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Kendrion INTORQ BFK458-ATEX, Original Operating Instructions

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Commissioning and operation

Kendrion INTORQ | BA 14.0217 | 07/2021

65

8.2.3

Testing the hand-release functionality

NOTICE

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

14

130

170

16

150

230

18

220

250*

20

260

330*

25

270

350*

Tab. 16: 

Actuating forces

* When used with a long lever

Summary of Contents for INTORQ BFK458-ATEX

Page 1: ...INTORQ BFK458 ATEX Spring applied brake with electromagnetic release Translation of the Original Operating Instructions www kendrion com...

Page 2: ...not be derived from this infor mation illustrations and descriptions We do not accept any liability for damage and operating interference caused by inappropriate use unauthorized modifications to the...

Page 3: ...Spring applied brakes of type BFK458 06 25 Design E Design N Double spring applied brake Kendrion INTORQ BA 14 0217 07 2021 3...

Page 4: ...Not coded Connection voltage hub bore diameter options Checking the delivery After receipt of the delivery check immediately whether the items delivered match the accompanying pa pers Kendrion INTORQ...

Page 5: ...plosive 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 Design 15 3 2 1 Spring applied brake as holding parking brake 15 3 2 2 Spr...

Page 6: ...5 14 ATEX marking 39 6 Mechanical installation 40 6 1 Design of end shield and shaft 41 6 2 Tools 42 6 3 Preparing the installation 42 6 4 Installing the hub onto the shaft 43 6 5 Mounting the brake 4...

Page 7: ...ble applications of the Kendrion INTORQ spring applied brake 63 8 2 Function checks before initial commissioning 64 8 2 1 Function check of the brake 64 8 2 2 Release voltage control 64 8 2 3 Testing...

Page 8: ...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 9: ...tuation 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 CA...

Page 10: ...and 20 C PN W Rated coil power at rated voltage and 20 C Q J Quantity of heat energy QE J Max permissible friction energy for one time switching thermal parameter of the brake QR J Braking energy fri...

Page 11: ...witching 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 Over excitation p...

Page 12: ...ing and rotating parts Such components require appropriate safety mechanisms Surfaces can become hot during operation Take appropriate safety measures to ensure contact touch protection Follow all spe...

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

Page 14: ...rely and for a short period of time in the sense of the ATEX guideline 2014 34 EU Kendrion INTORQ spring applied brakes must never be operated outside the performance limits corre sponding to ATEX bra...

Page 15: ...ful in 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...

Page 16: ...ndrion INTORQ GPN 605 1648 from the manufac turer P ppelmann 08 405197 398805 390665 10 405198 379810 131444 12 405199 398802 76767 14 405201 398803 73355 16 405202 398801 73355 18 120591 381517 73356...

Page 17: ...Basic 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...

Page 18: ...applied brake with a rotating brake disk rotor that is equipped on both sides with friction linings In its de energized state the rotor is clamped with braking force applied by pressure springs betwe...

Page 19: ...brake the coil of the stator is energized with the DC voltage provided The resulting magnetic flux works against the spring force to draw the armature plate to the stator This releases the rotor from...

Page 20: ...number of 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 cou...

Page 21: ...certification In an explosive gas atmosphere the resulting frictional heat in the friction gap created during the brak ing process creates a potential source of ignition It is not possible here to me...

Page 22: ...t Nm for 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...

Page 23: ...le limiting speeds Size sLN 0 1 0 05 sLmax Service 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 0...

Page 24: ...0 in 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...

Page 25: ...2 64 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 Characteristics screw set intermediate flange installation for doub...

Page 26: ...0 176 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...

Page 27: ...0 0 5 180 387 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 9...

Page 28: ...ngagement time t11 Delay time during engagement t2 Disengagement time up to M 0 1 Mdyn t12 Rise time of the braking torque Mdyn Braking torque at a constant speed of rotation U Voltage Size Rated torq...

Page 29: ...el 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 with a...

Page 30: ...issible 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 QSmax QE S...

Page 31: ...ndard 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 wor...

Page 32: ...25 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 1000...

Page 33: ...8 10 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 10...

Page 34: ...nformation 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 cours...

Page 35: ...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 36: ...ns 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 Mount i...

Page 37: ...f the brake Fig 12 Packaging label Kendrion INTORQ Manufacturer 13227500 ID number BFK458 12E Type refer to Product key Bar code SPRING APPLIED BRAKE Designation of the product family 205 V DC Rated v...

Page 38: ...ORQ Manufacturer ta 40 C Permissible ambient temperature Class F Insulation class F BFK458 12E Type refer to Product key 205 V DC Rated voltage 40 W Rated power 20 H7 Hub diameter No 15049627 ID numbe...

Page 39: ...e contains 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 br...

Page 40: ...nal speed could increase 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 T...

Page 41: ...e the customer must ensure that it is fully sup ported by the motor end shield Depending on the type of installation additional clearing bore holes may be required Threaded holes with minimum thread d...

Page 42: ...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 C...

Page 43: ...nting the hub on the brake The supporting length of the key should be equal to the hub length chosen The hub side dimensioning of the key connection takes into account one million braking operations i...

Page 44: ...RQ BA 14 0217 07 2021 44 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 Che...

Page 45: ...l 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 Characteristics screw kit for brake a...

Page 46: ...ir gap specifications Page 23 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...

Page 47: ...ng 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 permissib...

Page 48: ...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 Characteristics screw kit for brake assembly on separately screwed on flan...

Page 49: ...n be screwed to the end shield onto the outer hole circle refer to the table Characteristics screw kit for brake assembly on separately screwed on flange Page 24 NOTICE Clearing holes for the screws i...

Page 50: ...4 Installing the flange variants size 25 The flange can be screwed to the end shield onto the outer hole circle refer to the table Characteristics screw kit for brake assembly on separately screwed on...

Page 51: ...flange Page 24 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 installi...

Page 52: ...ith braking torques which are greater than the standard braking torque you need to check the screws connecting the first brake Please consult with Kendrion INTORQ 6 9 Cover ring assembly Fig 25 Cover...

Page 53: ...d surface 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 Complete stator D Terminal clip E Rotor F End shield Notice...

Page 54: ...the 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 te...

Page 55: ...start 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 sequenc...

Page 56: ...ig 28 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...

Page 57: ...upply 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 p...

Page 58: ...32 Supply 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 Br...

Page 59: ...45 UV 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...

Page 60: ...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 per...

Page 61: ...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 U1 input voltage 40...

Page 62: ...ly 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 7 7 4 Permissible current load a...

Page 63: ...ply to IP54 protection Because of the many ways the brake can be used it is necessary to check the functionality of all me chanical components under the corresponding operating conditions Notice Funct...

Page 64: ...re that the motor DOES NOT start up e g remove the two bridges on the motor terminals Do not disconnect the supply connections to the brake If the rectifier for the brake supply is connected to the ne...

Page 65: ...OTICE 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 9...

Page 66: ...r and intended usage 3 Release the lever A sufficient torque must build up immediately Notice If faults occur refer to the error search table Troubleshooting and fault elimina tion Page 79 If the faul...

Page 67: ...ules 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 ele...

Page 68: ...he values 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 bra...

Page 69: ...the entire brake must be 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 af ter the...

Page 70: ...f springs through radial backlash on re versal of armature plate Reduced spring force or fatigue failure Number of switching op erations of brake Tab 17 Causes for wear 9 2 Inspections To ensure safe...

Page 71: ...0 years at the latest Versions Service brakes Holding brakes with emergency stop BFK458 E N BFK458 L according to the service life calculation at least every 2 years or else every six months after 1 m...

Page 72: ...is removed Refer to Checking the air gap Page 73 Check release function and control Refer to Release volt age Page 73 Extended inspection maintenance after re moval of brake Adjusting the air gap Refe...

Page 73: ...table for the values 3 Adjust the air gap to sLN Refer to Adjusting the air gap Page 74 9 3 3 Release voltage DANGER Danger rotating parts The running rotor must not be touched DANGER There is a risk...

Page 74: ...ler gauge Refer to table Characteristics for air gap specifications Page 23 9 3 5 Checking the rotor thickness 1 Pull the rotor off the hub 2 Check for possible damage e g chipping in the friction lin...

Page 75: ...f the new rotor and the head thickness of the sleeve bolts use a caliper gauge 9 Calculate the distance between the stator and the armature plate as follows Distance rotor thickness sLN head height Fo...

Page 76: ...rious 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 Mo...

Page 77: ...to the 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 Aluminum rotor Alumi...

Page 78: ...1 78 Electrical accessories Bridge half wave rectifier Supply voltage Over excitation 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...

Page 79: ...al resistance Refer to Rated data for coil power Page 25 for the values If re sistance is too low replace the complete stator Check the coil for short to ground using a multimeter If there is a short...

Page 80: ...age 54 Rotor is too thin Air gap sL too small Check the air gap sL and adjust if necessary Adjusting the air gap Page 74 Rotor is too thin Voltage too high Rotor has not been replaced in time Replace...

Page 81: ...les 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 R...

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