EN

Gearless Lift Machine Code GM.8.003290.EN

Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 1

Gearless Lift Machines

servogearless

WSG-S2.4

eco

Translation of the Original Operating Instructions

WITTUR Holding GmbH

Rohrbachstraße 26-30 • D-85259 Wiedenzhausen, Germany
Tel. +49 (0) 81 34/18-0 • Fax +49 (0) 81 34/18-49
http://www.wittur.com, E-mail: [email protected]

Reprinting, translation or reproduction in any form - Wittur Holding GmbH reserves the right to make
whether in part or in full - requires the prior written changes in the information and pictures contained in
permission of WITTUR Holding GmbH. these operating instructions without prior notice.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 2

These operating instructions are

applicable to lift machines:

WSG - S2.4 - ....

WITTUR Electric Drives GmbH reserves the right to correct or

change the contents of this manual and these product details
without prior notice. We expressly reserve the right to make
technical changes which improve the lift machines or their
safety standards without prior notice. No liability can be
accepted for damage, injuries or expense arising therefrom.
We cannot guarantee the correctness and completeness of the
details.

Offenburger Str. 3
D-01189 Dresden
Germany
Tel. +49-(0) 3 51-40 44-0
Fax +49-(0) 3 51-40 44-1 11
[email protected]
www.wittur-edrives.de

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 3

Contents
1. General information ............................................................................................................................4
1.1. About this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3. Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4. Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Safety instructions...............................................................................................................................4
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2. Format of the safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Product overview .................................................................................................................................6
3.1. Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4. Installation ..........................................................................................................................................8
4.1. Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.2. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2.2. Motor connection / Winding protection / Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.3. Speed/Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2.4. Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5. Commissioning ..................................................................................................................................16
6. Operation and maintenance ..........................................................................................................17
6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6.2. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6.3. Regreasing the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.4. Replacing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.5. Filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.6. Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.7. Testing the brake system to EN 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.8. Replacing the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.9. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7. Type code .............................................................................................................................................23
8. Technical data ....................................................................................................................................24
9. Dimension drawing............................................................................................................................25
10. Accessories ..........................................................................................................................................26
10.1. Connecting cable for measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
10.2. Cable set for motor and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.3. Brake manual release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
11. Spare parts .........................................................................................................................................29

Annex
EU Declaration of Conformity
Calculation of the traction sheave shaft
Traction sheave shaft
EU type-examination certificate EU-BD 881
Brake operating instructions

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 4

1. General information
1.1. About this operating manual
The purpose of this operating manual is to ensure that any work on WSG-S2 lift machines is carried out safely.
Please regard it as part of the product and keep it within easy reach.
All persons working on or with WSG-S2 lift machines must have read and understood this operating manual.

1.2. Intended use

WSG-S2 lift machines are intended for use as gearless drives for rope lifts. They may only be used for their
intended purpose and with all safety devices in proper working order.
They may only be operated under the conditions described in this manual and with due regard to their perfor-
mance limits.

1.3. Scope of delivery

The WSG-S2 lift machines are customised to meet individual requirements. The exact scope of delivery can be
found in the accompanying documentation.

1.4. Warranty and liability

Our "Conditions of Sale and Delivery" shall apply for all our supplies and services.
Any warranty claims must be made immediately upon discovery of the deficiency or defect.
We do not accept any warranty or liability claims for personal injury or property damage resulting from one or
more of the following causes
• Improper use of the WSG-S2 lift machine
• Improper installation, commissioning, operation or maintenance
• Operation of the WSG-S2 with defective and/or inoperative safety or protective devices
• Non-compliance with the instructions contained in the operating manual or other documentation supplied
• Unauthorised construction modifications to the WSG-S2
• Insufficient monitoring of parts subject to wear
• Repairs carried out improperly
• Emergencies caused by external forces or force majeure

2. Safety instructions
2.1. General
WSG-S2 lift machines are not ready-to-use products; they may only be operated after they have been installed
in lift systems and their safe operation has been ensured by taking the appropriate measures.
WSG-S2 lift machines are intended for use in an enclosed, lockable operating area to which only qualified
personnel and personnel authorised by the customer have access.

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 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 5

Qualified personnel
Only qualified personnel are authorised to perform any planning, installation or maintenance work, and this
must be done in accordance with the relevant instructions. The personnel must be trained for the job and must
be familiar with the installation, assembly, commissioning and operation of the product.

2.2. Format of the safety instructions

The safety instructions contained in this operating manual are presented in a standardised format.
They comprise a danger symbol + signal word + instruction text. The danger symbol indicates the type of dan-
ger, the signal word specifies the severity of the danger, and the instruction text describes the danger and
explains how to avoid it.
Danger symbols

Risk of electric shock Property damage

General danger Information

Signal words
• Danger Serious injuries or death will result
• Warning Serious injuries or death may result.
• Caution Minor to moderate injuries may result.
• Notice Property damage may result.
• Information Points out useful information.

2.3. Safety precautions

• Check the proper functioning of the motor and the brake after installing the machine.
• Repairs may only be carried out by the manufacturer or an authorised repair agency. Unauthorised opening
and tampering may result in injuries to persons and property.
• The machines are not designed for direct connection to the three-phase system but are to be operated via an
electronic frequency inverter. Direct connection to the mains may damage the motor beyond repair.
• High surface temperatures may occur on the external parts of the machine. Therefore, no temperature-sensi-
tive parts may be in contact with these parts or attached to them. Protection against accidental contact
should be provided, if required.
• The EU type-examined fail-safe brakes provided are designed only for a limited number of emergency brak-
ing operations. They must not be used as working brakes.
• If the motor is not energised, no torque is produced. This may result in uncontrolled acceleration of the lift,
if the brakes are released. Therefore, the motor winding should be short-circuited to produce a speed-depen-
dent braking torque while the motor is not supplied with current. (Use the main contacts for short-circuiting
as rated motor current may be flowing.) The motor must never be short-circuited while it is energised.
• High voltages are present at the terminal connections during the operation of synchronous motors.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 6

3. Product overview
3.1. Product description
The compact gearless WSG-S2.4 synchronous lift machines are designed for traction sheave lifts. They are dis-
tinguished by their high efficiency, extremely low noise and excellent operating characteristics. The machines
can be supplied for several rated speeds.
The machine comprises a frame, the synchronous motor, the traction sheave, and the typetested safety brake,
which can be used to prevent uncontrolled upward movement of the car.
The nameplate of the lift machine is on the motor frame.

Type code of lift

machine

Serial no.
Rated voltage
Rated speed
Rated frequency Rated torque
cos 
Drive-Code
Weight

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Item Part WSG-S2.4

1 Bolts (3x) DIN 933 - M12x35-8.8
2 Lock washers (3x) NL 12-DIN 25201
3 Pressure disc
4 Bolts (2x) DIN 912 - M8x20
5 Washers (2x) DIN 125 - A 8,4
6 Traction sheave
7 Rope slip-off guard (2x)
8 Elbows (2x)
9 Bolts (2x) DIN 912 - M8x20
10 Frame
11 Bolts (6x) DIN 912 M16x210
12 Brake BFK 455-28
13 Plug-in shaft
14 Screws (3x) DIN 912 - M4x10
15 Clamping sleeve
16 Screws (4x) DIN 912 - M6x12
17 Measuring system
18 Screw DIN 912 M5x50

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 7

3.2. Transport and storage

• The lift machines leave the factory in perfect condition after being tested.
• Make a visual check for any external damage immediately upon their arrival on site. If any damage is found
to have occurred in transit, make a notice of claim in the presence of the carrier. If appropriate, do not put
these machines into operation.
• Observe the relevant safety regulations and take the centre of gravity into account when handling the lift
machines.
• Check that the eyebolts are tightly fitted before using them.
• Do not expose the motor to any shocks or impact.
The eyebolts are designed for the specified machine weight, i.e. additional loads must not be
Warning applied. Danger of breakage!

Storage
• Store the motors only in closed, dry, dust-free, well-ventilated and vibration-free rooms (storage tempera-
ture: -20°C to 60°C). Do not store lift machines in the open air. Bright parts are not sufficiently preserved to
withstand extended periods of exposure.
• Avoid excessive storage periods (recommendation: max. one year).
• After prolonged storage (>3 months), rotate the motor in both directions at a low speed (< 20 min-1) to
allow the grease to distribute evenly in the bearings.
• Measure the insulation resistance before initial operation of the machine. If the value has dropped below
1k per volt of rated voltage, the winding needs to be dried (insulation meter voltage: 1,000 V DC).
• This can be done, for instance, with hot air, in a drying oven, or by applying a DC voltage to the motor con-
nections. Make sure that the voltage selected does not exceed the values shown in the figure "Drying the
winding". Let the temperature rise to about 70 – 80°C and maintain it for several hours.

I ≈ 45% IN
u
A
v
U -
w

Drying the winding

Unpacking
• Dispose of the packaging material in an environmentally friendly manner or reuse it.
• Any special transport aids or shipping braces are left with the customer.

3.3. Disposal
• The lift machines consist of different materials. A waste separation of those different material components
has to be done.
• The disposal must be professional and environmentally friendly according to law.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 8

4. Installation
4.1. Setting up
Be sure to use calculations to check the base frame or foundation loads before installing the
Danger lift machine.

• The machines can be used in lift systems with or without a machine room
• The permissible uneveness of the mounting surface is 0.1 mm. The mounting surface must be sufficiently dis-
tortion-resistant and stable to accommodate the forces occurring in the system.
• The rope force can be applied to the lift machine in any direction
• The machine must be mounted on vibration dampers for vibration damping
• No welding work may be performed on the lift machine, nor is it permissible to use the machine as a mass
point for welding work. This might cause irreparable damage to the bearings and magnets.
• If there are more grooves on the traction sheave than the number of ropes used, position the ropes either in
the centre of the traction sheave or towards the motor end.

üok üok
• The measuring system is only accessible from the rear side. Therefore, leave enough space between the wall
and the rear side of the machine or ensure that the machine can be moved away from the wall.

Cover the machine and especially the brakes when doing any machining or dust-producing
Warning work in the shaft or machine room.

Securing the machine

• Fasten the machine using bolts
- 4 x M 24 bolts (strength class 8.8; tightening torque: 680 Nm) in case of using the threaded holes or
- 6 x M 24 bolts (strength class 8.8; tightening torque: 680 Nm) in case of using the mounting holes.
• After completing the adjusting work or after a breakdown, tighten all the fastening bolts of the machine,
using the specified torque .
• Lift machines are generally equipped with rope slip-off guards. After putting the ropes in place, adjust them
so that the distance between the rope and the rope slip-off guard does not exceed 1.5 mm.
• If the lift machine is not installed at the head of the machine room as is usually the case, it may be necessary
to modify the fitting of the rope slip-off guard to fulfill the requirements of EN 81-20 . Optional rope slip-off
guards are available for this purpose.
üok üok üok üok

When using the machine in a shaft, please take into account the patent situation.

Subject to changes without notice ! Subject to changes without notice !

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Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 9

Ambient conditions
• The following ambient conditions must be ensured 1,2
on site
Altitud: max. 1,000 m a.s.l. 1,1
Ambient temperature: -5°C ... 40 °C
Max. rel. humidity: 85% at 20°C 1,0
(no moisture condensation)

Factor k
• Install the machine so that ventilation is not obstruct, 0,9
ed, i.e. sufficient heat dissipation by convection and
radiation must be ensured. 0,8
Altitude < 1000 m
• The torque and power values indicated in the technical
Altitude < 2000 m
data apply to the above ambient temperatures and 0,7
Altitude < 3000 m
altitudes. In the case of a deviating altitude and/or
temperature, the reduction factors k shown in the dia- 0,6
gram "Ambient conditions" must be used. 0 10 20 30 40 50 60

Mpermiss = k * MN Ambient temperature [°C]

Ppermiss = k * PN

4.2. Electrical connection

4.2.1. General

Warning The electrical connection may only be made by a qualified electrician.

• Before starting any work on the machines, ensure that the lift machine or system is properly isolated.
Before making any electrical connections check that
• the connecting cables are suitable for their specific application and for the relevant voltages and currents.
• sufficiently dimensioned connecting cables, torsion, strain and shear relief, as well as anti-kink protection are
provided
• the protective conductor is connected to the earthing terminal
• there are no foreign bodies, dirt or moisture in the terminal boxes
• cable entries not in use and the terminal box itself are tightly sealed to prevent the ingress of dust or
splashing water.
The insulation system of the motors is designed such that they can be connected to a
inverter with a maximum DC link voltage Ulink max up to max. 700 V DC.
Ulink max is the maximum value of the DC link voltage which is only transient and approxi-
mately equivalent to the inception voltage of the braking chopper or of the energy recovery
Caution unit.
The maximum permissible rate of voltage rise (dU/dt) at the motor terminals is 4kV/µs. The
overvoltage at the motor terminals must not exceed 1.56 kV. It may be necessary to use
motor current filters or reactors to achieve these values.

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Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 10

4.2.2. Motor connection / Winding protection / Fan

• The electrical connection of the motor, the fan and the winding sensors is made in the terminal box located
on the motor.
• The motor cable must be shielded. Ensure that the cable shield contacts the frame over a large area at both
ends.
• The motor phases U1, V1 and W1 must be connected correctly to the corresponding phases of the inverter;
they must not be interchanged.
• We recommend using a inverter with a switching frequency of 12 kHz.
• The thermocouples installed in the winding such as PTC resistor detectors and thermostatic switches must be
evaluated in the control system or the frequency inverter to protect the motor from overheating.
• The separately driven fan must be properly connected and operated. If required, it can be switched in depen-
dence of the temperature by means of thermal switch S4 (relay must be used).

Terminal strip for motor

WAGO 2016 PE U1 V1 W1 Terminal strip for fan and win-
Cable cross-section: ding protection connections
0,5 - 16 mm2 WAGO 260
Stripping length required: max. Anschlussquerschnitt:
18-20 mm 1,5 mm2
Abisolierlänge der Adern:
8-9 mm

M 50 x 1,5 M 20 x 1,5

PTC Thermistor T
3 x STM-150.ES ... (150°C)
- embedded in the motor winding
S1
M - for motor protection Thermostatic switch

(250 V AC / 2,5 A / cos  = 1)

3~ 3 x S01.130.05 ... (130°C)

υ υ υ - embedded in the motor winding

- pre-warning overtemperature
T1
T2
T3
T4 υ υ υ
S1
U1 V1 W1 S2 υ
S3
S4
N
L
Thermoschalter S4
Terminal box
(250 V AC / 2,5 A / cos  = 1)
Cable entry M 1 x S02.60.05 ... (60°C)

1 x tapped hole M 50 - embedded in the motor winding

1 x tapped hole M 20 Separately driven fan F - e. g. for fan control
W2E 142-BB01-01

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Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 11

Cable cross-section required:

The currents specified under the machine data refer to duty type S3-40%. This must be taken into account
when selecting the cable cross-section required. The continuous r.m.s. value required for the selected cable is

I r.m.s. (cable). » I N (motor, S3-40%) / 1,58

approximated from:
Cable cross- Permissible max. Permissible max.
section current motor current IN
required (r.m.s. value) (S3 - 40%)
1.0 mm 2 13.1 A 20.7 A
The table on the right gives the standard values for
the current-carrying capacity of PVC cables at a 1.5 mm 2 15.7 A 24.8 A
maximum ambient temperature of 40°C. 2
2.5 mm 22.6 A 35.7 A
4.0 mm2 29.6 A 46.7 A
6.0 mm 2 38.3 A 60.5 A
10.0 mm 2 53.1 A 83.9 A

PTC thermistors
The maximum operating voltage of the PTC thermis-
tors is not allowed to exceed 25 V DC !
To achieve the maximum precision, the 3 x 4000
measurement voltage per PTC thermistor must not
Resistance []

exceed 2.5 V DC. 3 x 1330

3 x 550
3 x 250

-20°C
130°C 165°C
145°C 155°C
150°C Temperature

Short-circuiting the motor terminals

• The motor terminals of the synchronous lift machines, type WSG, can be short-circuited, if required, to brake
the lift machine faster.
• However, this is only permissible at speeds less than or equal to the rated speed of the respective motor.

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Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 12

4.2.3. Speed/Position measuring system

• The basic version of the lift machines is equipped with an sendix 8.5873 SineCosine encoder from Kübler
GmbH. The encoder is connected by cable (length: 10m) with open wire ends (no plug).
• Alternatively, the machines can be equipped with ECN 413 or ERN 487 encoders (from Heidenhain GmbH).
We can also provide other measuring systems on request.
• Use a shielded cable to connect the Heidenhain measuring systems to the inverter system. We recommend
the use of our cable sets, which can be supplied as an accessory.

The measuring system of WSG lift machines with a

synchronous motor (WSG) is matched to the associated
inverter. Do not change the adjustment, as this may
Caution make it impossible to use the motor. On the measur-
ing system housing there is a label showing the "offset
angle" and the inverter type.
The offset angle depends on the inverter used.

Measuring system Sendix 8.5873 Measuring system ECN 413

Number of sine-cosine Number of sine-cosine
periods per rotation: 2048 periods per rotation: 2048
Operating voltage: 5V Operating voltage: 5V
Data interface: BISS Data interface:: SSI or ENDAT

Core Signal Pin Signal

white 0 V (Up) 1 Up Sensor
brown Up 4 0 V Sensor
green Clock + 7 Up
yellow Clock - 8 Clock + 1
11 12
grey DATA + 9 Clock - 2
10 16 3
17
pink DATA - 10 0 V (Up) 9 13
4
blue SET 11 inner shield 8 15 14 5
red DIR 7 6
12 B+
black A+ 13 B-
violet A- 14 DATA +
Pin contacts of flanged con-
grey-pink B+ 15 A+
nector socket (exterior)
red-blue B- 16 A-
shield shield 17 DATA -

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Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 13

4.2.4. Brake
• Refer also to the operating instructions for the brake.
• The brakes are supplied with DC voltage by the overexcitation rectifiers, which are supplied separately or in
the terminal box.
• Only the overexcitation rectifiers which are included in our scope of supply are to be used for the brake
activation.
• Repeated switching of the brake magnets during the overexcitation period must be avoided as this will result
in overloading of the brake control unit. Therefore, a minimum brake operating time of approx. 1.5 – 2 s
should be maintained, especially during an inspection or commissioning drive.
• To reduce the switch-off time, switching can be effected from the DC side. However, switching must also be
performed from the AC side at the same time ! (Wiring with a varistor as shown in the circuitry suggestion
on page 15!)

Note on the use of DC/AC side switching:

AC side switching is recommended for normal operation, since the lift machine is then decelerated in a con-
trolled manner to zero speed and the switching noise of the brake is negligible.
When braking in the event of a breakdown (emergency stop) or during an inspection drive, the switching
should be performed from the DC side, since this ensures a faster braking effect with the car being stopped
earlier. We therefore recommend the use of 2 separate contactors for the brake control circuitry, one of
which switches at the DC side, the other at the AC side.

AC side switching DC side switching

• Low-noise switching of the brake • Noisy switching
• No protective measures required for switching • Burn-up protection for switching contact required
contact (e.g. varistor, free-wheeling diode)
• Slow application of the brake. • Fast application of the brake.
+
+
~ Br
~ Br
-
-
Attention: schematic diagram! Attention: schematic diagram!

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 14

Monitoring the brakes

• The switching states of the brakes are monitored by means of dust-proof microswitches with gold contacts.
Both the n.c. and the n.o. contact connections are available.
The microswitches must be evaluated separately for each partial brake to ensure compliance
Warning with the requirements of the type examination.

Connection of the brakes

The brake solenoids, the brake control units and the monitoring contacts are connected to the mains in the
brake terminal box.

Connections for brake monitoring contacts

WAGO 260
cable cross-section: 1,5 mm2
stripping length required: 8-9 mm

M 16 x 1,5

123456
C NO blue
123456

2nd. partial brake NC grey

M 16 x 1,5
black

C NO blue
1st. partial brake NC grey
black

Subject to changes without notice ! Subject to changes without notice !

 Circuitry suggestion for brake control WSG-S2.4
WSG-S2.4

Subject to changes without notice !

Operating Instructions

DC side switching and separate control of K1 and K2 must swith simultaneously .

the partial brakes
Gearless Lift Machine

K2
230 V ±10%
40...60 Hz
S10 K275
black
6-
5+
K1 Brake magnet
4 u
3 blue
to the 2nd. partial brake blue Brake monitoring
2~ NO
3 C

intorq
BEG-561...
1~ grey NC
2
black
1

release
{

to control cabinet
Circuitry suggestion for brake control WSG-S2.4

1st. Partial brake

Brake terminal box

AC side switching and separate control of

the partial brakes

S10 K275 black

6-
5+
Brake magnet
K1 4 u
blue
3
to the 2nd. partial brake
2~ blue NO Brake monitoring

intorq
BEG-561...
3 C
1~ grey NC
2
black
release
{ 1
2 x Overexcitation rectifier
to control cabinet
1st. Partial brake
Date

Page
Code

Version
EN

15
0.10
13.06.2016
GM.8.003290.EN

Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 16

5. Commissioning
The following points should be checked or completed:
• Check that all performance and application data specified on the name plate of the machine are consistent
with your application.
• Have all securing, auxiliary and installation tools been removed from the danger area?
• Check that the lift machine is being used for its intended purpose – comply with the permissible ambient
conditions.
• Check that the lift machine has been properly fastened with the fastening bolts – have the bolts been tight-
ened to the specified torque and secured?
• Has the motor been properly connected, including the motor protection? Has the PE terminal been properly
connected? Is the potential equalisation with the machine frame ensured?
• Check the proper functioning of the temperature monitoring devices (e.g. by interrupting the temperature
monitoring circuit).
• Check the brake connection and the proper functioning of the brake monitoring switches.
• Ensure that the brake operates correctly; perform a brake test using one partial brake.
• Has the measuring system been properly connected?
• Check that the offset value indicated on the measuring system agrees with the value set on the inverter.
• Is the rope slip-off guard properly tightened and adjusted?

An initial function test of the motor and the brake, together with the inverter, should be performed before
the ropes are put in place.
If the motors are being operated at no shaft load (no ropes put in place) for an extended period of time,
abnormal noise may occur resulting from the bearing type used

Half-load test

If the motor winding is short-circuited with the control system deactivated, a speed-dependent braking
torque will be produced, even at low speeds. Therefore, the short-circuiting should be deactivated during the
half-load test. It is imperative for it to be reactivated after the test.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 17

6. Operation and maintenance

6.1. General
• The regulations concerning operation, maintenance and inspection pursuant to the applicable safety regula-
tions for lift construction such as DIN EN 81-20, DIN EN 81-50, LD 2014/33/EU and other relevant regulations
are to be strictly observed.
• The operator is responsible for ensuring that the motor is installed properly and in accordance with the safe-
ty requirements, as well as for its inspection and maintenance as specified in the applicable regulations.
• The proper maintenance of gearless lift machines requires adequately trained specialist personnel and special
devices and tools.
• Repairs other than those described in these operating instructions are not to be carried out by the lift fit-
ter/maintenance technician for liability reasons.

Bolt/screw tightening torques

• When performing any work on the machine or Dimension Tightening torque [Nm]
replacing parts, make sure that the specified Strength class 8.8 10.9 12.9
bolt/screw strength class and the tightening M4 2,8 4,1 4,8
torques are observed (see table).
M5 5,5 8,1 9,5
• Secure the bolts/screws with "omnifit 100" or a M6 9,6 14 16
similar product against accidental loosening.
M8 23 34 40
M10 46 67 79
M12 79 115 135
M16 195 290 340
M20 395 560 660
M24 680 970 1150

6.2. Maintenance intervals

Check the brake air gap every six months see the brake operating instructions
Check the proper functioning of the brakes and the
every six months see the brake operating instructions
brake monitoring switches
Check the bearing noise every six months

Regrease the bearings see section 6.3

Check the traction sheave for wear every six months

Make a visual check of the fasteningbolts/screws on
every six months see section 6.1.
the frame, brake and traction sheave
Check the electrical cables every six months see section 4.2.

Check the rope slip-off guard every six months

Check the guards and safety devices for their condi-
every six months
tion and safe functioning
Clean the external machine surfaces;
as required see section 6.5.
clean the fan filter mats

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 18

6.3. Regreasing the bearings

The anti-friction bearings have been provided with a grease filling at the factory that is sufficient for the
planned service life of the machine. Under normal operating conditions, regreasing is not required or recom-
mended.

6.4. Replacing the traction sheave

Warning The traction sheave can work loose if it is not properly installed.

Necessary tools
• Hoisting equipment • Spacer (4 ... 7 mm)
• Torque wrench (M 12) • Cleaning cloth
Disassembly
• Disconnect the system and safeguard against accidental restarting.
• Secure the car and the counter-weight.
• Remove the rope slip-off guards and the rope guards, if provided. 1
• Relieve the load on the traction sheave; remove the ropes.
• Support the traction sheave by means of a hoisting gear.
• Remove the three M 12 bolts (1) at the pressure disc and the pres-
sure disc itself.
• Insert two fastening bolts (2) into the outer hole circle of the
pressure disc (3) and into the traction sheave. 2
• Insert a spacer (4) between the pressure disc and the shaft
journal. 4
• Pull off the traction sheave from the tapered shaft seats by tight-
ening the bolts evenly. 3
Assembly
• Clean the traction sheave and the motor shaft.
• Support the traction sheave by means of a hoisting gear. 5
• Insert the feather key (5) into the shaft end.
• Slide the traction sheave onto the motor shaft.
3
• Fit the pressure disc (3) to the traction sheave and fasten it using
three pairs of NORD-LOCK washers (6) and M 12 bolts (1). Tighten 6
the bolts alternately around the circle in three torque steps (30,
60 and 85 Nm) as far as they will go. Tightening torque: 85Nm 1
• Replace the ropes and reinstall the rope slip-off guard.

6.5. Filter mats

Remove the two screws from the protective screen. Then remove the screen and filter to clean or replace the
filter mats.

Warning Do this work only with the fan switched off as the rotating fan wheel could be dangerous.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 19

6.6. Emergency evacuation

All actions for evacuation in case of emergency have to be done by qualified service
Danger personnel.

Manually operated evacuation in case of emergency

• The brakes can be opened manually by using the lifting levers (option)
• Two different options can be chosen (shown in the following pictures):

Manual lifting rods (machine room): Brake manual release remotelly controlled:

Release
Lever extension

Release
(~ 470 N)

• Is the brake opened manually, the cabin moves in the direction of the higher weight. In case of balance, the
cabin has to be weighted down with suitable additional mass.
• The motor winding has to be short-circuited via the motor contactors. With the short circuit the motor cre-
ates a brake torque, which is dependent on the motor speed. This prevents an uncontrolled acceleration of the
elevator.
• It is possible that the brake torque which is created by the motor short circuit is not enough to limit the
speed of the elevator. Therefore the cabin speed has to be observed carefully during the evacuation and if
needed, the evacuation has to be stopped.
• When the cabin has reached the next floor, the manually opened brake is closed again. The rescue of the
trapped persons in the cabin can begin.
When the evacuation is finished, the initial state has to be restored. Especially the
Warning lever extensions have to be removed.

Electrically operated evacuation in case of emergency

• The electrical opening of the brakes is done using the power grid or an UPS.
• The operating instructions of the controller, the inverter or the evacuation unit with UPS have to be followed!

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 20

6.7. Testing the brake system to EN 81

The brake system should be tested with the car about halfway down the shaft. If any motor short-circuit
connections have been made, these should be deactivated so that the brake effect can be tested
independently.

Overload
• The brake system should be tested by interrupting the power supply to the motor and brake system with the
car moving downward at rated speed and 1.25 times the rated load. The brake system must be capable of
decelerating the car.

Failure of a brake
• If one brake fails, the brake system must still be capable of decelerating the car sufficiently during its down-
ward travel at rated load and rated speed.
• When simulating the failure of one brake, the other brakes must be kept open separately, even if the safety
circuit is open. This should be done using suitable electric circuitry or by hand.
• This state must not be maintained in the long term!
• Observe the lift during this test. If it does not decelerate, close the open brake circuit immediately.

Separate operation of the individual brakes

• The only method by which the partial brakes can be released separately is through electrical control. The
brakes can be activated/deactivated quickly using individual control buttons.

Monitoring the brakes

• Check the brake monitoring switches individually. No car travel must be permitted if a microswitch signal is
missing or a wrong signal operates.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 21

6.8. Replacing the measuring system

The measuring system is only accessible from the rear side of the motor.
See the mounting instructions for the Kübler encoder.
Disassemble the measuring system only if this is necessary because of a defect. Remember to readjust the offset
value after reassembly (see the inverter operating instructions).

Disassembly

1. 2. 3. 4.
Loosen 2 x bolts. Remove 2 x bolts with Loosen fixing bolt. Unscrewing the fixing bolt cau-
washers. ses the encoder to disengage
from the motor shaft.

Assembly

1. 2. 3. 4.
Screw the fixing bolt into the Tighten the fixing bolt Attach the encoder with 2 x Tighten the 2 x bolts.
motor shaft. This causes the with 3+0.5 Nm. bolts and washers.
encoder to be drawn into
the cone.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 22

6.9. Trouble shooting

Fault Possible cause Remedy

Motor does not start, operates out of • Motor not connected in proper • Connect motor correctly
control or develops no torque phase sequence
• Measuring system not properly • Connect measuring system correctly
connected
• Inverter parametrisation incorrect • Check inverter parametrisation
• EMC disturbance • Carry out shielding and earthing mea-
sures as described by the inverter man-
ufacturer
• Measuring system offset angle in- • Check measuring system offset angle
correctly set
• Measuring system defective • Replace measuring system

Motor noise • Bearing defective • Notify customer service

• Inverter parametrisation incorrect • Check inverter parametrisation
Braking system does not release • Braking system is not supplied with • Check electrical connection
voltage
• Brake magnet voltage too low • Check braking voltage supply voltage
• Brake shoes mechanically blocked • Remove mechanical blocking
• Overexcitation rectifier defective • Replace overexcitation rectifier

Delay in braking system release • Overexcitation rectifier defective • Replace overexcitation rectifier

Braking system does not engage • Brake shoe mechanically blocked • Remove mechanical blocking

Delay in engaging of braking system • Switch-off time too short with AC • Brake control using DC side switching
side switching of the overexcitation rectifier

Brake makes loud switching noise • DC side switching of the brake in • Change over to brake control by AC
"normal operation" side switching in "normal operation"
• Brake air gap too large • Adjust brake air gap

Braking torque too low • Brake friction surface or brake lin- • Clean friction surface / brake linings
ings dirty.
• Foreign bodies between friction • Remove foreign bodies
surface and brake lining
• Brake friction surface or brake lin- • Replace brake lining, clean brake drum
ing have come into contact with thoroughly
oily or greasy materials
• Load torque too high • Reduce load torque

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 23

7. Type code
Example: W S G- S2 . 4 - 0 E 19 / 3TI - DF

W S G- S2 . 4 - X1 X2 X3 X4 / X5 X6 X7 - X8 X9

Customer specific
identifier

S = Synchronous motor

G = gearless
U = gearless; UL-CSA approved

Frame size

Overall length:

X1: Customer specific identifier

X2: Motor voltage:

E: serie „ECO“, suitable for inverter supply using a link voltage
of 500 …. 620 V

X3 X4: Rated speed:

e.g. 07: 75 min-1 (with DT = 320 mm v = 0.63 m/s; suspension 2:1)
11: 119 min-1 (with DT = 320 mm v = 1.0 m/s; suspension 2:1)
19: 191 min-1 (with DT = 320 mm v = 1.6 m/s; suspension 2:1)

X5 X6 X7: Traction sheave design

(Traction sheave diameter; width, groove design, groove geometry)

X8 X9: Variant code (brake, measuring system, modifications)

DZ: dual-curcuit brake; measuring system Sendix 8.5873-2048 Inkr. - BISS-Interface
DE: dual-curcuit brake; measuring system ECN 413-2048 incr. - SSI-interface
HE: dual-curcuit brake with manual release; measuring system ECN 413-2048 incr. - SSI interface
DF: dual-curcuit brake; measuring system ECN 413-2048 incr. - ENDAT-interface
DG: dual-curcuit brake; measuring system ERN 487-2048 incr.

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 24

8. Technical data
Duty type: S3 - 40 % ED
Dual-circuit fail-safe brake
Traction sheave: dia. 320 mm or dia. 400 mm
Type: BFK 455-28
Traction sheave hard- mind. 220 HB 30
Max. braking torque: 2 x 1200 Nm
nesse: formbeständige Keilrille HRC 55
Air gap sB: 0,4± 0,05 mm (new air gap)
Typical number of carry-
8 x dia. 8 mm; 9 x dia. 10 mm Max. air gap sB max: 0,7 mm
ing ropes and dia.:
Holding voltage: 103 V DC
DE bearing: self-aligning roller bearing
Holding current: 2 x 1.06 A
NDE bearing: ball bearing Overexcitation voltage: 205 V DC
Permissible shaft load: up to 45 kN Overexcitation current: 2 x 2.12 A
Drive motor: synchronous motor
Brake control units
Number of pole pairs: 8
BEG-561-255-130 from Intorq
Thermal class: 155 (F) Type:
GmbH (accessories)
Degree of protection: IP 33 Operating voltage: UN = 230 V AC ( ±10 %), 40... 60 Hz
Overload capability: 1.9-fold (Imax/IN) Dimensions: 52 x 22 x 38 (w x h x l)
triple PTC 150°C Brake monitoring contacts
Winding protection: triple therm. switch (NC contact)130°C
therm. switch (NO contact) 60°C Contact rating: 12 - 30 V DC / 0,01 - 0,1 A
Min. contact current: 10 mA
Site conditions Mechanical life of contacts: 2x 106 switching operations
max. 1,000 m
Max. altitude: Separately driven fan
(derating required at higher altitudes)
Ambient temperature: -5°C ... +40°C Type: W2E 142-BB01-01
85 % at 20°C Operating voltage: 230 V / 50/60 Hz
Max. rel. humidity:
(no moisture cendensation) Current consumption: 0,12/0,13 A

The table is applicable to an overall shaft efficiency of approx. 73..85 % (counterweight: 50 %).
*) Reference values. Achievable nominal load It lists a standard selection of machines. The lift and project data will be adapted to actual site
depends on specific lift system data. conditions and may deviate from the above values.

motor WSG-S2.4

torque S3-40%, 240 S/h MN [Nm] 900

max. torque Mmax [Nm] 1700

traction sheave Æ DT [mm] 320 400
for loads *) Q [kg] up to 1600 up to 1275
suspension table applies for 2:1
v nN PN IN nN PN IN
[m/s] [rpm] [kW] [A] [rpm] [kW] [A]
0,5 60 5,7 18,0 48 4,5 18,0
Motor currents applicable to
0,63 75 7,1 21,0 60 5,7 18,0
500 ... 620 V DC link
voltage (serie „ECO“) 1,0 119 11,2 29,5 95 9,0 24,5
1,6 191 18,0 46,0 153 14,4 38,0
1,75 209 19,7 46,0 167 15,7 38,0
2,0 191 18,0 46,0

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 25

9. Dimension drawing

450
Fs
420

DT
495
200

28*)

55
306 24 ) BT
30

350 104 104 66 C

404 340
388
*) 6 mounting holes Ø 28
L
#) and 4 threaded holes M 24

motor WSG- S2.4

Æ DT 320 400
BT 105 120 105 150
L 854 869 857 902
C 100 107 100 122
weight mG [kg] 445 447 460 474

inertia JG [kgm2] 1,03 1,06 1,62 2,06

shaft loads up to FS [kN] 45

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 26

10. Accessories
10.1. Connecting cable for measuring systems

Inverter type recom. recommended

encoder system measurement system cable

E-Pack ECN 413

503 325 021 xx
Arkel ARCODE (EnDat / SSI)

D-Pack
ECN 413
Arkel ADrive 502 452 021 xx
(EnDat / SSI)
CT unidrive SP

emotron/ Dietz ECN 413

501 112 022 xx
DSV 5445 (EnDat / SSI)

ECN 413
Fuji Frenic 502 679 022 xx
(EnDat)

ECN 413
KEB F5 502 363 022 xx
(EnDat)

LTi DRiVes
ECN 413 (SSI) 505 677 022 xx
Lust CDD 3000

RST Elektronik ECN 413

508 752 022 xx
FRC (EnDat)

GEFRAN (SIEI)
ERN 487 503 499 022 xx
AVY-L-M

ECN 413
Vacon NXP 503 289 021 xx
(EnDat)

Yaskawa/
Omron L7
ECN 413
xx... cable length [m]

Telemecanique/ 503 715 022 xx

(EnDat)
Schneieder
Altivar 71

Ziehl-Abegg ECN 413

508 749 022 xx
2SY/3BF (EnDat / SSI)

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 27

10.2. Cable set for motor and brake

motor cable

brake cable (magnet)

brake cable (monitoring)

xx - cable length [m]

05 - 5 m; 10 - 10 m; 15 - 15 m;

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 28

10.3. Brake manual release

As an option the brake is available with a manual release.

Brake with or without manual release as specified with the
order. No possibility for retrofit !
The necessary manual release lever including the Bowden
cable for releasing can be delivered, if required.
The standard length of the Bowden cable is 3 m. Other
lengths on request.

Installation:
Install the manual brake releasing device with the brake dis-
connected from the power supply.
• Lock the car and the counterweight. Ensure that the re-
quired safety measures are observed for the lift system.
• Install the lever block.
• Insert the Bowden cable into the brake lever (a and b)
and the lever block . Adjusting of the Bowden cable on
the lever block. Set LF = 300 mm on the lever block with
LF = 300
the assistance of threaded rod.
Do not actuate the lever block ! a b
• Perform a functional test (at least three times). Threaded
rod

The Bowden cable has to be installed in wide

arcs only (bending radius > 0.5 m, if possible).
Put no loops !

Lever block

Alternatively, another simple version of the manual re-

leasing device is available for lifts with a machine room.

Release
Lever extension

Subject to changes without notice ! Subject to changes without notice !

 EN
Gearless Lift Machine Code GM.8.003290.EN
Date 13.06.2016
WSG-S2.4 Version 0.10
Operating Instructions Page 29

11. Spare parts

Item Part Description

Motor
01 traction sheave acc. machine nameplate type code X5 X6 X7
02 Measuring system (depending on spec.) ECN 413 / SSI / 2048 incr. / clamping ring
ECN 413 / ENDAT / 2048 Inkr. / clamping ring
ERN 487 / 2048 Inkr. / clamping ring

Brake system
04 Overexcitation rectifier BEG-561-255-130
05 Micro switch (brake monitoring) ET 37 74 210 0807
06

Subject to changes without notice ! Subject to changes without notice !

Technical information 01-12/2012 Re:

WSG-S2.4
Traction sheave shaft (Annex - calculation of the shaft)

Brake Motor Traction sheave

Werkstoff: Stahl DIN EN 10 083-1 - 42CrMo4

Denticulation: steel DIN EN 10 083-1 - 42CrMo4

Offenburger Str. 3 [email protected] Phone: +49 (0) 351 40 44-0 M.S. 07.12.2012
01189 Dresden www.wittur-edrives.de Fax: +49 (0) 351 40 44-111
Germany
 Annex to the EC Type-Examination Certificate
No. EU-BD 881 of 2016-03-18

1 Scope of application

1.1 Use as braking device – part of the the protection device against overspeed for the car moving
in upwards direction – permissible brake torque and tripping rotary speed
1.1.1 Permissible brake torque when the braking device acts on the shaft of the traction sheave while the
car is moving upward
Permissible brake torque Maximum tripping rotary speed of the traction sheave
(Nm) (rpm)
2 x 1200 = 2400
2 x 1700 = 3400
455
2 x 1800 = 3600
2 x 2065 = 4130
1.1.2 Maximum tripping speed of the overspeed governor and maximum rated speed of the lift
The maximum tripping speed of the overspeed governor and the maximum rated speed of the lift
must be calculated on the basis of the traction sheave’s maximum tripping rotary speed as outlined
below taking into account traction sheave diameter and car suspension.
v = Tripping (rated) speed (m/s)
v= DTS = iameter of the traction sheave from rope’s center to rope’s center (m)
n = 3,14
i n = Rotary speed (rpm)
i = Ratio of the car suspension

1.2 Use as braking element – part of the protection device against unintended car movement (act-
ing in up and down direction) – permissible brake torque, tripping rotary speed and character-
istics
1.2.1 Nominal brake torque and response times with relation to a brand-new brake element
Overexcitat
Maximum Brake ion at
Nominal Maximum response times**
tripping control
brake [ms] [x- fold
rotary [parallel or se- non-release
torque* with / without overexcitation voltage]
speed rial]
[Nm]
[rpm]
t10 t50 t90
2 x 1200 = 2400 255 160 / 197 214 / 252 267 / 306 parallel 2-fold
2 x 1200 = 2400 455 189 / 207 290 / 295 390 / 382 serial 1,43-fold
2 x 1700 = 3400 455 61 / 73 123 / 136 184 / 199 parallel 2-fold
2 x 1800 = 3600 455 59 / 70 110 / 122 160 / 174 parallel 2-fold
2 x 2065 = 4130 255 89 / 108 158 / 177 226 / 247 parallel 2-fold
Explanations:
* Nominal brake torque: Brake torque assured for installation operation by the safety component manufac-
turer.
** Response times: tX time difference between the drop of the braking power until establishing X% of
the nominal brake torque, t50 optionally calculated t50= (t10+ t90)/2 or value taken from
the examination recording

1.2.2 Assigned execution features

Type of powering / deactivation continuous current / continuous current end
Nominal air gap 0.45 mm
Damping elements YES

Note: The English text is a translation of the German original. In case of any discrepancy, the German version is valid only. Page 1 of 2
 Annex to the EC Type-Examination Certificate
No. EU-BD 881 of 2016-03-18

2 Conditions
2.1 Above mentioned safety component represents only a part at the protection device against over-
speed for the car moving in upwards direction and unintended car movement. Only in combination
with a detecting and triggering component in accordance with the standard (two separate compo-
nents also possible), which must be subjected to an own type-examination, can the system created
fulfil the requirements for a protection device.
2.2 The installer of a lift must create an examination instruction to fulfil the overall concept, add it to the
lift documentation and provide any necessary tools or measuring devices, which allow a safe exami-
nation (e. g. with closed shaft doors).
2.3 The manufacturer of the drive unit must provide calculation evidence that the connection traction
sheave – shaft – brake disc and the shaft itself is sufficiently safe, if the brake disc is not a direct
component of the traction sheave (e. g. casted on). The shaft itself has to be statically supported in
two points.
The calculation evidence must be enclosed with the technical documentation of the lift.
2.4 The setting of the brake torque has to be secured against unauthorized adjustment (e. g. sealing
lacquer).
2.5 The identification drawing no. 5018294 or 5019746 including stamp dated 2016-03-18 shall be in-
cluded to the EU type-examination for the identification and information of the general construction
and operation and distinctness of the approved type.
2.6 The EU type-examination certificate may only be used in combination with the corresponding annex
and enclosure (List of authorized manufacturer of the serial production). The enclosure will be up-
dated immediately after any change by the certification holder.

3 Remarks
3.1 In the scope of this type-examination it was found out, that the brake device also functions as a
brake for normal operation, is designed as a redundant system and therefore meets the require-
ments to be used also as a part of the protection device against overspeed for the car moving in up-
wards direction and as braking element as part of the protection device against unintended car
movement.
3.2 Checking whether the requirements as per section 5.9.2.2 of EN 81-20:2014 (D) have been complied
with is not part of this type examination.
3.3 Other requirements of the standard, such as reduction of brake moment respectively brake force due
to wear or operational caused changes of traction are not part of this type examination.

3.4 This EU type-examination certificate was issued according to the following standards:
 EN 81-1:1998 + A3:2009 (D), Annex F.7 and F.8
 EN 81-20:2014 (D), part 5.6.6.11, 5.6.7.13
 EN 81-50:2014 (D), part 5.7 and 5.8

3.5 A revision of this EU type-examination certificate is inevitable in case of changes or additions of the
above mentioned standards or of changes of state of the art.

Note: The English text is a translation of the German original. In case of any discrepancy, the German version is valid only. Page 2 of 2
 Enclosure to the EU Type-Examination Certificate
No. EU-BD 881 of 2016-03-18

Authorised Manufacturer of Serial Production – Production Sites (valid from: 2016-03-18):

Company INTORQ GmbH & Co. KG

Address Wülmser Weg 5
31855 Aerzen – Germany

Company INTORQ (Shanghai) Co., Ltd.

Address No. 600, Xin Yuan Nan Road
Building no.6 / Zone B
Nan Hui District, Lingang
201306 Shanghai - P.R. China

- END OF DOCUMENT -

Based on: Application form from Co. INTORQ GmbH & Co. KG of 2015-12-02 Page 1 of 1
 setting the standard

INTORQ BFK455-28
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 -

Legend for the product key

INTORQ BFK455
A Product group Brakes
B Product type Spring-applied brake
C Type 455
D Size 28

Not coded: Supply voltage, hub bore, options

INTORQ | BA 14.0196 | 04/2016 2

Identification

Packaging label Example

Manufacturer Type number
Type (see product key) Bar code
Designation
Qty. per box
Rated/holding voltage Rated torque
Rated/holding power Hub diameter Packaging date
Model identification
CE mark
Note

Name plate Example

Manufacturer
CE mark
Type (see product key) EC-type examination identification
Rated/holding voltage Rated/holding power Hub diameter
Type number Rated torque Date of manufacture

Label product traceability Example

Type (see product key)
Type number QR-Code
Serial number
Manufacturer

Notes
The brake is marked with the following labels, which have to be observed:

for the holding voltage for setting the air gap

Lüftspannung DE: Den nach der Erstinstallation eingestellten Luftspalt
Release voltage: 205 V DC nicht verstellen!
Haltespannung: EN: Do not re-adjust the air-gap after the first installation!
Holding voltage: 103 V DC FR: Ne plus regler l‘entrefer après la première installa-
Nur mit BEG-561-255-130 betreiben! tion!
Only use with BEG-561-255-130!
Nr./No. 33000224

INTORQ | BA 14.0196 | 04/2016 3

Document history

Material number Version Description

33000756 1.0 05/2011 TD09 First edition
33000756 1.1 05/2012 TD09 Change in telephone and fax number
Front and back page new
Addition of the EC type test number
Supplemented by chapter “Project planning notes”
Supplemented by chapter “Wear of spring-applied brakes”
33002468 2.0 03/2013 TD09 Amended by new chapter on manual release installation
Tables of dimensions and switching times were changed
Supplement for spare parts list and the spare parts order
33002468 3.0 04/2013 TD09 Limitation of the adjustability
Note on the suppressor circuit added to the “Electrical installation”
chapter
Values for characteristic torque 2x2065 Nm added to “Dimensions”
table
33002468 4.0 01/2015 SC Restructured FM
33002468 4.1 11/2015 SC Changing the model identification test numbers
33002468 5.0 04/2016 SC Updates
Changing the model identification test numbers

INTORQ | BA 14.0196 | 04/2016 4

Contents

1 Preface and general information .......................................................................................................................... 6

1.1 About these Operating Instructions .............................................................................................................. 6
1.2 Terminology used ......................................................................................................................................... 6
1.3 Conventions in use ....................................................................................................................................... 6
1.4 Abbreviations used ....................................................................................................................................... 7
1.5 Safety instructions and notices ..................................................................................................................... 8
1.6 Scope of delivery .......................................................................................................................................... 9
1.7 Disposal ........................................................................................................................................................ 9
1.8 Drive systems ............................................................................................................................................. 10
1.9 Legal regulations ........................................................................................................................................ 10
2 Safety instructions .............................................................................................................................................. 11
2.1 General safety instructions ......................................................................................................................... 11
2.2 Application as directed ............................................................................................................................... 12
3 Technical specifications ..................................................................................................................................... 13
3.1 Product description ..................................................................................................................................... 13
3.2 Rated data .................................................................................................................................................. 16
3.3 Rated data (design data) ............................................................................................................................ 17
3.4 Switching energy / switching frequency ..................................................................................................... 19
3.5 Emissions ................................................................................................................................................... 20
4 Mechanical installation ....................................................................................................................................... 21
4.1 Important notes .......................................................................................................................................... 21
4.2 Necessary tools .......................................................................................................................................... 21
4.3 Assembly .................................................................................................................................................... 22
4.4 Installation .................................................................................................................................................. 23
4.5 Manual release ........................................................................................................................................... 29
4.6 Cover ring assembly ................................................................................................................................... 34
5 Electrical installation ........................................................................................................................................... 35
5.1 Important notes .......................................................................................................................................... 35
5.2 Bridge/half-wave rectifier (optional) ............................................................................................................ 36
5.3 Electrical connection .................................................................................................................................. 38
6 Commissioning and operation ........................................................................................................................... 39
6.1 Important notes .......................................................................................................................................... 39
6.2 Function checks before commissioning ..................................................................................................... 39
6.3 Commissioning ........................................................................................................................................... 40
6.4 During operation ......................................................................................................................................... 41
7 Maintenance and repair ...................................................................................................................................... 42
7.1 Wear of spring-applied brakes ................................................................................................................... 42
7.2 Inspections ................................................................................................................................................. 43
7.3 Maintenance ............................................................................................................................................... 44
7.4 Spare-parts list ........................................................................................................................................... 46
7.5 Ordering spare parts .................................................................................................................................. 47
8 Troubleshooting and fault elimination .............................................................................................................. 48

INTORQ | BA 14.0196 | 04/2016 5

Preface and general information

1 Preface and general information

1.1 About these Operating Instructions

❚ 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.

1.2 Terminology used

Term In the following text used for

Spring-applied brake Electromagnetically Released Spring-Applied Brake
Drive system Drive systems with spring-applied brakes and other drive components

1.3 Conventions in use

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.

INTORQ | BA 14.0196 | 04/2016 6

Preface and general information

1.4 Abbreviations used

Letter symbol Unit Designation

FR N Rated frictional force
I A Current
IH A Holding current, at 20 °C and holding voltage
IL A Release current, at 20 °C and release voltage
IN A Rated current, at 20 °C and rated voltage
MA Nm Tightening torque of fixing screws
Mdyn Nm Braking torque at a constant speed of rotation
MK Nm Rated torque of the brake, rated value at a relative speed of rotation of
100 rpm
nmax rpm Maximum occurring speed of rotation during the slipping time t3
PH W Coil power during holding, after voltage change-over and 20 °C
PL W Coil power during release, before voltage change-over and 20 °C
PN W Rated coil power, at rated voltage and 20 °C
Q J Quantity of heat/energy
QE J Maximally 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 switching, depending on the
switching frequency
RN Ohms Rated coil resistance at 20 °C
Sh 1/h Switching frequency: the number of switching operations evenly spread
over the time unit
Shue 1/h Transition switching frequency, thermal parameter of the brake
Shmax 1/h Maximum permissible switching frequency, depending on the friction
energy per switching operation
sL mm Air gap: the lift of the armature plate while the brake is switched
sLN mm Rated air gap
sLmin mm Minimum air gap
sLmax mm Maximum air gap
t1 ms Engagement time, sum of the delay time and braking torque - rise time
t1 = t11 + t12
t2 ms Disengagement time, time from switching the stator until reaching 0.1 Mdyn
t3 ms Slipping time, operation time of the brake (according to t11) until standstill

INTORQ | BA 14.0196 | 04/2016 7

Preface and general information

Letter symbol Unit Designation

t11 ms Delay during engagement (time from switching 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
reaching the braking torque
tue s Over-excitation time
U V Voltage
UH V DC Holding voltage, after voltage change-over
UL V DC Release voltage, before voltage change-over
UN V DC Rated coil voltage; in the case of brakes requiring a voltage change-over,
UN equals UL

1.5 Safety instructions and notices

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

INTORQ | BA 14.0196 | 04/2016 8

Preface and general information

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.

1.6 Scope of delivery

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

The spring-applied brake consists of different types of material.

❚ Recycle the metal and plastic parts.
❚ Ensure professional disposal of assembled circuit boards according to the applicable environmental reg-
ulations.

INTORQ | BA 14.0196 | 04/2016 9

Preface and general information

1.8 Drive systems

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.

1.9 Legal regulations

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.

INTORQ | BA 14.0196 | 04/2016 10

Safety instructions

2 Safety instructions

2.1 General 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 | BA 14.0196 | 04/2016 11

Safety instructions

2.2 Application as directed

❚ 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!

Usage conditions for the INTORQ spring-applied brake

❚ Humidity: no restrictions
- In the event of condensation or moisture formation: provide for appropriate ventilation to ensure that
all components will dry quickly.
❚ Ambient temperature:
-5 °C to +40 °C
❚ At high humidity and low temperature:
- Take measures to protect the armature plate and rotor from freezing.
❚ Protect the electrical connections against any contact or touching.

INTORQ | BA 14.0196 | 04/2016 12

Technical specifications

3 Technical specifications

3.1 Product description

Versions

Basic module

Fig. 1 Design of a BFK455 spring-applied brake

1.1 Stator 3 Complete rotor 6 Flange

1.2 Pressure springs 4 Hub 8 Coil
2 Armature plate 5 Shaft 13 Cover ring

INTORQ | BA 14.0196 | 04/2016 13

Technical specifications

3.1.1 General information

The spring-applied brake is designed for converting 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 speed
of rotation. The wear increases as the switching energy increases (operating speeds 17).
The BFK455 spring-applied brake is a double-disk brake with four friction surfaces. The braking torque is
applied through two separate braking circuits, both electrical and mechanical, via several compression
springs (1.2) in the form of generated friction. The brake circuits are released electromagnetically. Due to its
division into two brake circuits, the brake is particularly suitable for applications such as lift systems and
stage/platform technology. The brake can be selected based on the rated torque for one brake circuit. The
second brake circuit meets the requirement for redundancy.
The division of the brake circuits is done using two separate armature disks (2) with their corresponding com-
pression springs (1.2) and electromagnetic coils (8). Each brake circuit can be operated individually due to
the separate supply lines for each stator and armature plate ( 36).
Each brake circuit has a micro-switch which monitors the switching state of the spring-applied brake. Using
the associated switching device, the supply voltage (AC voltage) is rectified and, when the brake is released,
lowered after a short period of time. This results in a reduction of the average electrical power of the brake.
The stator (1.1) is supplied in heat class F. The limit temperature of the coils (8) is 155 °C. The BFK455
spring-applied brake is designed for a maximum operating time of 60 % with holding current reduction.

Certificate

Type Characteristic torque EC-type examination certificate

[Nm]
Directive 95/16/EC UCM Directive 2014/33 EU
2 x 1200
BFK455-28 2 x 1700, 2 x 1800 ABV 881/2 ESV 881/2 EU-BD 881
2 x 2065

3.1.2 Brake
During the braking procedure, the pressure 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.

INTORQ | BA 14.0196 | 04/2016 14

Technical specifications

3.1.3 Brake release

When the brakes are applied, an air gap “sL” is present between the stator (1.1) and the armature plate (2).
To release the brake, the coil of the stator (1.1) is energised with the DC voltage provided. The resulting mag-
netic flux works against the spring force to draw the armature plate (2) to the stator (1.1). This releases the
rotor (3) from the spring force and allows it to rotate freely

3.1.4 Release monitoring

The spring-activated brake has a micro-switch for each braking circuit to monitor the switching state. When
the brake is released, the micro-switches toggle. This means that it is possible to prevent the drive from being
operated when the brake is closed. The micro-switches can be connected as both normally open and also
normally closed.
To check that the micro-switches function correctly, we recommend testing the switching status (refer to ta-
ble 6) in both the released and applied braking states.

3.1.5 Encapsulated design (optional)

This design not only avoids the penetration of spray water and dust, but also the spreading of abrasion par-
ticles outside the brake. This is achieved by:
❚ a cover seal over the armature plate and rotor.

3.1.6 Project planning notes

❚ The brakes are dimensioned in such a way that the given rated torques are 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.
❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactivated
regularly.

INTORQ | BA 14.0196 | 04/2016 15

Technical specifications

3.2 Rated data

3.2.1 Dimensions

s LN s LN

Type Rated torque Air gap Permitted Rotor thickness Weight

wear complete
stator

[NM] sLN+0.05 [mm] sLmax. [mm] [mm] min. [mm] max. [mm] m [kg]
2 x 1100
2 x 1200
0.7 0.3 17.7
BFK455-28 2 x 1700 0.4 18 46
2 x 1800
2 x 2065 0.6 0.2 17.8

Type Pitch circle Fixing screws Minimum thread depth Tightening torque
DIN 912

without with without with without with

flange flange flange flange flange flange
∅ [mm] Thread [mm] [mm] [mm] [mm] MA [Nm] MA [Nm]
BFK455-28 314 M16 6 x M16x210 6 x M16x220 25 22.5 206 265
Tab. 1: Dimensions of the BFK455-28

CAUTION

❚ The minimum thread depth of the end shield must be maintained! Tab. 1.
❚ 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!

INTORQ | BA 14.0196 | 04/2016 16

Technical specifications

3.2.2 Electrical data

Type Voltage Power Coil resistance Current

Release ±10% Holding ±10% Brake release Holding
UL [V DC] UH [V DC] PN [W] PH [W] RN ± 5% [] IL [A]
103 52 2 x 24.5 2 x 4.21
BFK455-28 205 103 2 x 434 2 x 108.5 2 x 97 2 x 2.12
360 180 2 x 298.6 2 x 1.21
Tab. 2: Coil power ratings of the BFK455-28

3.3 Rated data (design data)

Fig. 2 Operating/switching times of the spring-applied brakes

t1 Engagement time t11 Reaction delay of 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

INTORQ | BA 14.0196 | 04/2016 17

Technical specifications

Type Rated torque1) Max. Transitional Switching times [ms]2) Max. speed3)
permitted switching at sLN and 0.7 IN
switching frequency
energy
MK QE Shue Engaging DC side4) Disengaging
nmax.
[Nm] [J] [1/h] t11 t12 t1 t2
[rpm]
2 x 1100 80 300 455
370
2 x 1200 60 280 255
BFK455-28 2 x 1700 360000 7 220
20 240 480 455
2 x 1800
2 x 2065 30 250 460 255
Tab. 3: Switching energy - switching frequency - switching times
1)
Minimum brake torque with run-in friction components at Δn=100 rpm
2)
Typical values
3)
Max. speed according to EC-type examination certificate (for higher speeds, consultation with the manufacturer is re-
quired)
4)
Measured with induced voltage limitation of -800 V DC

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: 36
❚ 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).

NOTICE
If the brake is using AC-side switching, the engagement times increase approximately by a fac-
tor of 5 (refer to 35 for connection).

Disengagement time
The disengagement time is the same for DC and AC switching. The specified disengagement times always
refer to control using over-excitation.

INTORQ | BA 14.0196 | 04/2016 18

Technical specifications

3.4 Switching energy / switching frequency

Fig. 3 Switching energy as a function of the switching frequency

A Switching energy Q [J] B Switching frequency Sh [1/h]

 – 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 3). 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.

INTORQ | BA 14.0196 | 04/2016 19

Technical specifications

3.5 Emissions

Electromagnetic compatibility

NOTICE
The user must ensure compliance with EMC Directive 2014/30/EU 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 switching noise during engagement and disengagement varies depending on the air gap, braking torque
and brake size.
Depending on the natural oscillation after installation, operating conditions and state of the friction surfaces,
the brake may squeak during braking.

Miscellaneous
The abrasion of the friction parts produces dust.

INTORQ | BA 14.0196 | 04/2016 20

Mechanical installation

4 Mechanical installation

4.1 Important notes

NOTICE

The toothed hub and screws must not be lubricated with grease or oil.

4.2 Necessary tools

Type Torque wrench Open-jawed spanner

Bit for hexagon socket screws

Measuring range [Nm] Wrench width [mm] Adjustment tubes -

wrench size [mm]
BFK455-28 40 - 400 14 24

Multi-meter Caliper gauge Feeler gauge

INTORQ | BA 14.0196 | 04/2016 21

Mechanical installation

4.3 Assembly

4.3.1 Important notes

Brake size Minimum requirements: Use as counter friction surface

Material1) Evenness Axial Roughness Miscellaneous

[mm] run-out
[mm]

S235 JR ❚ Threaded holes with mini-

28 C15 < 0.1 0.1 Rz10 mum thread depth 16
EN-GJL-250 ❚ Free of grease and oil

Tab. 4: Counter friction face design of the end shield

1)
For other materials, please consult with INTORQ.
The diameter of the shaft shoulder must not be greater than the tooth root diameter of the hub.

4.3.2 Preparation
1. Unpack the spring-applied brake.
2. Check for completeness.
3. Check the nameplate data (especially the rated voltage).

4.3.3 Overview

without separate counter friction face with flange

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Mechanical installation

4.4 Installation

NOTICE

The toothed hub and screws must not be lubricated with grease or oil.

NOTICE
When you have ordered a version with flange, attach the hub first ( 23), then continue with
the “Assembly of the counter friction faces”.

4.4.1 Brake assembly

Mounting the first hub onto the shaft

15

Fig. 4

4 Hub 4.1 Key 15 End shield

1. Insert the key (4.1) into the shaft.

2. Press the first hub (4) onto the shaft.
3. Secure the hub (4) against axial displacement (for example, by using a circlip (4.2)).

NOTICE

For reverse operations, we recommend also glueing the hub to the shaft.

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Mechanical installation

Assembly of the counter friction faces

Flange (option)

15
4

Fig. 5 Assembly of the flange

4 Hub 15 End shield

6 Flange

4. Hold the flange (6) to the end shield (15).

5. Align the through holes in the flange to the threads of the fastening bore holes.
In the following sections, only assembly for the version with flange will be described.

Assembly of the first rotor

15
6
4
3

Fig. 6 Mounting of the rotor

3 Rotor 6 Flange 15 End shield

4 Hub

6. Push the rotor (3) onto the hub (4) and check whether it can be moved by hand.

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Mechanical installation

NOTICE

Only in the case of rotors with mounting paste on their gear 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!

Installation of the second hub onto the shaft

4.1

4 4.2 2.

4.2

1.
5
3.

4.

Fig. 7 Mounting of the second hub

4 Hub 3 Complete rotor 4.2 Circlip

5 Shaft 4.1 Key

7. Insert second key (4.1) into the shaft (5) if required.

8. Press second hub (4) onto the shaft (5).
9. Secure hub (4) against axial displacement, e.g. by using a circlip (4.2).

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Mechanical installation

Assembly of the first stator

Fig. 8 Assembly of the stator

1 Stator, complete 4 Hub 6 Flange

3 Shaft 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

Fig. 9 Mounting of the rotor

1 Stator, complete 4 Hub 15 End shield

3 Complete rotor 6 Flange

12. Push the complete rotor (3) onto the hub (4) and check whether it can be moved by hand.

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Mechanical installation

NOTICE

Only in the case of rotors with mounting paste on their gear 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!

NOTICE
If a manual release is to be installed, the procedure described in section 4.5.2 (Step 2) must be
carried out now!

Assembly of the second stator

15
6
1
3

10

10

10

10

Fig. 10 Assembly of the stator

1 Stator, complete 6 Flange 15 End shield

3 Complete rotor 10 Fixing screws

13. Push the complete stator onto the shaft.

14. Align the through holes in the complete stator (1) to the threads of the fastening bore holes in the first
stator.
15. Evenly tighten the brake with the six socket head cap screws (10) included in the scope of supply in sev-
eral runs using a torque key.
16. Establish the electrical connection and energize the brake ( 35).
17. Use a torque key to re-tighten the supplied fixing screws (10) with the required tightening torque
( 16).
18. Switch off the power.

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Mechanical installation

4.4.2 Check the air gap

DANGER

Danger: rotating parts!

Switch off the voltage. The brake must be free of residual torque.

s LN s LN

Fig. 11 Check the air gap

1. Check the air gap near the screws (10) by means of a feeler gauge. Compare the measured values to
the values for "sLN" in the table ( 16).

NOTICE
Do not insert feeler gauge more than 10 mm between armature plate (2) and stator (1.1)!

If the measured value “sL” is outside the tolerance of “sLN”, set the dimension:

Fig. 12 Adjusting the air gap during the initial installation

2. Loosen the bolts (10).

NOTICE
First correctly adjust the air gap with every 2nd bolt (10) / sleeve bolt (9)! The other three sleeve
bolts should be screwed into the stator so that they do not touch the flange or the bearing
shield. Then repeat the process with the other three bolts (10).

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Mechanical installation

3. Slightly turn the sleeve bolts (9) using an open end spanner.
- If the air gap is too large, screw into the stator (1.1).
- If the air gap is too small, screw them out of the stator (1.1).
- A 1/6 turn will change the air gap by approximately 0.15 mm.
4. Tighten the screws (10) (for torques, see table 16).
5. Check the air gap “sL” near the screws (10) using a feeler gauge, (“sLN” 16).
6. Repeat the adjustment procedure if the deviation of “sLN” is too large.

4.5 Manual release

NOTICE
❚ The manual release is designed for activation via a Bowden cable.
❚ For activation without a Bowden cable, the lever has to be extended.
❚ An individual brake circuit can only be released electrically.

The manual release is mounted when the double-spring-applied brake is installed. No power is applied to
the brake.
1. Mount the first rotor (3), the first complete stator (1), and the second rotor (3A) according to section 4.4.1,
steps 1 through 12 ( 23 and 26).

4.5.1 Components of the manual release

12.8A
12.5
12.14

12.8

12.11

12.1

Fig. 13 Manual release

12.1 Manual release lever 12.8 Lock nut 12.14 Tension rod
12.5 Pressure spring 12.11Clip

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Mechanical installation

4.5.2 Installing the manual release

15
1
3A

1A

12.1

Fig. 14 Applying the manual release lever

2. Put both levers completely (12.1) onto the second stator (1A). To do this, push in the plates' pins into
the corresponding holes of the stator (using a suitable tool).

NOTICE
The plates are not symmetric. The pin with the greater distance from the axis of rotation must
be oriented towards the outside. The lever must also face outwards.

12.14
12.11 12.5
12.8
1A
12.5
12.14

Fig. 15 Installation of the tension rods

3. Assemble four pre-assembled tension rods (12.14) with one spring (12.5) each
Carry out steps 4 and 5 separately for each side of every lever.

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Mechanical installation

4. From the armature plate end, plug one pair of pre-assembled tension rods (12.14) each into the provided
bore holes (Ø11 mm) of the complete stator (1A). Insert the springs (12.5) of the tension rod into the
clearing hole of the armature plate (Ø16.5 mm) in the process.

Fig. 16 Assembly parts

5. Attach the clips (12.11) with the bore holes (Ø12 mm) to the tension rods (12.14) and tighten them with
the lock nuts (12.8). The blind holes (Ø17 mm) are now pointing in the direction of the stator and the
screw heads of the manual release levers are completely sunk into the clips (12.11).
6. Position the second complete stator (1A) in front of the complete stator (1). Insert the pre-assembled
tension rods (12.14) into the through holes (Ø12 mm) of the first complete stator (1) in the process.

NOTICE

Tension rods must not be bent!

Fig. 17 Pre-assembly of the brake with manual release on the motor

7. Screw four lock nuts (12.8A) between the motor end shield and the complete stator (Pos.1) onto the ten-
sion rods (12.14) up to the point where the back side of the lock nut aligns with the top of the tension rod.
8. Evenly tighten the brake with the six socket head cap screws (10) included in the scope of supply in sev-
eral runs using a torque key (as shown in Figure 17).

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Mechanical installation

9. Establish the electrical connection and energize the brake ( 35).

10. Use a torque key to re-tighten the supplied fixing screws (10) with the required tightening torque
( 16).
11. Switch off the power.

4.5.3 Checking the air gap

Fig. 18 Checking the air gap

12. Check the air gap using a feeler gauge and correct it if necessary (sLN = 0.4 +0.05 mm) according to
Figures 11 and 12.

4.5.4 Setting the manual release

NOTICE

For setting the manual release, always lock the pre-assembled hexagon nut of the tension rod
(12.14) against rotation and rotate the lock nuts at the ends of the tension rod only.

Carry out steps 13 and 14 separately for each side of every lever
13. Tighten the lock nuts (pos. 12.8) on the clips (12.11) evenly until the nuts of the tension rod are in contact
with the armature plate of the second stator (1A) (there should be noticeable resistance). While tighten-
ing, make sure that the clips (12.11) are parallel to the rear of the stator (1A). (Check using a caliper
gauge.) If there are dimensional differences where X > 0.1 mm (see Figure 19), this should be corrected
by loosening the lock nut (12.8) at the smaller dimension and tightening the lock nut (12.8) at the larger
dimension until the clips (12.11) are adjusted in parallel to the back of the brakes (as shown in Figure
19).
14. Evenly tighten the lock nuts on the motor end shield side up to the point where the nuts of the tension
rod are in contact with the armature plate of the first stator (1) (tangible resistance).
15. Loosen the lock nuts (12.8) at the clips (12.11) by a ¾ revolution (270°).
Carry out steps 16 and 17 separately for each side of every lever.

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Mechanical installation

Fig. 19 Test dimensions and reference dimensions

16. Check of the correct setting (nominal dimension 1.05 ... 1.15 mm):
- For this purpose, position two feeler gauges of the same thickness (e.g. 1.1 mm) for each tension
rod between 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 that the manual release functions properly. Attach pipe sections onto the levers and press them
together to check whether the motor shaft can rotate freely.
19. Connect the Bowden cable (not included in this delivery) and pull until the motor shaft can be freely ro-
tated.

NOTICE
The actuation force between the Bowden cable's hanging points is approximately 900 N. The
actual pull force required may be higher depending on the characteristics and position of the
cable.

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Mechanical installation

4.6 Cover ring assembly

NOTICE

Brakes without flange require a groove at the end shield for the lip of the cover seal.

Fig. 20 Cover ring assembly

1 Stator, complete 6 Flange 13 Cover ring

1. Disconnect 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) and flange (6) / end
shield.
5. Press the lips of the second cover ring into the groove of the first and second complete stator (1).
6. Re-establish the electrical connection.

NOTICE

Cover ring with condensation drain hole:

Attach the cover ring so that condensation can drain through the hole.

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Electrical installation

5 Electrical installation

5.1 Important notes

DANGER

There is a risk of injury by electrical shock!

❚ The electrical connections must only be made by skilled personnel!
❚ Only carry out connection work when no voltage is applied (no live parts)! There is a risk of
unintended start-ups or electric shock.

NOTICE

❚ Make sure that the supply voltage corresponds to the data on the nameplate.
❚ Voltages must be adjusted to the local environment!

NOTICE

❚ 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

❚ To functionally test the individual brake circuits, the power supply must be able to be
switched off individually. For a new over-energizing during switch-on, it is also necessary
to open switches K1/K3.
❚ The protective circuitry contained in the INTORQ switching device BEG-561- -
(terminals 3 and 4) is not permitted for use in the lift system. The protective circuitry
must be connected parallel to the brake coil ( 36).

NOTICE

❚ Only operate the brake with a holding current reduced to 25 % of Pmax !

❚ You can use the INTORQ switching device BEG-561- - for this purpose.

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Electrical installation

5.1.1 Switching suggestions

230 V AC or 400 V AC

Brake circuit 1 Brake circuit 2

observe the observe the

polarity polarity

Suppressor Suppressor
circuit circuit

Brake Brake

Fig. 21 INTORQ BFK455 connection diagram

Switching on
❚ K2/K4 must be switched on before or at the same time as K1/K3!
Switching off
❚ Normal - AC switching
- K2/K4 remain closed
- K1/K3 open
❚ Emergency stop - DC switching
- K1/K3 and K2/K4 are opened at the same time

NOTICE
Recommended current load for the micro-switches
❚ 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 switching times ( 17).

5.2 Bridge/half-wave rectifier (optional)

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.

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Electrical installation

5.2.1 Assignment: Bridge/half-wave rectifier - brake size

Rectifier type Supply voltage Coil voltage Assigned brake

Release / holding
[V AC] [V DC]
BEG-561-255-130 230 ±10% 205 / 103 BFK455-28 (205 V)
BEG-561-440-130 400 ±10% 360 / 180 BFK455-28 (360 V)

5.2.2 Technical specifications

Rectifier 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 voltage U1

Max. current Imax Over-excitation time tue (± 20%)
(40 Hz ... 60 Hz)
Min. Rated max. Bridge half-wave at U1 min at U1 Nom at U1 max
[V ~] [V ~] [V ~] [A] [A] [s] [s] [s]
BEG-561-255-130 160 230 255 3.0 1.5 1.870 1.300 1.170
BEG-561-440-130 230 400 440 3.0 1.5 2.300 1.300 1.200
Tab. 5: Data for bridge/half-wave rectifier type BEG-561

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Electrical installation

5.2.3 Permissible current load at ambient temperature

1 For screw assembly with metal surface (good heat dissipation)

2 For other assembly (e.g. adhesive)

5.3 Electrical connection

DANGER

There is a risk of injury by electrical shock!

The brake must only be electrically connected when no voltage is applied!

NOTICE
Compare the coil voltage of the stator to the DC voltage of the installed rectifier.

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Commissioning and operation

6 Commissioning and operation

6.1 Important notes

DANGER

❚ The live connections and the rotating rotor must not be touched.
❚ The drive must not be running when checking the brake.

6.2 Function checks before commissioning

6.2.1 Functional checks

Brake with micro-switch

DANGER

Danger: rotating parts!

The brake must be free of residual torque. The motor must not run!

DANGER

There is a risk of injury by electrical shock!

Live connections must not be touched.

1. The switching contact for the brake must be open.

2. Remove two bridges from the motor terminals to de-energise the motor.
- Do not switch off the voltage supply to the brake.

NOTICE

If the brake is connected to the neutral point of the motor, the PE conductor must also be con-
nected to this point.

3. Apply DC voltage to the brake.

4. Measure the AC voltage at the motor terminals. The measured level must be zero.
5. Close the switching contact for the brake.
- The brake is released.

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Commissioning and operation

6. Measure the DC voltage at the brake:

- The measured DC voltage after the over-excitation time (see bridge/half-wave rectifier, 36)
must correspond to the holding voltage (see table 5). A deviation of ±10 % is permissible.
7. Check the air gap “sL”.
- It must be zero and the rotor must rotate freely.
8. Check the switching status of the micro-switch (see table 6).
9. Open the switching contact for the brake.
- The brake is applied.
10. Check the switching status of the micro-switch (see table 6).
11. Switch off DC voltage for the brake.
12. Screw the bridges onto the motor terminals.
13. If necessary, remove the neutral conductor from the neutral point (step 2).

Contact type Connection Brake released Micro-switch closed

yes no
NC contact black / grey
no yes
yes yes
NO contact black / blue
no no

Tab. 6: Switching status of the micro-switch

The preparations for commissioning are completed.

6.3 Commissioning

1. Switch on the drive system.

2. Carry out a braking test.

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Commissioning and operation

6.4 During operation

DANGER

Danger: rotating parts!

The running rotor must not be touched.

DANGER

There is a risk of injury by electrical shock!

Live connections must not be touched.

❚ Checks must be carried out regularly. Pay special attention to:

- unusual noises or temperatures
- loose attachment elements
- the condition of the electrical cables
❚ The armature plate must be tightened and the rotor must move without residual torque.
❚ Measure the DC voltage at the brake.
- The measured DC voltage after the over-excitation time (see bridge/half-wave rectifier, 36)
must correspond to the holding voltage (see table 5). A deviation of ±10 % is permissible.
❚ If faults occur once, go through the troubleshooting table in chapter 8. If the fault cannot be fixed or elim-
inated, please contact your customer service.

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Maintenance and repair

7 Maintenance and repair

7.1 Wear of spring-applied brakes

INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The friction
lining and braking mechanism are subject to operational wear. For safe and trouble-free operation, the brake
must be checked at regular intervals or replaced, if necessary 43.

NOTICE

The air gap must not be re-adjusted after it has been correctly adjusted during the initial
installation of the brake on the motor! This could result in a loss of braking torque.

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.

Component Cause Effect Influencing factors

Friction lining Braking during operation Wear of friction lining Friction work
Emergency stops
Overlapping wear during start and
stop of drive
Active braking via the drive motor
with support of brake (quick stop)
Starting wear in case of motor Number of start-stop
mounting position with vertical shaft, cycles
even when the brake is not applied
Armature plate and Rubbing of brake lining Armature plate and flange Friction work
flange are run in
Gear teeth of brake Relative movements and shocks Wear of gear teeth (primarily Number of start-stop
rotor between brake rotor and brake shaft on the rotor side) cycles
Brake support Load reversals and jerks in the back- Breaking of armature plate Number of start/stop
lash between the armature plate and and guide pins cycles, braking torque
guide pins
Springs Axial load cycle and shear stress of Reduced spring force or Number of switching oper-
springs through radial backlash on fatigue failure ations of brake
reversal of armature plate

Tab. 7: Causes for wear

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Maintenance and repair

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.

7.2.1 Maintenance intervals

Type Time interval

for service brakes: for holding brakes with emergency stop:

BFK455-28 ❚ according to service life calculation ❚ at least every two years
❚ or else every six months ❚ after 1 million cycles at the latest
❚ after 4000 operating hours at the latest

Maintenance

Inspections with assembled brake: Inspections after the brake has been
removed:
❚ Check release function and 44 ❚ Check the play of the rotor 45
control gear teeth (replace worn-out
rotors)
❚ Measure the air gap 45 ❚ Check for breaking out of the
torque support at the sleeve
bolts and the armature plate
❚ Measure the rotor thickness 45 ❚ Check the springs for damage
(replace rotor if required)
❚ Check for thermal damage ❚ Check the armature plate and
of the armature plates or flange or bearing shield
flange (dark-blue - Levelness < 0.1 mm
tarnishing) - Max. run-in depth = rated
air gap for the size

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Maintenance and repair

7.2.2 Release / voltage

1. Start motor and control system!

DANGER

Danger: rotating parts!

The running rotor must not be touched.

DANGER

There is a risk of injury by electrical shock!

Live connections must not be touched.

2. Observe the air gap “sL” when the drive is running. It should be zero.
3. Measure the DC voltage at the brake.
- After the over-excitation time (see bridge/half-wave rectifier, 36), the measured DC voltage
must correspond to the holding voltage ( 37). A deviation of ±10 % is permissible.

7.3 Maintenance

NOTICE
Brakes with defective armature plates, socket head cap screws, springs or counter friction
faces must always be replaced completely. Observe the following for inspections and mainte-
nance 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 oper-
ation for the friction surfaces has been completed. After replacing the rotor, the run-in arma-
ture plates and counter friction faces have an increased initial rate of wear.

7.3.1 Check the rotor thickness

DANGER

Danger: rotating parts!

The motor must not run during the check.

1. Stop the motor and control system!

2. Remove the motor cover and remove the cover ring, if present.
3. Measure the rotor thickness using a caliper gauge.
4. Compare the measured rotor thickness with the minimally permissible rotor thickness, 16.
5. If required, replace the rotor completely ( 45).

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Maintenance and repair

7.3.2 Check the air gap

DANGER

Danger: rotating parts!

The motor must not run during the check.

1. Stop the motor and control system!

2. Measure the air gap “sL” near the fixing screws between the armature plate and the stator using a feeler
gauge.
3. Compare the measured air gap with the maximum permitted air gap “sLmax” ( 16).
4. If required, replace both rotors completely.

7.3.3 Replacing the rotor

DANGER
Danger: rotating parts!
The brake must be free of residual torque.

1. Switch off voltage!

2. Disconnect the connection cable.
3. Loosen the screws evenly and remove them completely.
4. Remove the complete stator from the bearing shield. Pay attention to the connection cable.
5. Pull the complete rotor from the hub.
6. Check the gear teeth of the hub.
7. Replace the hub if it is worn.
8. Check the friction surface on the bearing shield. In case of strong scoring at the flange, replace the
flange. In case of strong scoring on the bearing shield, rework the friction surface.
9. Measure the rotor thickness (new rotor) and head height of the sleeve bolts with a caliper gauge.
10. Calculate the distance between the stator and the armature plate as follows:
Distance = rotor thickness + sLN - head height
(“sLN” 16)
11. Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is
reached.
12. Install and adjust the new complete rotor and stator ( 23).
13. Reconnect the connection cable.

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Maintenance and repair

7.4 Spare-parts list

❚ Only parts with item numbers are available.

- The item numbers are only valid for the standard design.
❚ Please include the following information with the order:
- Order number of the brake
- Position number of the spare part

Fig. 22 BFK455-28 spring-applied brake

Item Designation Variant

1 Stator, complete Voltage
3 Complete rotor
Rotor, complete noise-reduced
4 Hub Bore diameter
6 Flange
10 Fixing screws for mounting to the motor
Socket head cap screw set, DIN912 for flange with through hole
12 Complete manual release
13 Cover ring

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Maintenance and repair

7.5 Ordering spare parts

Stator, complete

Size 28

Voltage 103 V / 52 V 205 V / 103 V 360 V / 180 V

Braking torque Nm (see torque gradation)

Cable length Standard (1000 mm)

Armature plate Standard

Micro-switch Monitoring the switching function

Components

Rotor Aluminium Noise-reduced (rotor with sleeve)

Hub mm (for hole diameter, see dimensions)

Fixing screw set For mounting

For mounting with flange
Counter friction face Flange

Seal Cover ring

Complete manual release

Electrical accessories
Rectifier type: Selection see chapter 5.2.1

Rectifier BEG-561-255-130
BEG-561-440-130

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Troubleshooting and fault elimination

8 Troubleshooting and fault elimination

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.

Fault Cause Remedy

Brake cannot be Coil interruption ❚ Measure the coil resistance using a multimeter:
released, air gap is - If resistance is too high, replace the complete stator.
not zero Coil has contact to ❚ Measure coil resistance with multimeter:
earth or between wind- - Compare measured value with rated resistance.
ings - Values: 17
- If resistance is too low, replace the complete stator.
❚ Check coil for short circuit to ground using a multimeter:
- Replace the complete stator if short circuit to ground is detected.
❚ Check brake voltage (see “defective rectifier, voltage too low”).
Wiring defective ❚ Check and correct.
or incorrect - Check cable for continuity using a multimeter:
❚ Replace the complete stator if a cable is defective.
Defective or incorrect ❚ Measure rectifier DC voltage using a multimeter.
rectifier If DC voltage is zero:
❚ Check AC rectifier voltage. If AC voltage is zero:
- Switch on power supply.
- Check fuse.
- Check wiring.
If AC voltage is OK:
- Check rectifier.
- Replace the defective rectifier.
If DC voltage is too low:
- Check rectifier.
- If diode is defective, use a suitable new rectifier.
❚ Check coil for inter-turn fault or short circuit to ground.
❚ If the rectifier defect occurs again, replace the entire stator, even if you
cannot find any fault between turns or short circuit to ground. The fault
may occur later during heating-up.
Incorrect micro-switch Check the wiring of the micro-switch and correct it.
wiring
Micro-switch incor- Replace the complete stator and make a complaint about the setting of
rectly set the micro-switch
to the manufacturer.
Brake cannot be Air gap “sL” is too large ❚ For adjustable brakes:
released, air gap is - Readjust air gap.
not zero ❚ For non-adjustable brakes:
- Replace all rotors.

INTORQ | BA 14.0196 | 04/2016 48

Troubleshooting and fault elimination

Fault Cause Remedy

Rotor cannot rotate Air gap “sL” too small Readjust the air gap “sL” ( 28).
freely
Rotor thickness too Rotor has not been Replace the rotor ( 45).
small replaced in time
Voltage is not zero Incorrect micro-switch Check and correct the wiring of the micro-switch.
during functional wiring
test (6.2.2 or 6.2.3) Micro-switch defective Replace the complete stator and return the defective complete stator to
or incorrectly set the manufacturer.
Voltage too high Brake voltage does Adjust rectifier and brake voltage to each other.
not match the rectifier
Voltage too low Brake voltage does Adjust rectifier and brake voltage to each other.
not match the rectifier
Defective rectifier Replace defective rectifier with a suitable undamaged one.
diode
AC voltage is not Fuse is missing or Select a connection with proper fusing.
mains voltage defective
Incorrect micro-switch Check and correct the wiring of the micro-switch.
wiring
Micro-switch defective Replace the complete stator and return the defective complete stator to
or incorrectly set the manufacturer.

INTORQ | BA 14.0196 | 04/2016 49

Notes

Notes

INTORQ | BA 14.0196 | 04/2016 50

  INTORQ GmbH & Co KG
Germany
PO Box 1103
D-31849 Aerzen
Wülmser Weg 5
D-31855 Aerzen
 +49 5154 70534-444
 +49 5154 70534-200
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 ᓊᤉḥ࡬ࣞಞ δр⎭εᴿ䲆䍙Ա‫ޢ‬ਮ
INTORQ (Shanghai) Co., Ltd.
р⎭ᐸ⎜ђ᯦॰⌛ค䭽᯦‫ݹ‬঍䐥  ਭ
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No. 600, Xin Yuan Nan Road,
Building No. 6 / Zone B
Nicheng town, Pudong
201306 Shanghai
 +86 21 20363-810
 +86 21 20363-805
 [email protected]

 INTORQ US Inc.
USA
300 Lake Ridge Drive SE
Smyrna, GA 30082, USA
 +1 678 236-0555
 +1 678 309-1157
 [email protected]

 INTORQ India Private Limited

India
Plot No E-7/3
Chakan Industrial Area, Phase 3
Nighoje, Taluka - Khed
33002468 | BA 14.0196 | EN | 5.0 | © 04/2016 | SC |

Pune, 410501, Maharashtra

 +91 2135625500
 [email protected]

www.intorq.com