ELECTROFRENO
ELECTROFRENO
ELECTROFRENO
INTORQ BFK457
Electromagnetically Released Spring-Applied Brake
Translation of the Original Operating Instructions
www.intorq.com
www.intorq.com
This documentation applies to the:
Product key
INTORQ B FK -
Nameplate Example
Manufacturer Model identification CE mark
Type (see product key) Design
Designation
Rated voltage Rated power
Type number Rated torque Date of manufacture
Document history
You can access the latest version of the Operating Instructions at www.intorq.de
❚ These Operating Instructions will help you to work safely with the spring-applied brake with electromag-
netic release. They contain safety instructions that must be followed.
❚ All persons working on or with the electromagnetically released spring-applied brakes must have the Op-
erating Instructions available and observe the information and notes relevant for them.
❚ The Operating Instructions must always be in a complete and perfectly readable condition.
This document uses the following styles to distinguish between different types of information:
Spelling of numbers Decimal separator Point The decimal point is always used.
For example: 1234.56
Symbols Page reference Reference to another page with additional
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.
The following icons and signal words are used in this document to indicate dangers and important safety in-
formation:
Safety instructions
Structure of safety instructions:
SIGNAL WORD
Icon
Indicates the type of danger
Signal word
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
Danger level
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or mod-
erate injury.
NOTICE
Notice about a harmful situation with possible consequences: the product itself or surrounding
objects could be damaged.
After receipt of the delivery, check immediately whether the items delivered match the accompanying pa-
pers. 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.
1.7 Disposal
Labelling
Drive systems and components are unambiguously designated by the indications on the nameplate.
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 – apply to a complete stator.
❚ The labelling is not included when modules are delivered individually.
Liability
❚ The information, data and notes in these Operating Instructions met the state of the art at the time of
printing. Claims referring to drive systems which have already been supplied cannot be derived from this
information, illustrations and 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
- operating errors
- disregarding the documentation
Warranty
❚ Terms of warranty: Refer to the terms of sale and delivery for INTORQ GmbH & Co. KG.
❚ Warranty claims must be made to INTORQ immediately after the defects or faults are detected.
❚ The warranty is void in all cases when liability claims cannot be made.
2 Safety instructions
❚ INTORQ components:
- ... must only be used as directed.
- ... must not be commissioned if they are noticeably damaged.
- ... must not be technically modified.
- ... must not be commissioned if they are incompletely mounted or connected.
- ... must not be operated without the required covers.
- ... can include live (current-carrying) as well as moving or rotary parts during operation according to
their degree of protection. Surfaces may be hot.
❚ For INTORQ components:
- ... the documentation must always be kept at the installation site.
- ... only permitted accessories are allowed to be used.
- ... only original spare parts of the manufacturer are allowed to be used.
❚ Follow all specifications and information found in the corresponding enclosed documentation.
These must be followed to maintain safe, trouble-free operations and to achieve the specified product
characteristics.
❚ 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.
- ... who have the qualifications necessary for their occupation.
- ... who know and apply all regulations for the prevention of accidents, directives, and laws relevant
on site.
❚ Risk of burns!
- Surfaces may be hot during operation! Provide for protection against accidental contact.
❚ Risk of injury due to a rotating shaft!
- Wait until the motor is at standstill before you start working on the motor.
❚ The friction lining and the friction surfaces must never contact oil or grease since even small amounts
reduce the braking torque considerably.
❚ The brake is designed for operation under 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 the corresponding operating conditions.
❚ INTORQ components:
- ... are intended for use in machinery and systems.
- ... must only be used for the purposes ordered and confirmed.
- ... 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!
3 Technical specifications
Fig. 1 Spring-applied brake BFK457-01...16 Compact, completely mounted with rotor and flange
A Sticker nameplate
Fig. 2 Construction of a spring-applied brake BFK457-06...16 Basic, stator complete with rotor
A Sticker nameplate
This spring-applied brake is a single-disk brake with two friction surfaces. The braking torque is generated
by several pressure springs (1.2) by friction locking. The braking circuits are released electromagnetically.
The spring-applied brake converts mechanical work and kinetic energy into heat energy. Due to the static
braking torque, loads can be held at standstill. Emergency braking is possible at high rotations speeds (refer
to operating speeds 16). The wear increases as the switching energy increases. Remember that the
coefficient of friction and thus the braking torque is dependent on the rotation speed.
Spacer bushings (1.6) are used for this spring-applied brake.
NOTICE
Re-adjust the air gap:
❚ BFK457 size 06 ... 16 Basic
- Adjustment not possible.
- When the wear limit is reached, replace the rotor.
❚ BFK457 size 01 ... 16 Compact
- Adjustment not possible.
- When the wear limit is reached, replace the brake.
3.1.2 Brake
During the braking procedure, the inner and outer springs (1.2) use the armature plate (2) to press the rotor
(3) (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.
1)
The default (as delivered) air gap results from the sum tolerances of the individual components.
CAUTION
❚ The minimum thread depth of the end shield must be maintained! Tab. 2.
❚ 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!
❚ The material of the end shield must have a tensile strength of Rm >= 250 N/mm2!
t2 Disengagement time (up to M = 0.1 Mdyn) t12 Rise time of the braking torque
t11 t12 t1 t2
BFK457 -01 0.12 200 160 2 9 11
17
BFK457 -02 0.25 400 125 3 5 8
BFK457 -03 0.5 800 100 5 7.5 12.5 18
BFK457 -04 1 1200 90 9 9 18 23
BFK457 -05 2 1800 80 10 16 26 35
BFK457 -06 4 3000 79 29 19 48 37
BFK457 -08 8 7500 50 60 35 42
95
BFK457 -10 16 12000 40 35 60 100
BFK457 -12 32 24000 30 45 53 98 135
BFK457 -14 60 30000 28 50 57 107 240
BFK457 -16 80 36000 27 71 50 121 275
Tab. 5: Switching energy - switching frequency - switching times
1)
Minimum braking torque when all components are run in
Engagement time
The transition from a brake-torque-free state to a holding-braking torque is not free of time lags.
For emergency braking, short engagement times for the brake are absolutely essential. The DC switching in
connection with a suitable spark suppressor must therefore be provided.
❚ The engagement times apply for DC switching with a spark suppressor.
- Spark suppressors are available for the rated voltages.
- Connect the spark suppressors in parallel to the contact. If this switching 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: 30
❚ If the drive system is operated with a frequency inverter so that the brake will not be de-energised before
the motor is at standstill, AC switching is also possible (not applicable to emergency braking).
Disengagement time
The disengagement time is not influenced by DC and AC switching operations. The disengagement time can
be shortened by using special equipment for fast-response excitation or over-excitation.
Q[J]
Q[J
5
10
16
14
12
10
4 10
08
06
05
3 04
10
03
02
01
2
10
A
10
1 5 10 20 10 2 10 3 10 4 Sh [h -1 ]
B
– S hue
-------------------
– S hue Sh
S hmax = -------------------------------- Q smax = Q E 1 – e
Q R
ln 1 – ---------
Q E
The permissible switching frequency Shmax depends on the amount of heat QR (refer to Figure 4). At a pre-
set switching frequency Sh, the permissible amount of heat is QSmax.
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.
3.5 Emissions
Electromagnetic compatibility
NOTICE
The user must ensure compliance with EMC Directive 2004/108/EC 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.
If the spring-applied brake uses a rectifier from another manufacturer for the switching, it may become nec-
essary to connect a spark 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 electrical energy into heat, the surface
temperature varies considerably, depending on the operating conditions and possible heat dissipation. Un-
der unfavourable conditions, the surface temperature can reach 130 °C.
Noise
The loudness of the switching noise during engaging and disengaging depends on the air gap “sL”, the brak-
ing torque, and the brake size.
Depending on the natural oscillation after installation, operating conditions and the state of the friction sur-
faces, the brake may squeak during braking.
Miscellaneous
The abrasion of the friction parts produces dust.
4 Mechanical installation
NOTICE
The toothed hub and screws must not be lubricated with grease or oil.
06 ❚ Threaded holes
08 0.03 with minimum
Rz 6 thread depth
10 S235JR; C15;
0.05 Rz 16 17
12 EN-GJL-250 ❚ Free of grease
0.05
14 and oil
Rz 10
16 0.08
4.2 Assembly
4.2.1 Preparation
1. Unpack the spring-applied brake.
2. Check for completeness.
3. Check the nameplate data (especially the rated voltage).
NOTICE
The customer is responsible for constructing the shaft-hub connection. Make sure that the
bearing length of the key is identical to the length of the hub.
NOTICE
NOTICE
For reverse operations, we recommend also glueing the hub to the shaft!
NOTICE
The socket head cap screws (10.1) must be removed evenly to ensure trouble-free operations
(so that the armature plate does not tilt).
5 Electrical installation
DANGER
NOTICE
❚ Make sure that the supply voltage corresponds to the data on the nameplate.
❚ If an emergency stop is carried out without the required suppressor circuit, the control unit
may be destroyed.
❚ Observe the correct polarity of the suppressor circuit!
NOTICE
Compare the coil voltage of the stator to the DC voltage of the installed rectifier.
Circuit suggestions
NOTICE
The terminal pin sequence shown here does not match the actual order.
UV
L1 L2 L3
4-pole
BEG-14x
BEG-24x
U1 V1 W1 6-pole
W2 U2 V2 BEG-16x
BEG-26x
UN
UV
L1 L2 L3
4-pole
BEG-14x
BEG-24x
U1 V1 W1
6-pole
W2 U2 V2
BEG-16x
BEG-26x
UN
UV
L1 L2 L3
U1 V1 W1 6-pole
W2 U2 V2
BEG-16x
BEG-26x
UN
UV
L1 L2 L3
U1 V1 W1 6-pole
W2 U2 V2 BEG-16x
BEG-26x
UN
UV
L1 N
4-pole
BEG-14x
BEG-24x
6-pole
BEG-16x
BEG-26x
UN
UV
L1 L2
4-pole
BEG-14x
BEG-24x
6-pole
BEG-16x
BEG-26x
UN
UV
L1 L2
or
L1 N
6-pole
BEG-16x
BEG-26x
UN
UV
L1 L2
or
L1 N
14.198.00.xx
4-pole
BEG-14x
BEG-24x
14.198.00.xx
UN
BEG-561- -
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. Depending on the design of the load, an improvement of the switching be-
haviour or a reduction in performance is possible.
[V AC] [V DC]
BEG-561-255-030
BEG-561-255-030
BEG-561-255-030
230 ±10% 205 / 103
BEG-561-255-030
BEG-561-255-130
BEG-561-255-130 BFK457-01...16 Compact
BEG-561-440-030-1 BFK457-06...16 Basic
BEG-561-440-030-1
BEG-561-440-030-1
400 ±10% 360 / 180
BEG-561-440-030-1
BEG-561-440-130
BEG-561-440-130
1 2 3 4 5 6 1 2 3 4 5 6
A B C A C
DANGER
WARNING
CAUTION
❚ The brakes are dimensioned in such a way that the specified rated torques are normally reached safely
after a short run-in process.
❚ However, since the organic friction linings used do not all have identical properties and because envi-
ronmental conditions can vary, deviations from the specified braking torques are possible. These must
be taken into account in the form of appropriate dimensioning tolerances. Increased breakaway torque
is common, in particular after long downtimes in humid environments where temperatures vary.
❚ Check the braking torque when the brake is being used on the customer's friction surfaces.
❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactivated
regularly.
DANGER
DANGER
WARNING
The brake must be free of residual torque. The motor must not run!
1. Remove two bridges from the motor terminals. Do not switch off the DC voltage supply to the brake.
When connecting the rectifier to the neutral point of the motor, the PE conductor must also be connected
to this point.
2. Connect the mains supply.
3. Measure the DC voltage at the brake.
- Compare the DC voltage with the voltage indicated on the nameplate. A deviation of 10 % is per-
missible.
4. Check the air gap “sL”. It must be zero and the rotor must rotate freely.
5. Switch off the current.
6. Screw the bridges onto the motor terminals. Remove any additional PE conductor.
The preparations for commissioning are completed.
If faults occur, refer to the the error search table at 50. If the fault cannot be fixed or eliminated, please
contact your customer service.
6.3 Commissioning
The table below shows the different causes of wear and their impact on the components of the spring-applied
brake. The influential factors must be quantified so that the service life of the rotor and brake can be calcu-
lated and so the prescribed maintenance intervals can be specified accurately. The most important factors
in this context are the applied friction energy, the initial speed of rotation of braking and the switching fre-
quency. If several of the causes of friction lining wear occur in an application at the same time, the influencing
factors should be added together when the amount of wear is calculated.
7.2 Inspections
To ensure safe and trouble-free operations, the spring-applied brakes must be checked at regular intervals
and, if necessary, replaced. Servicing will be easier at the plant if the brakes are made accessible. This must
be considered when installing the drives in the plant.
Primarily, the required maintenance intervals for industrial brakes result from their load during operation.
When calculating the maintenance interval, all causes for wear must be taken into account, 42. For
brakes with low loads (such as holding brakes with emergency stop function), we recommend a regular in-
spection at a fixed time interval. To reduce costs, the inspection can be carried out along with other regular
maintenance work in the plant.
Failures, production losses or damage to the system may occur when the brakes are not serviced. Therefore,
a maintenance strategy that is adapted to the particular operating conditions and brake loads must be de-
fined for every application. For the spring-applied brakes, the maintenance intervals and maintenance oper-
ations listed in the table below must be followed. The maintenance operations must be carried out as
described in the detailed descriptions.
Time interval for operating brakes: for holding brakes with emergency stop:
7.3 Maintenance
NOTICE
Brakes with defective armature plates, springs or flanges must be completely replaced.
Observe the following for inspections and maintenance works:
❚ Contamination by oils and greases should be removed using brake cleaner, or the brake
should be replaced after determining the cause. Dirt and particles in the air gap between
the stator and the armature plate endanger the function and should be removed.
❚ After replacing the rotor, the original braking torque will not be reached until the run-in op-
eration for the friction surfaces has been completed. After replacing the rotor, the run-in ar-
mature plates and the flanges have an increased initial rate of wear.
WARNING
1. Measure the air gap “sL” between armature plate and rotor using a feeler gauge (refer to Values 16).
2. Compare the measured air gap with the maximum permitted air gap “sLmax” (refer to Values 16).
3. If necessary, replace rotor (only for basic version BFK457-06...16) or replace complete brake (only for
compact version BFK457-01...16).
DANGER
WARNING
1. Observe the brake functionality while the drive is operating. The armature plate must be tightened and
the rotor must move without residual torque.
2. Measure the DC voltage at the brake.
- The DC voltage measured after the over-excitation time (see bridge/half-wave rectifier) must be half
the voltage indicated on the nameplate. A deviation of 10 % is permissible.
WARNING
WARNING
NOTICE
2. Unbolt the fastening screws and remove the brake from the end shield. Pay attention to the connection
cable.
3. Pull rotor from hub.
4. Check the gear teeth of the hub. If you notice wear, dismount and replace the hub.
5. Check friction surfaces.
- In case of strong scoring at the flange, replace the flange.
- In case of strong scoring on the bearing shield, rework the friction surface.
6. Measure the rotor thickness using a caliper gauge and compare the results with the values stated in
chapter 3.2. Replace the rotor if necessary.
7. Check the brake function ( 42).
8. If necessary, install a new brake.
9. Reconnect the connection cable.
10. Recommission the brake, 39.
NOTICE
After replacing the rotor, the original braking torque will not be reached until the run-in opera-
tion for the friction surfaces has been completed. After replacing the rotor, the run-in armature
plates and the flanges have an increased initial rate of wear.
Compact design
NOTICE
If the level of permitted wear ( 16) has been reached, the complete brake must be
replaced when you are using the compact version.
Basic version
Rotor Noise-reduced
Size 01 02 03 04 05 06 08 10 12 14 16
If any malfunctions should occur during operations, please check for possible causes based on the following
table. If the fault cannot be fixed or eliminated by one of the listed measures, please contact customer ser-
vice.
Notes
应拓柯制动器 (上海)有限责任公司
INTORQ (Shanghai) Co., Ltd.
上海市浦东新区泥城镇新元南路 600 号
6 号楼一楼 B 座
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
INTORQ US Inc.
USA
300 Lake Ridge Drive SE
Smyrna, GA 30082, USA
+1 678 236-0555
+1 678 309-1157
info@us.intorq.com
www.intorq.com