INTORQ BFK458-ATEX Translation Of The Original Operating Instructions Download Page 1

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INTORQ BFK458-ATEX

Spring-applied brake with electromagnetic release

Translation of the Original Operating Instructions

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Summary of Contents for BFK458-ATEX

Page 1: ...INTORQ BFK458 ATEX Spring applied brake with electromagnetic release Translation of the Original Operating Instructions 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: ...Spring applied brakes of type BFK458 06 25 Design E Design N Double spring applied brake INTORQ BA 14 0217 09 2019 3...

Page 4: ...INTORQ B FK Not coded Connection 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...

Page 5: ...explosive areas 13 2 3 Disposal 13 3 Product description 14 3 1 Proper and intended usage 14 3 1 1 Standard applications 14 3 2 Layout 15 3 2 1 Spring applied brake as holding parking brake 15 3 2 2...

Page 6: ...4 ATEX marking 40 6 Mechanical installation 41 6 1 Design of end shield and shaft 42 6 2 Tools 43 6 3 Preparing the installation 43 6 4 Installing the hub onto the shaft 44 6 5 Mounting the brake 45 6...

Page 7: ...otect the electrical connections against any contact or touching 64 8 2 Function checks before initial commissioning 65 8 2 1 Function check of the brake 65 8 2 2 Release voltage control 65 8 2 3 Test...

Page 8: ...omplete 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 Poin...

Page 9: ...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 10: ...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 11: ...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 12: ...ponents require the appropriate safety mechanisms Surfaces can become hot during operation Take the appropriate safety measures to ensure contact touch protection Follow all specifications and informa...

Page 13: ...d with then the temperatures defined on the ATEX name plate for the dust zone must be mon itored on the brake s magnet housing using a suitable temperature measurement mechanism If there is no availab...

Page 14: ...rt period of time in the sense of the ATEX guideline 2014 34 EU INTORQ spring applied brakes must never be operated outside the performance limits corresponding to ATEX brakes NOTICE If the spring app...

Page 15: ...n redundant braking applications 3 2 1 Spring applied brake as holding parking brake If the spring applied brake shall be used as a holding parking brake all braking torques listed in the BFK458 sprin...

Page 16: ...05 1648 from the manu facturer P ppel mann 08 405197 398805 390665 10 405198 379810 131444 12 405199 398802 76767 14 405201 398803 73355 16 405202 398801 73355 18 120591 381517 73356 20 120592 364510...

Page 17: ...c module L Description of the long life design Armature plate with low backlash and reinforced torque support Pressure springs with guide pins for protection against shearing forces Aluminum rotor wit...

Page 18: ...ied brake with a rotating brake disc rotor that is equipped on both sides with friction linings In its de energised state the rotor is clamped with braking force applied by pressure springs between th...

Page 19: ...and the armature plate To re lease the brake the coil of the stator is energised with the DC voltage provided The resulting magnetic flux works against the spring force to draw the armature plate to...

Page 20: ...switching operations corresponding to the required friction work is determined from the friction performance charts The number of switching operations must be evenly distributed over the course of on...

Page 21: ...ity operator cannot ensure that the specified friction work and operating frequencies will be complied with then the temperatures defined on the ATEX name plate for the dust zone must be mon itored on...

Page 22: ...duty cycle DC of 100 with brake released armature plate permanently tightened at an ambient temperature of 40 C as a holding parking brake as a holding brake with emergency stop function and as an ope...

Page 23: ...or design type E 0 2 0 35 0 8 1 3 1 7 1 6 3 6 5 6 6 2 Tab 2 Braking torques and possible brake torque reduction Adjustable for the design types N Type without brake torque adjustment E Type with brake...

Page 24: ...ing speeds Size sLN 0 1 0 05 sLmax Operating brake sLmax Holding brake Max adjustment per missible wear distance Rotor thickness Protrusion adjustment ring hEmax min 1 max mm mm mm mm mm mm mm 06 0 2...

Page 25: ...n reference to the center axle of the hand release lever 3 Hex head screw according to DIN EN ISO 4017 8 8 Size Screw hole circle Screw set for mounting onto the motor friction plate Screw set for fla...

Page 26: ...M5x20 14 75 4 x M6 M6x20 10 1 16 85 M6x25 15 18 95 4 x M8 M8x25 17 24 6 20 110 4 x M10 M10x25 20 48 25 140 M10x30 10 9 71 Tab 7 Rated data screw set intermediate flange installation for double spring...

Page 27: ...32 180 1013 0 177 30 190 1203 0 157 33 205 1273 0 160 12 40 24 14 4 1 66 96 230 4 0 41 103 265 2 0 388 170 722 5 0 235 180 810 0 222 190 902 5 0 210 205 1051 0 195 14 50 24 11 5 2 08 96 184 3 0 52 53...

Page 28: ...180 387 2 0 472 190 424 7 0 447 205 494 4 0 414 20 100 24 5 76 4 16 96 92 2 1 04 103 106 1 0 970 170 289 0 588 180 324 0 55 190 328 2 0 578 205 420 3 0 487 25 110 24 5 24 4 58 96 83 8 1 14 103 96 5 1...

Page 29: ...ngagement time t11 Delay time during engagement t2 Disengagement time up to M 0 1 Mdyn t12 Rise time of the brake torque Mdyn Braking torque at a constant speed of rotation U Voltage Size Rated torque...

Page 30: ...rallel to the contact 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 If the drive system is operated wi...

Page 31: ...ble brake torques of the BFK458 spring applied brake must be observed from the tables Maximum permissible rated torques as specified in the follow ing chapters Shue 1 QR QE Shmax In e 1 Qhmax QE Shue...

Page 32: ...spring applied brake BFK458 Notice The number of switching operations must be evenly distributed over the course of one hour Size Number of switching operations per hour Permissible friction work J 0...

Page 33: ...18 16 14 12 08 10 06 Fig 6 Friction work as a function of the operating frequency for the BFK 458 ATEX for gas atmospheres for the speed 800 rpm Friction work Q J R Operating frequency Sh h 1 100000 1...

Page 34: ...06 Fig 8 Friction work as a function of the operating frequency for the BFK 458 ATEX for gas atmospheres for the speed 1800 rpm Friction work Q J R Operating frequency Sh h 1 100000 10000 1000 100 1...

Page 35: ...ation differs from the values given in the oper ating instructions for the standard spring applied brake BFK458 Notice The number of switching operations must be evenly distributed over the course of...

Page 36: ...tching operations per hour are allowed In order not to overload the brake thermally these 85 switching operations should be distributed evenly over the time interval 60 minutes x 60 seconds 85 switchi...

Page 37: ...itions and the state of the friction sur faces the brake may squeak during braking 5 12 Hand release The hand release mechanism is used to release the brake by hand and can be retrofitted refer to In...

Page 38: ...e brake Fig 12 Packaging label INTORQ Manufacturer 13 227 500 ID number BFK458 12E Type refer to Product key Bar code SPRING APPLIED BRAKE Designation of the product family 205 V DC Rated voltage 32 N...

Page 39: ...Name plate example INTORQ Manufacturer BFK458 12E Type refer to Product key 205 V DC Rated voltage 40 W Rated power 20 H7 Hub diameter No 15049627 ID number 32 NM Rated torque 20 Mar 2018 Date of man...

Page 40: ...tains the following information Haltebremse holding brake II 3G Ex ec IIC T4 Gc X II 3D Ex tc IIIB 120 C Dc X II 3G Ex ec IIC T3 Gc X II 3D Ex tc IIIB 120 C Dc X Fig 14 Name plate ATEX holding brake a...

Page 41: ...rease when the motor is switched off As a result the brak ing procedure would be carried out at a much higher speed and higher friction work than assumed in the preliminary design This would result in...

Page 42: ...upported by the end shield across the full surface Depending on the type of installation additional clearing bore holes may be required Threaded holes with minimum thread depth refer to Rated data scr...

Page 43: ...mm mm 06 1 to 12 3 8 7 5 5 45 55 08 4 9 10 7 52 55 10 5 12 68 75 12 80 90 14 20 to 100 6 15 12 8 16 95 100 18 10 110 115 13 20 135 145 17 25 8 17 155 165 NOTICE Tightening torques refer to the table R...

Page 44: ...chosen The hub side dimensioning of the key connection takes into account one million braking operations in reversing mode without additional operational loads e g additional load spectra with engaged...

Page 45: ...14 0217 09 2019 45 6 5 Mounting the brake Mounting the rotor without friction plate without brake flange Fig 16 Assembly of the rotor A Rotor B Hub C End shield 1 Push the rotor on the hub 2 Check if...

Page 46: ...clip D Rotor E End shield 3 Screw the complete stator to the end shield Use the supplied screw set and a torque wrench for tight ening torque refer to the table Rated data screw kit for brake assembly...

Page 47: ...ap specifications Page 24 Fig 19 Adjusting the air gap 6 If the measured value sL is outside of the tolerance sLN readjust this dimension Loosen the socket head cap screws slightly and adjust the air...

Page 48: ...the screw in holes 6 7 Mounting the flange 6 7 1 Mounting the flange without additional screws NOTICE When dimensioning the thread depth in the end shield be sure to take into account the permissible...

Page 49: ...s against the end shield Fig 21 Flange mounting for sizes 06 16 A Screw 1 B Flange C Hub D End shield 1 According to the table Rated data screw kit for brake assembly on separately screwed on flange P...

Page 50: ...end shield onto the outer hole circle refer to the table Rated data screw kit for brake assembly on separately screwed on flange Page 25 NOTICE Clearing holes for the screws in the end shield must be...

Page 51: ...variants size 25 The flange can be screwed to the end shield onto the outer hole circle refer to the table Rated data screw kit for brake assembly on separately screwed on flange Page 25 NOTICE Clear...

Page 52: ...Page 25 6 8 Installing the double spring applied brake Fig 24 Installing the intermediate flange A Screw from the screw set B Intermediate flange C Rear stator D Front hub NOTICE When installing the d...

Page 53: ...braking torques which are greater than the standard braking torque you need to check the screws connecting the first brake Please consult with INTORQ first 6 9 Cover ring assembly Fig 25 Cover ring a...

Page 54: ...face roughness of Rz 3 2 m in the sealing area Fig 26 Installing the shaft sealing ring A Socket head cap screw B Shaft sealing ring C Stator complete D Terminal clip E Rotor F End shield Notice Pleas...

Page 55: ...e armature plate and through the bore hole in the stator 4 Screw the hex head screws into the yoke pins 5 Tighten the hex head screws to fasten the armature plate against the stator 6 Remove the termi...

Page 56: ...tart ups or electric shock NOTICE Make sure that the supply voltage matches the voltage specification on the name plate 7 1 Electrical connection Switching suggestions NOTICE The terminal pin sequence...

Page 57: ...Supply Phase neutral Bridge rectifiers Half wave rectifiers BEG 1xx UN V DC 0 9 UV V AC BEG 2xx UN V DC 0 45 UV V AC 3 3 U2 W2 V2 UN L1 L2 L3 UV V1 U1 W1 UV 4 pole BEG 14x BEG 24x 6 pole BEG 16x BEG...

Page 58: ...y Phase neutral Bridge rectifiers Half wave rectifiers BEG 1xx UN V DC 0 9 UV V AC BEG 2xx UN V DC 0 45 UV V AC 3 3 U2 W2 V2 UN L1 L2 L3 UV V1 U1 W1 UV 6 pole BEG 16x BEG 26x Fig 31 Supply Phase phase...

Page 59: ...upply Phase N Bridge rectifiers Half wave rectifiers BEG 1xx UN V DC 0 9 UV V AC BEG 2xx UN V DC 0 45 UV V AC L1 L2 UV UN 4 pole BEG 14x BEG 24x 6 pole BEG 16x BEG 26x Fig 33 Supply Phase phase Bridge...

Page 60: ...V V AC 1 For most regional national high voltage mains voltages this only makes sense for supplies on L1 and N L1 N L1 L2 UV UN 4 pole BEG 14x BEG 24x 14 198 00 xx or Fig 35 Supply Phase phase or phas...

Page 61: ...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 INTORQ Once a set overexcitation period has el...

Page 62: ...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 U1 input voltage 40 60 H...

Page 63: ...de switching fast engagement Otherwise there will be no overexcitation when it is switched back on Delayed engagement Fast engagement Mains Bridge Coil Mains Coil 7 7 4 Permissible current load at amb...

Page 64: ...the environmental conditions that apply to IP54 protection Because of the numerous possibilities of using the brake it is still necessary to check the functionality of all mechanical components under...

Page 65: ...ections to the brake If the rectifier for the brake supply is connected to the neutral point of the motor also connect the neutral conductor to this connection DANGER Danger rotating parts Your system...

Page 66: ...This operational test must also be carried out Fig 38 Turning direction of the lever Size Hand force N Standard braking torque Hand force N Maximum braking torque 06 20 30 08 35 50 10 55 75 12 90 120...

Page 67: ...ion 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 Notice I...

Page 68: ...to ensure that nobody can touch a connection Checks must be carried out regularly Pay special attention to unusual noises or temperatures loose fixing attachment elements the condition of the electric...

Page 69: ...lues for the braking torque reduction for each latched in position Observe the max permissible protrusion hEmax of the torque adjustment ring over the stator Refer to the table Rated data for braking...

Page 70: ...cleared of impurities caused by the explosive dust atmosphere In order to eliminate the risk of ignition and injury the spring applied brakes may only be dismantled after they cool down 9 1 Wear of s...

Page 71: ...friction of the brake lining Run in of armature plate and counter friction sur face Friction work Gear teeth of brake rotor Relative movements and shocks between brake rotor and brake shaft Wear of ge...

Page 72: ...e 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 described in the detailed des...

Page 73: ...ature plate and flange or end shield Flatness depending on the size Refer to the table Design of end shield and shaft Page 42 Max run in depth rated air gap for the size Refer to the table Rated data...

Page 74: ...e values 3 Adjust the air gap to sLN Refer to Adjusting the air gap Page 75 9 3 4 Release voltage DANGER Danger rotating parts The running rotor must not be touched DANGER There is a risk of injury by...

Page 75: ...e torque values 4 Check the value of sL near the screws using a feeler gauge Refer to table Rated data for air gap spe cifications Page 24 9 3 6 Replace rotor DANGER Danger rotating parts Switch off t...

Page 76: ...LN refer to the table Rated data for air gap specifications Page 24 10 Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is reached 11 You can now ins...

Page 77: ...s designs and lengths for mounting to the flange for mounting to the motor friction plate for flange with through hole E Complete stator module E Complete stator module N Voltage braking torque Module...

Page 78: ...e flange for mounting to the motor friction plate for flange with through hole E Complete stator module N Voltage braking torque Optionally with rear threads F Complete rotor Aluminium rotor Aluminium...

Page 79: ...Electrical accessories Bridge half wave rectifier Supply voltage Overexcitation Holding current reduction Coil voltage Size Coil voltage Size V AC V DC V DC BEG 561 255 030 230 103 06 25 205 06 14 BE...

Page 80: ...Refer to Rated data for coil powers Page 26 for the values If res istance is too low replace the complete stator Check the coil for short to ground using a multimeter If there is a short to ground re...

Page 81: ...ergized The di mensions must be the same on both sides Correct if required Refer to Installing the hand release retrofitting Page 55 Air gap sL too small Check the air gap sL and adjust if necessary A...

Page 82: ...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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INTORQ BFK458-ATEX, Translation Of The Original Operating Instructions

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