 86 21 20363 810 86 21 20363 805 info cn intorq com INTORQ US Inc USA 300 Lake Rid...

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