INTORQ BFK458 - User Manual

INTORQ BFK458
Spring-applied brake with electromagnetic release
Translation of the Original Operating Instructions
setting the standard
www.intorq.com

Summary

Document History

Legal Regulations

Liability

Legal statement regarding product usage and limitations.

Warranty

Conditions and procedures for warranty claims.

Product Key

Checking the Delivery

Procedure for verifying received items against documentation.

Technical Specifications

Brake Torques

Details on braking torque values for different sizes and types.

Rated Data for Air Gap Specifications

Specifications for air gap dimensions and adjustments.

Switching Times

Information on engagement and disengagement times.

Switching Energy and Operating Frequency

Data on energy consumption and operational frequency limits.

Electromagnetic Compatibility

Information regarding EMC compliance for the product.

Labels on Product

Description and meaning of labels on the product and packaging.

General Information

Using these Operating Instructions

Guidance on how to safely use the operating instructions.

Conventions in Use

Explanation of document styles, symbols, and page references.

Safety Instructions and Notices

Overview of safety icons, signal words, and important safety information.

General Information

Terminology Used

Definitions of key terms used throughout the document.

Safety Instructions

General Safety Instructions

Essential safety precautions for operating INTORQ components.

Disposal

Guidelines for the proper disposal of INTORQ components.

Product Description

Proper and Intended Usage

Defines the correct applications and limitations of the brake.

Product Description

Layout

Description and illustration of the brake's physical components and modules.

Product Description

Function

Explanation of how the spring-applied brake operates.

Product Description

Braking and Release

Details on the process of applying and releasing the brake.

Project Planning Notes

Considerations for designing systems using the brake.

Optional Configuration

Overview of available optional features like hand-release and micro-switches.

Mechanical Installation

Design of End Shield and Shaft

Requirements for the brake's mounting interface and shaft.

Mechanical Installation

Tools

List of required tools for installation and maintenance.

Preparing the Installation

Initial steps before mounting the brake assembly.

Mechanical Installation

Installing the Hub onto the Shaft

Instructions for mounting the brake's hub onto the drive shaft.

Mechanical Installation

Mounting the Rotor

Procedure for installing the brake rotor onto the hub.

Mechanical Installation

Mounting the Complete Stator

Steps for attaching the stator assembly to the end shield.

Mechanical Installation

Adjusting the Air Gap

Procedure for setting and verifying the brake's air gap.

Mechanical Installation

Installing the Friction Plate (Optional)

Instructions for fitting the optional friction plate.

Mounting the Flange

Steps for attaching the brake flange to the assembly.

Mechanical Installation

Installing the Flange (Variants: Size 06 - 16)

Specific flange mounting instructions for sizes 06 to 16.

Mechanical Installation

Installing the Flange (Variants: Size 18 - 20)

Specific flange mounting instructions for sizes 18 to 20.

Mechanical Installation

Installing the Flange (Variants: Size 25)

Specific flange mounting instructions for size 25.

Mechanical Installation

Installing the Double Spring-Applied Brake

Procedure for mounting the double brake configuration.

Mechanical Installation

Cover Ring Assembly

Instructions for fitting the cover ring to the brake assembly.

Mechanical Installation

Installing the Shaft Sealing Ring

Procedure for installing the shaft sealing ring.

Mechanical Installation

Installing the Hand-Release (Retrofitting)

Steps for retrofitting the manual hand-release mechanism.

Electrical Installation

Electrical Connection

Instructions for making electrical connections to the brake.

Electrical Installation

AC Switching at the Motor - Extremely Delayed Engagement

Wiring diagrams for AC motor switching with delayed engagement.

Electrical Installation

DC Switching at the Motor - Fast Engagement

Wiring diagrams for DC motor switching with fast engagement.

Electrical Installation

AC Switching at Mains - Delayed Engagement

Wiring diagrams for AC mains switching with delayed engagement.

Electrical Installation

DC Switching at Mains - Fast Engagement

Wiring diagrams for DC mains switching with fast engagement.

Electrical Installation

Minimum Bending Radius for Brake Connection Line

Specifies minimum bending radii for the brake's electrical cable.

Technical Specifications for the Micro-Switch

Details on the micro-switch option and its functionality.

Electrical Installation

Bridge;Half-Wave Rectifier (Optional)

Information on optional rectifiers for power supply.

Electrical Installation

Reduced Switch-off Times

Notes on achieving reduced switch-off times with AC switching.

Commissioning and Operation

Protect Electrical Connections

Safety measures for protecting electrical connections from contact.

Functionality for Different Operating Conditions

Notes on performance variations based on operating conditions.

Operation Without Dynamic Loads

Guidelines for using the brake as a pure holding brake.

Commissioning and Operation

Function Checks Before Initial Commissioning

Procedures for verifying brake functionality before first use.

Commissioning and Operation

Testing the Hand-Release Functionality

Procedure for testing the manual release mechanism.

Commissioning and Operation

Commissioning

Steps for putting the drive system into operation.

Operation

General guidelines and checks during normal operation.

Commissioning and Operation

Brake Torque Reduction

How to adjust and reduce the brake torque using the adjustment ring.

Maintenance and Repair

Wear of Spring-Applied Brakes

Analysis of causes of wear and their impact on brake components.

Maintenance and Repair

Inspections

Regular checks required to ensure safe and trouble-free operation.

Maintenance and Repair

Checking the Components

Procedures for inspecting various brake components.

Check the Rotor Thickness

Method for measuring rotor thickness and replacement criteria.

Maintenance and Repair

Checking the Air Gap

Procedure for measuring and verifying the brake's air gap.

Release; Voltage

Checks related to brake release functionality and voltage supply.

Maintenance and Repair

Adjusting the Air Gap

Detailed steps for adjusting the brake's air gap.

Replace Rotor

Instructions for replacing the brake rotor.

Maintenance and Repair

Spare Parts List

List of available spare parts for the brake assembly.

Troubleshooting and Fault Elimination

Brake Cannot Be Released, Air Gap Is Not Zero

Diagnosing and resolving issues where the brake fails to release.

Rectifier Defective or Incorrect

Troubleshooting problems related to the rectifier unit.

Troubleshooting and Fault Elimination

Rotor Cannot Rotate Freely

Troubleshooting steps when the rotor fails to rotate.

Voltage Too High or Too Low

Identifying and resolving issues with incorrect supply voltage.

Appendix

Holding Brake for the ATEX Zone

Specific information for ATEX-certified holding brakes.

INTORQ BFK458 Specifications

General

Voltage	24 V DC
Protection Class	IP54
Temperature Range	-20°C to +40°C
Housing Material	Aluminum
Operating Temperature	-20°C to +40°C
Type	Electromagnetic Brake
Weight	Varies depending on size