Ba WSG-S1.2-3 v17 EN

EN
Gearless Lift Machine Code GM.8.003277.EN

Date 22.09.2016
WSG-S1.2/3 Version 0.17
Operating Instructions Page 1
Gearless Lift Machines
servogearless
WSG-S1.2
WSG-S1.3
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
Date 22.09.2016
These operating instructions are

applicable to lift machines:
WSG - S1.2 - ....

WSG - S1.3 - ....
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 com-
pleteness 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

EN
Date 22.09.2016
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.3. Speed/Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2.4. Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5. Commissioning ..................................................................................................................................17
6. Operation and maintenance ..........................................................................................................18
6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.3. Regreasing the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.4. Replacing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.5. Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.6. Testing the brake system to EN 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.7. Replacing the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.8. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
7. Type code .............................................................................................................................................24
8. Technical data ....................................................................................................................................25
9. Dimension drawing............................................................................................................................26
10. Accessories ..........................................................................................................................................27
10.1. Connecting cable for measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.2. Cable set for motor and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
10.3. Brake manual release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
10.4. Rope guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
10.5. Brake voltage 24 /12 V DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
11. Spare parts .........................................................................................................................................31
Annex
EU Declaration of Conformity
Calculation of the traction sheave shaft WSG-S1
Traction sheave shaft WSG-S1
Calculation of the traction sheave shaft WSG-S1 (traction sheave: 160 mm)
Traction sheave shaft WSG-S1 (traction sheave: 160 mm)
EU type-examination certificate EU-BD 863
Brake operating instructions

EN
Date 22.09.2016
1. General information
1.1. About this operating manual
The purpose of this operating manual is to ensure that any work on WSG-S1 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-S1 lift machines must have read and understood this operating manual.
1.2. Intended use

WSG-S1 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-S1 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-S1 lift machine
• Improper installation, commissioning, operation or maintenance
• Operation of the WSG-S1 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-S1
• 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-S1 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-S1 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.

EN
Date 22.09.2016
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.

EN
Date 22.09.2016
3. Product overview
3.1. Product description
The compact gearless WSG-S1 synchronous lift machines are designed for traction sheave lifts. They are distin-
guished by their high efficiency, extremely low noise and excellent operating characteristics.
The machines can be supplied for several rated speeds, which can be further adapted to meet individual cus-
tomer requirements. 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

Item Part WSG-S1

1 Bolts (3x) M 8x25-8.8
2 Lock washers (3x) NL 8-DIN 25201
3 Pressure disc
4 Bolts (2x) DIN 912 - M8x20
5 Rope slip-off guard
6 Washers (2x) DIN 125 - A 8,4
7 Traction sheave
8 Frame
9 Brake BFK 464-19S
10 Bolts (6x) DIN 912 M10x110
11 Locking ring DIN 471 - 48x1,75
12 Plug-in shaft
13 Screws (3x) DIN 912 - M4x10
14 Clamping sleeve
15 Screws (4x) DIN 912 - M6x16
16 Measuring system
17 Cylinder-head screw DIN 912 M5x50

EN
Date 22.09.2016
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.
• Do not expose the motor to any shocks or impact.
• Check that the eyebolts are tightly fitted before using them.
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. The ropes must not be fitted.
• 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).
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.

EN
Date 22.09.2016
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 4 M 20 bolts - strength class 8.8; tightening torque: 380 Nm .
• 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.

EN
Date 22.09.2016
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
• The torque and power values indicated in the technical Altitude < 1000 m
data apply to the above ambient temperatures and 0,7
Altitude < 2000 m
altitudes. In the case of a deviating altitude and/or Altitude < 3000 m
temperature, the reduction factors k shown in the dia-

gram "Ambient conditions" must be used. 0,6
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
CAUTION 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
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.

EN
Date 22.09.2016
4.2.2. Motor connection / Winding protection

• The electrical connection of the motor and the winding sensors is made in the terminal box, by power con-
nector or by cable (standard length: 5 m).
• 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 PTC resistor embedded in the winding must be evaluated in an appropriate manner in the control system
or the frequency inverter to protect the motor from overheating.
Screw plugs 2 x M 16 and 1 x M 20
2 x M 16 Cable gland
for cable diameter 5-10 mm
1. Terminal box
M 20 Cable gland
WAGO 262
Triplet PTC Cable cross-section: ... 4 mm2
M Type STM-150.DS... Stripping length required: 9-10 mm
As an option, the electrical connection of the

Pin Signal motor and the winding temperature sensors
1 U1 is made by a rotatable 8-pole power connec-
2. Plug connection
D tor provided on the motor. A type B ST A 078

2 PE C 3
FR 05 08 0035 000 connector from
3 W1 B 4 2
"intercontec" can be used, for example, as
A 1 the female plug.
4 V1
A not assigned
B not assigned
C temperature Pin contacts of flanged

sensor connector socket
D temperature (exterior)
sensor

EN
Date 22.09.2016
Core marking
shield
3. Cable connection
PE green/yellow
U1 U1 / 1
M V1
V1 / 2
W1 / 3
W1
T1 T1 / 5 / BR1
T2 T2 / 6 / BR2
triplet PTC
Ferrules
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.
2.5 mm2 22.6 A 35.7 A
4.0 mm 2 29.6 A 46.7 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.

EN
Date 22.09.2016
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

CAUTION synchronous motor (WSG) is matched to the associated
inverter. Do not change the adjustment, as this may
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 -

EN
Date 22.09.2016
4.2.4. Brake
• Please 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 acti-
vation.
• 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 16!)
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!

EN
Date 22.09.2016
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
terminal box, by power connector or by cable (standard length: 5 m).
Screw plugs 2 x M 16 and 1 x M 20
2 x M 16 Cable gland
1st. partial 2nd. partial M 20 Cable gland

brake brake for cable diameter 7-12 mm
1. Terminal box
black
grey
blue
black
grey
blue
WAGO 262
Cable cross-section: ... 4 mm2
NC
NO
NC
NO
Stripping length required: 9-10 mm

C
„release“ 1st. partial brake „release“ 2nd. partial brake
Option: terminal box

without brake control
unit

EN
Date 22.09.2016
As an option, the electrical connection

of the brake made by a 9-pole power
connector mounted on the brake. A
type B ST A 908 FR11 85 001A 000
connector from "intercontec" can be
used, for example, as the female plug.
2. Plug connection
PIN
1st. partial brake black
1
blue
2
2nd. partial brake black
3 3 1
E 2 E
grey A A
1st. partial brake blue D B
B C
black
C
blue
2nd. partial brake grey
D
E
Core marking
1st. partial brake black
1
3. Cable connection
blue
2
2nd. partial brake black
3
1st. partial brake

grey 4
blue
5
black
6
blue
2nd. partial brake grey
7
8
Ferrules

Circuitry suggestion for brake control WSG-S1.2/3
WSG-S1/S2
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
Brake connector
230 V ±10%
40...60 Hz
S10 K275
6-
2
5+
K1 Brake magnet
4 u
3
3
to the 2nd. partial brake grey Brake monitoring
2~ NC
E C
intorq
BEG-561...
1~ NO
D blue
C black
release
{
Circuitry suggestion for brake control WSG-S1
Brake connector
to control cabinet
1st. Partial brake
AC side switching and separate control of

the partial brakes
Brake connector
S10 K275
6-
2
5+
Brake magnet
K1 4 u
3
3
to the 2nd. partial brake
2~ grey NC Brake monitoring
intorq
BEG-561...
E C
1~ blue NO 2 x Overexcitation rectifier
D
black (Must be installed in the
release
{ C
contol cabinet.)
to control cabinet
1st. Partial brake
Date
Page
Code
Version
EN
16
0.17
22.09.2016
GM.8.003277.EN
Subject to changes without notice !

EN
Date 22.09.2016
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.

EN
Date 22.09.2016
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

EN
Date 22.09.2016
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 8) • 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.
• Relieve the load on the traction sheave; remove the 1
ropes.
• Support the traction sheave by means of a hoisting
gear.
• Remove the three M 8 bolts (1) at the pressure disc and
the pressure 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 4-7 mm spacer (4) between the pressure disc
and the shaft journal. 4
• Pull off the traction sheave from the tapered shaft
seats by tightening the bolts evenly. 3
Assembly
• Clean the traction sheave and the motor shaft.
5
• Support the traction sheave by means of a hoisting
gear.
• Insert the feather key (5) into the shaft end.
3
• Slide the traction sheave onto the motor shaft.
• Fit the pressure disc (3) to the traction sheave and fas- 6
ten it using three pairs of NORD-LOCK washers (6) and
M 8 bolts (1). Tighten the bolts alternately around the 1
circle in three torque steps (10, 20 and 25 Nm) as far as
they will go. Tightening torque: 25 Nm
• Replace the ropes and reinstall the rope slip-off guard.

EN
Date 22.09.2016
6.5. 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
Eyebolts
~ 800 N
Lever extension
Release
• 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!

EN
Date 22.09.2016
6.6. 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.

EN
Date 22.09.2016
6.7. 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.

EN
Date 22.09.2016
6.8. 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
• Converter parametrisation incorrect • Check inverter parametrisation
• EMC disturbance • Carry out shielding and earthing mea-
sures as described by the inverter man-
• Measuring system offset angle in- ufacturer
correctly set • Check measuring system offset angle
• Measuring system defective
• Replace measuring system
Motor noise • Bearing defective • Notify customer service

• Converter 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

EN
Date 22.09.2016
7. Type code
Example: W S G- S1 . 3 - 0 E 15 / 24A - DF
W S G- Z1 Z2 . Z3 - X1 X2 X3 X4 / X5 X6 X7 - X8 X9
Customer specific
identifier
S = Synchronmotor
G = gearless
Z1 Z2: Frame size
Z3: Overall length:

2 overall lengths are available;
identified by: 2, 3
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. 10: 100 min-1 (with DT = 240 mm v = 0.63 m/s; suspension 2:1)
15: 159 min-1 (with DT = 240 mm v = 1.0 m/s; suspension 2:1)
25: 255 min-1 (with DT = 240 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
DF: dual-curcuit brake; measuring system ECN 413-2048 incr. - ENDAT-interface
DG: dual-curcuit brake; measuring system ERN 487-2048 incr.

EN
Date 22.09.2016
8. Technical data
Duty type: S3 - 40 % ED
Traction sheave: dia. 210 mm, dia. 240 mm or dia. 320 mm Dual-circuit fail-safe brake
Traction sheave hard- mind. 220 HB 30 Type: BFK 464-19S
nesse: formbeständige Keilrille HRC 55
Max. braking torque: 2 x 280 Nm
Typical number of carry- 8 x dia. 6,5 mm oder
ing ropes and dia.: 6 x dia. 8 mm
Air gap sB: 0,4± 0,05 mm (new air gap)
DE bearing self-aligning roller bearing
Max. air gap sB max: 0,6 mm
NDE bearing: ball bearing Holding voltage: 103 V DC
Drive motor: synchronous motor Holding current: 2 x 0,6 A
perm. shaft load: 16 ... 20 kN Overexcitation voltage: 205 V DC
Number of pole pairs: 8 Overexcitation current: 2 x 1,2 A
Thermal class: 155 (F)
Brake control units
Degree of protection: IP 33
BEG-561-255-130 from Intorq
Overload capability: 2,5-fold (Imax/IN) Type:
GmbH (accessories)
Winding protection: triple PTC 150°C Operating voltage UN = 230 V AC ( ± 10 %), 40... 60 Hz
Site conditions Dimensions: 52 x 22 x 38 (w x h x l)
max. 1,000 m
Max. altitude:
(derating required at higher altitudes) Brake monitoring contacts
Ambient temperature: -5°C ... +40°C Contact rating 12 - 30 V DC / 0,01 - 0,1 A
85 % at 20°C Min. contact current 10 mA
Max. rel. humidity:
(no moisture cendensation) Mechanical life of contacts: 2x 106 switching operations
The table is applicable to an overall shaft efficiency of approx. 73..85 % (counterweight:

*) Reference values. Achievable nominal load 50 %). It lists a standard selection of machines. The lift and project data will be adapted to
depends on specific lift system data. actual site conditions and may deviate from the above values.
motor WSG-S1.2 WSG-S1.3

torque S3-40%, 240 S/h MN [Nm] 170 230
max. torque Mmax [Nm] 425 575
traction sheave Æ DT [mm] 240 320 240 320
for loads *) Q [kg] up to 480 up to 360 up to 630 up to 480
suspension table applies for 2:1
v nN PN IN nN PN IN nN PN IN nN PN IN
[m/s] [rpm] [kW] [A] [rpm] [kW] [A] [rpm] [kW] [A] [rpm] [kW] [A]
0,5 80 1,4 6,1 60 1,1 6,1 80 1,9 6,8 60 1,4 5,6

Motor currents applicable to
500 ... 620 V DC link 0,63 100 1,8 6,1 75 1,3 6,1 100 2,4 7,6 75 1,8 6,8
voltage (serie „ECO“)
1,0 159 2,8 8 119 2,1 6,9 159 3,8 10,4 119 2,9 9,4
1,6 255 4,5 11,6 191 3,4 9,2 255 6,1 14,5 191 4,6 11,4
1,75 209 3,7 10 209 5 12,5

EN
Date 22.09.2016
9. Dimension drawing
232
motor WSG- S1.2 S1.3

Æ DT 160 210 240 320 160 210 240 320
BT 130 120 92 105 130 120 92 105
L 548 525 510 510 548 525 510 510 *) Reference values. Achievable nominal load
C 118,5 99 86,5 91,5 118,5 99 86,5 91,5 depends on specific lift system data.
weight mG [kg] 145,5 141 141 150 145,5 141 141 150
The table is applicable to an overall shaft efficiency of approx. 73..85 %
inertia JG [kgm2] 0,16 0,19 0,21 0,43 0,19 0,22 0,24 0,46 (counterweight: 50 %). It lists a standard selection of machines. The
lift and project data will be adapted to actual site conditions and may
shaft load up to FS [kN] 16 20 20 20 16 20 20 20 deviate from the above values.
motor WSG-S1.2 WSG-S1.3

torque S3-40%, 240 S/h MN [Nm] 170 230
max. torque Mmax [Nm] 425 575
traction sheave Æ DT [mm] 160 210 160 210
for loads *) Q [kg] up to 675 up to 500 up to 1000 up to 750
suspension table applies for 2:1
v nN PN IN nN PN IN nN PN IN nN PN IN
[m/s] [rpm] [kW] [A] [rpm] [kW] [A] [rpm] [kW] [A] [rpm] [kW] [A]
Motor currents applicable to
500 ... 620 V DC link 0,5 119 2,1 6,9 91 1,6 6,1 119 2,9 9,4 91 2,2 7,6
voltage (serie „ECO“)
0,63 150 2,7 8 115 2 6,9 150 3,6 10,4 115 2,8 9,4
1,0 239 4,3 11,6 182 3,2 9,2 239 5,8 14,5 182 4,4 11,4

EN
Date 22.09.2016
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)

EN
Date 22.09.2016
10.2. Cable set for motor and brake
motor cable
Motor cable set
Terminal box
brake cable (magnet)
brake cable (monitoring)
xx - cable length [m]

WSG-Sx 05 - 5 m; 10 - 10 m; 15 - 15 m;
Pin Ader / wire

motor cable 1 (U1)
4 (V1)
No. 1
No. 2
3 (W1) No. 3
PE gn/ge / gn/ye
Connector - standard
C (T1) No. 5 / BR1 / BRK

503 120 A21-xx D (T2) No. 6 / BR2 / BRK
Motor cable set
Pin Ader / wire

1 No. 1
2 No. 2
3 No. 3
brake cable PE gn/ge / gn/ye
A No. 4
B No. 5
C No. 6
D No. 7
503 121 011-xx E No. 8
WSG-Sx A = 1: 1,5mm2 (IS3-40% < 25A) xx - cable length [m]

A = 2: 2,5mm2 (IS3-40% < 35A) 05 - 5 m; 10 - 10 m; 15 - 15 m;
Connector - halogen free cable
Pin Ader / wire

1 (U1) No. 1
motor cable 4 (V1) No. 2
3 (W1) No. 3
PE gn/ge / gn/ye
C (T1) No. 5 / BR1 / BRK
508 828 A21-xx D (T2) No. 6 / BR2 / BRK
Motor cable set
Pin Ader / wire

1 No. 1
2 No. 2
3 No. 3
brake cable PE gn/ge / gn/ye
A No. 4
B No. 5
C No. 6
D No. 7
508 829 011-xx E No. 8
A = 1: 1,5mm2 (IS3-40% < 25A) xx - cable length [m]

WSG-Sx A = 2: 2,5mm2 (IS3-40% < 35A)
05 - 5 m; 10 - 10 m; 15 - 15 m;
Halogen-free cable !

EN
Date 22.09.2016
10.3. Brake manual release
The brake can be fitted with a manual brake

releasing device on customer request. The device Release Threaded
can also be retrofitted. rod
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. Lever block
Installation: ~ 800 N
Install the manual brake releasing device with the
brake disconnected from the power supply.
• Lock the car and the counterweight. Ensure that
the required safety measures are observed for Bowden cable
the lift system.
• Install the manual lifting lever (12.1) on the
1
brake as described in the brake operating
instructions. 12.4
12.1
12.6
12.7
12.8
48,5
180 (WSG-S1)
195 (WSG-S2)
• Install the lever block.

• Insert the Bowden cable into the brake lever and
the lever block . Adjusting of the Bowden cable
on the lever block. Set LF = 115 mm on the lever Alternatively, another simple version of the manual releasing de-
block with the assistance of threaded rod. (Do vice is available for lifts with a machine room.
not actuate the lever block !)
• Perform a functional test (at least three times).

Eyebolts
Lever extension
The Bowden cable has to be in-

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

EN
Date 22.09.2016
10.4. Rope guards
The standard version of the WSG-S1 is equipped with the

rope slip-off guard (5) (see figure "Machine cross-
section" on page 6).
In addition, we offer a guard version as shown in the fig-
ure "Top guard for traction sheave". This top guard has Standard rope slip-off guard
the double function of a rope slip-off guard and protec-
tion of the traction sheave.
Alternatively a version „multi roof“ is availible. only for
DT = 240 mm
Top guard for traction sheave
only for
DT = 240 mm
Version „multi roof“
10.5. Brake voltage 24 /12 V DC +24V 0V
Among the standard voltage of the brake coil (205 /103V)

a variant with 24 /12 V is available, optionally.
3- 2+ Uin
The provided brake control units of type
45B/E 2412-F3-13 have to be used for con-
trol (per brake coil one unit). The supply of
Caution the devices occurs by d. c. voltage – pay
attention to the right polarity!
Dual-circuit fail-safe brake

Type: WSG-S1.2/3 WSG-S2.1/2
Holding voltage: 12 V DC
Holding current: 2 x 4,2 A 2 x 5,5 A
Overexcitation voltage: 24 V DC
Overexcitation current: 2 x 8,5 A 2 x 11,0 A
Brake control units 1 (3) / A1 (A2)

45B/E 2412-F3-13 (from Reissmann GmbH) 4- 5+ Uout
Type: Br
(accessoires)
Holding voltage: UN = 24 V DC ( ± 10 %)
2 / E1 (E2)
Dimensions: 68x22.5x95 (for mounting rail to EN 50 022)

EN
Date 22.09.2016
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

Technical information 01-04/2013 Re:
WSG-S1
Traction sheave shaft (Annex - calculation of the shaft)
Brake Motor Traction sheave
Werkstoff: Stahl DIN 1013 - C45

Denticulation: steel DIN 1013 - C45
Offenburger Str. 3 [email protected] Phone: +49 (0) 351 40 44-0 M.S. 04.04.2013
01189 Dresden www.wittur-edrives.de Fax: +49 (0) 351 40 44-111
Germany
Technical information 03-05/2013 Re:
WSG-S1 (trac. sheave: 160 mm)

Traction sheave shaft (Annex - calculation of the shaft)
Brake Motor Traction sheave
Werkstoff: Stahl DIN 1013 - C45

Denticulation: steel DIN 1013 - C45
Offenburger Str. 3 [email protected] Phone: +49 (0) 351 40 44-0 M.S. 16.05.2013
01189 Dresden www.wittur-edrives.de Fax: +49 (0) 351 40 44-111
Germany
Annex to the EC Type-Examination Certificate
No. EU-BD 863 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 mov-
ing in upwards direction – permissible brake torques and tripping rotary speeds
1.1.1 Permissible brake torque when the braking device acts on the
shaft of the traction sheave while the car is moving upward 560 Nm
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
above taking into account traction sheave diameter and car suspension.
v = Tripping (rated) speed (m/s)
DTS = iameter of the traction sheave from rope’s center to rope’s center (m)
n
v= = 3,14
i n = Rotary speed (rpm)
i = Ratio of the car suspension
Maximum tripping rotary speed of the traction sheave 800 rpm
1.2 Use as braking element – part of the protection device against unintended car movement (act-
ing in up and down direction) – permissible brake torques, tripping rotary speeds and charac-
teristics
1.2.1 Nominal brake torques and response times with relation to a brand-new brake element
Maximum response times**
[ms]
Nominal brake torque* [Nm]
without / with overexcitation
t10 t50 t90
2 x 280 = 560 31 / 37 48 / 55 66 / 74
Interim values can be interpolated
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
Brake control parallel
Nominal air gap 0.45 mm
Damping elements YES
Overexcitation 2-fold non-release voltage
Maximum tripping rotary speed 800 rpm
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 863 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 ex-
amination (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. 5019942 or 5019967 or 5019969 or 5020893 including stamp dated
2016-03-18 shall be included 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 an-
nex and enclosure (List of authorized manufacturer of the serial production). The enclosure will be
updated 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
upwards 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 com-
plied 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 863 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 BFK464
Electromagnetically Released Spring-Applied Brake
Translation of the Original Operating Instructions
www.intorq.com
www.intorq.com
This documentation applies to the:
BFK464-17S
BFK464-18S
BFK464-18S.2
BFK464-19S
BFK464-20S
BFK464-20S.1
BFK464-22S
BFK464-25S
BFK464-25S.1
BFK464-28S
Product key
INTORQ B FK -
Legend for the product key

INTORQ BFK464
A Product group Brakes
B Product type Spring-applied brake
C Type 464
D Size 17, 18, 19, 20, 22, 25, 28
E Design S
S.1
S.2
Not coded: Supply voltage, hub bore, options
INTORQ | BA 14.0197 | 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
INTORQ | BA 14.0197 | 04/2016 3

Document history
Material number Version Description

33002149 1.0 09/2010 TD09 First edition
33002149 2.0 11/2010 TD09 Enlarged to include 19S and 28S sizes
Supplement of the tables in the Characteristics chapter
Supplement of the important instructions in the Commissioning and
operation chapter
33002149 3.0 08/2012 TD09 Supplement of the model identification number for the sizes 18S, 19S
and 28S
Revision of the operating times
Supplemented by versions 18S.2 and 25S.1
Change of the phone and fax number as well as the cover page and
back
33002149 4.0 06/2014 SC New construction FM, supplement of the size 17S
33002149 5.0 12/2014 SC Supplement of the size 22S
33002149 5.1 11/2015 SC Changing the model identification test numbers
33002149 6.0 04/2016 SC Updates
Changing the model identification test numbers
INTORQ | BA 14.0197 | 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 Rating (design data) ................................................................................................................................... 18
3.4 Switching energy / operating 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 procedure ................................................................................................................................. 23
5 Electrical installation ........................................................................................................................................... 31
5.1 Electrical connection .................................................................................................................................. 31
5.2 Bridge/half-wave rectifier (optional) ............................................................................................................ 32
5.3 Electrical connection .................................................................................................................................. 35
6 Commissioning and operation ........................................................................................................................... 36
6.1 Important notes .......................................................................................................................................... 36
6.2 Function checks before commissioning ..................................................................................................... 36
6.3 Commissioning ........................................................................................................................................... 38
6.4 During operation ......................................................................................................................................... 39
7 Maintenance and repair ...................................................................................................................................... 40
7.1 Wear of spring-applied brakes ................................................................................................................... 40
7.2 Inspections ................................................................................................................................................. 41
7.3 Maintenance ............................................................................................................................................... 42
7.4 Spare-parts list ........................................................................................................................................... 44
7.5 Ordering spare parts .................................................................................................................................. 45
8 Troubleshooting and fault elimination .............................................................................................................. 46
INTORQ | BA 14.0197 | 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 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: BFK464- = BFK464-10
Note Important notice about ensuring smooth
operations or other key information.
INTORQ | BA 14.0197 | 04/2016 6

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 Max. permissible friction energy for one-time switching, thermal parameter of
the brake
QR J Braking energy, friction energy
QSmax J Max. permissible friction energy for cyclic switching, depending on the switch-
ing frequency
Rm N/mm2 Tensile strength
RN Ohms Rated coil resistance at 20 °C
Rz μm Average surface roughness
Sh 1/h Operating 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
sHL mm Air gap for manual release
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 14.0197 | 04/2016 7

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 reach-
ing 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
Characterises 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 14.0197 | 04/2016 8

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
❚ The drive systems are combined individually according to a modular design. The scope of delivery is
indicated in the accompanying papers.
❚ After receipt of the delivery, check immediately whether the items delivered match the accompanying
papers. INTORQ does not accept any liability for deficiencies claimed subsequently. You should make
a complaint concerning:
- visible transport damage immediately to the forwarder.
- visible deficiencies / incompleteness immediately to INTORQ GmbH & Co. KG.
1.7 Disposal
The spring-applied brake consists of different types of material.

❚ Recycle metals and plastics.
❚ Ensure professional disposal of assembled circuit boards according to the applicable environmental reg-
ulations.
INTORQ | BA 14.0197 | 04/2016 9

1.8 Drive systems
Labelling
Drive systems and components are unambiguously designated by the indications on the name plate.
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,
name plate 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 14.0197 | 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 however necessary to check the function-
ality of all mechanical components under the corresponding operating conditions.
INTORQ | BA 14.0197 | 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 their intended and confirmed purposes.
- ... 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!
Possible applications of 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 14.0197 | 04/2016 12

Technical specifications
3 Technical specifications
3.1 Product description
Versions
Abb. 1 Design of the BFK464- S / S.1 / S.2 spring-applied brake
1.1 Stator 5 Shaft 10 Socket head cap screw, DIN EN ISO

4762
1.2 Pressure springs 6 Flange (optional) 13 Cover plate (optional)
2 Armature plate 8 Coil 16 Microswitch
3 Complete rotor 9 Sleeve bolts 18 Silencer (optional)
4 Hub
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 18).
The BFK464 spring-applied brake is a single-disk brake with two friction surfaces. The braking torque is ap-
plied 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/plat-
form technology. The brake can be selected based on the rated torque for one brake circuit. The second
brake circuit meets the requirement for redundancy.
INTORQ | BA 14.0197 | 04/2016 13

The division of the brake circuits is done using a two-part armature disk (2) with the respectively allocated
compression springs (1.2) and electromagnetic coils (8). Each brake circuit can be operated individually due
to the separate supply lines for each coil group and armature disk segment ( 32). Each brake circuit has
a microswitch (16) 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) is supplied in heat class F. The limit temperature of the coils (8) is 155 °C. The BFK464 spring-
applied brake is designed for a maximum operating time of 60 % with holding current reduction.
Certificate
Type EC-type examination certificate

Directive 95/16/EC UCM Directive 2014/33 EU
BFK464-17S ABV 948/1 ESV 948/1 EU-BD 948
BFK464-18S ABV 862/1 ESV 862/1 EU-BD 862
BFK464-18S.2 ABV 903/1 ESV 903/1 EU-BD 862
BFK464-19S ABV 863/1 ESV 863/1 EU-BD 863
BFK464-20S ABV 849/1 ESV 849/1 EU-BD 849
BFK464-20S.1 ABV 850/1 ESV 850/1 EU-BD 849
BFK464-22S ABV 975/1 ESV 975/1 EU-BD 975
BFK464-25S ABV 851/1 ESV 851/1 EU-BD 851
BFK464-25S.1 ABV 869/1 ESV 869/1 EU-BD 851
BFK464-28S ABV 859/1 ESV 859/1 EU-BD 859
3.1.2 Braking
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.
3.1.3 Brake release

When the brakes are applied, an air gap "sL" is present between the stator (1) and the armature plate seg-
ment (1). To release the brake, the coils (8) of the existing magnetic circuit are supplied with the correct DC
voltage. The resulting magnetic force works against the spring force to draw the armature plate segments
(1) to the stator (7). 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 microswitch (16) for each braking circuit to monitor the switching state.
When the brake is released, the microswitches (16) toggle. This means that it is possible to exclude the drive
being operated when the brake is closed. The microswitches can be connected as both normally open and
also normally closed.
To check that the microswitches function correctly, we recommend testing the switching status (refer to table
6) in both the released and applied braking states.
INTORQ | BA 14.0197 | 04/2016 14

3.1.5 Manual release (optional)

To temporarily release the brake when there is no electricity available, a manual release function is available
as an option (instead of the transport safety bolts otherwise used). The manual release system works on both
brake circuits together.
NOTICE
❚ The manual release is designed for activation via a Bowden cable.
❚ Releasing an individual brake circuit is only possible electrically.
NOTICE
It is possible to retrofit the manual release system, 29.
3.1.6 Optional cover ring

This design reduces the penetration of spray water and dust. It also prevents the spread of abrasive particles
outside the brake. This is achieved by a cover seal over the armature plate and rotor.
3.1.7 Noise reduction (optional)

In addition to the standard noise reduction, the armature plates can be fitted with noise reducers. This will
reduce the switching noises.
3.1.8 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, as the organic friction linings used do not all have identical properties and because environ-
mental conditions can vary, deviations from the specified braking torques are possible. These must be
taken into account in the form of appropriate dimensioning tolerances. Increased breakaway torque is
common in particular after long downtimes in humid environments where temperatures vary.
❚ Check the braking torque if the brake is inserted on the customer's friction surfaces.
❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactivated
regularly.
INTORQ | BA 14.0197 | 04/2016 15

3.2 Rated data
3.2.1 Dimensions
1.1 Stator, complete 2 Armature plate 6 Flange
Type Stator weight

Air gap Perm. wear Rotor thickness
complete
sLN +0.05 [mm] sLmax [mm] [mm] min. [mm] max. [mm] m [kg]
BFK464-17S 12
BFK464-18S 12.7 13 15
BFK464-18S.2 14.5
BFK464-19S 18.8
BFK464-20S 0.4 0.6 0.2 15.7 16
22
BFK464-20S.1
BFK464-22S 24
BFK464-25S 19.7 20
42
BFK464-25S.1
BFK464-28S 0.5 0.8 0.3 17.6 18 46
INTORQ | BA 14.0197 | 04/2016 16

Type Pitch Fixing screws Minimum thread depth Tightening torque

circle DIN 912 +1.0 mm
without with without with without with
 Flange Flange Flange Flange flange flange
[mm] Thread [mm] [mm] [mm] [mm] MA [Nm] MA [Nm]
BFK464-17S 180 6 x M8x85 6 x M8x95 14 13 24.6
1)
BFK464-18S M8 6 x M8x105 24.6 36.1
196 6 x M8x90 17 19.5
BFK464-18S.2 6 x M8x105 24.6
BFK464-19S 220 24 23
BFK464-20S 6 x M10x110 48
230 6 x M10x100 19 18
BFK464-20S.1
M10 48
BFK464-22S 250 6 x M10x1201) 14 19.5
BFK464-25S 71
278 6 x M10x110 6 x M10x1301) 18 22.5
BFK464-25S.1
BFK464-28S 314 M16 6 x M16x120 6 x M16x130 30 27.5 206 206
Tab. 1: Dimensions of the BFK464- S; S.1; S.2

1)
Bolt fastening class 10.9 with washers in accordance with ISO 7089- -300HV-A2C
3.2.2 Electrical data
Type Voltage Power1) Coil resistance Current2)

Release ±10% Holding ±10% Release Holding
U [V] DC [V] DC Pmax [W] PN [W] RN±5% [] Imax [A]
BFK464-17S 2 x 194 2 x 49 2 x 216 2 x 0.95
BFK464-18S 2 x 220 2 x 55 2 x 191 2 x 1.07
BFK464-18S.2 205 103 2 x 120 2 x 30 2 x 350 2 x 0.59
BFK464-19S 2 x 235 2 x 59 2 x 179 2 x 1.15
BFK464-20S 2 x 256 2 x 64 2 x 164 2 x 1.25
BFK464-20S.1 103 72 2 x 168 2 x 82 2 x 64 2 x 1.62
BFK464-22S 2 x 272 2 x 68 2 x 154 2 x 1.33
205 103
BFK464-25S 2 x 300 2 x 75 2 x 140 2 x 1.46
BFK464-25S.1 103 72 2 x 150 2 x 73 2 x 71 2 x 1.45
BFK464-28S 205 103 2 x 404 2 x 101 2 x 104 2 x 1.97
Tab. 2: Coil power ratings of the BFK464- S; S.1; S.2

1)
Power at 20 °C
2)
Current at 20 °C during release
INTORQ | BA 14.0197 | 04/2016 17

3.3 Rating (design data)
Abb. 2 Operating 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
Type Rated Max. perm. Transitional Operating times [ms] Max.

torque1) switching energy switching frequency at sLN and 0.7 IN2) speed4)
Engaging Disengaging
MK QE Shue DC side3)
t11 t12 t1 t2 nmax
[Nm] [J] [1/h] [r/min]
BFK464-17S 2 x 140 42000 25 14 72 150 700
58
BFK464-18S 2 x 225 10 68 170
60000 20 455
BFK464-18S.2 2 x 165 15 45 60 180
BFK464-19S 2 x 280 68000 12 50 62
190 800
BFK464-20S 2 x 325 19 14 70 84
80000
BFK464-20S.1 2 x 275 22 60 82 180 455
BFK464-22S 2 x 450 90000 18 24 70 94 230 600
BFK464-25S 2 x 600 15 90 105 280 800
120000 15
BFK464-25S.1 2 x 500 37 95 132 230
455
BFK464-28S 2 x 900 180000 14 14 98 112 300
Tab. 3: Switching energy - operating frequency - operating times
1)
Minimum brake torque with run-in friction components at n=100 r/min
2)
Typical values
3)
Measured with induced voltage limitation of -800 V DC
4)
Max. speed according to EC-type examination certificate (for higher speeds, contact with the manufac-
turer is required)
INTORQ | BA 14.0197 | 04/2016 18

Disengagement time
The disengagement time is not influenced by DC or AC switching operations.
Engagement time
The transition from brake-torque free state to 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 is therefore to be provided.
❚ The engagement times apply for DC switching with a spark suppressor.
- Spark suppressors are available for the rated voltages.
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). In this case, the
engagement times increase approximately by a factor of 5 (for connection refer to 31).
3.4 Switching energy / operating frequency
J
1000000
20S + 20S.1 22S
25S + 25S.1
28S
100000
28S
energy
Schaltarbeit QRQR
19S
10000 18S + 18S.2
Switching
17S
1000
100 h-1
1 10 100 1000
Operating frequency
Schalthäufigkeit Sh Sh
Abb. 3 Switching energy as a function of the operating frequency
– S hue –S
S hmax = ------------------------------
-  hue
-
----------------
Sh
Q QS = QE  1 – e 
ln  1 – -------R- max  
 Q E  
The permissible operating frequency Shmax depends on the amount of heat QR (refer to Figure 3). At a pre-
set operating 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 14.0197 | 04/2016 19

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 and if the operating frequency
exceeds five switching operations per minute, the use of a mains filter is required.
If the spring-applied brake uses a rectifier of another manufacturer for the switching, it may become neces-
sary to connect a spark suppressor in parallel with the AC voltage. Spark suppressors are available on re-
quest, 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 path, braking
torque and brake size.
Depending on the natural oscillation after installation, operating conditions and the state of the friction sur-
faces, the brake may squeak during braking.
Others
The abrasion of the friction parts produces dust.
INTORQ | BA 14.0197 | 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 Allen key for transport

Insert for hexagonal socket (Allen) safety bolts
screws
Sleeve bolts Manual

release - nuts
Width across Width across flats Width across flats

Measuring range
flats [mm] [mm]
[Nm]
[mm]
BFK464-17S 4
BFK464-18S 6 15 10
5
BFK464-18S.2
BFK464-19S
BFK464-20S 20 - 100
BFK464-20S.1
8 17 13 6
BFK-46422S
BFK464-25S
BFK464-25S.1
BFK464-28S 40 - 250 14 24 17 8
Multi-meter Calliper gauge Feeler gauge
INTORQ | BA 14.0197 | 04/2016 21

4.3 Assembly
4.3.1 Important notes
Brake size Minimum requirements: Use as counter friction surface
Material1) Evennes Axial Roughness Others

s run-out
[mm] [mm]
17 – 28 S235 JR < 0.1 0.1 Rz10 ❚ Threaded holes with mini-
C15 ... mum thread depth 17
EN-GJL-250 Rz16 ❚ Free of grease and oil
Tab. 4: Counter friction face design of the end shield

1)
In case of other materials, please consult 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 name plate data (especially the rated voltage).
4.3.3 Overview
without separate counter friction face with flange (optional)
INTORQ | BA 14.0197 | 04/2016 22

4.4 Installation procedure
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 Install the hub onto the shaft
NOTICE
For reverse operations, we recommend also glueing the hub to the shaft.
Abb. 4 Installing the hub onto the shaft
4 Hub 4.2 Securing device

4.1 Key 15 End shield
1. Insert the key (4.1) into the shaft.

2. Press the hub (4) onto the shaft.
3. Secure the hub against axial displacement (for example, by using a circlip (4.2)).
INTORQ | BA 14.0197 | 04/2016 23

4.4.2 Brake assembly

Assembly without counter friction face
Abb. 5 Assembly without counter friction face
4 Hub 15 End shield
Install the counter friction faces
Abb. 6 Assembly of the flange
4 Hub 6 Flange 15 End shield
1. Hold the flange (6) to the end shield (15).

2. Align the through holes in the flange and the threads of the fastening bore holes.
INTORQ | BA 14.0197 | 04/2016 24

Assembly of the rotor
Abb. 7 Mounting the hub onto the shaft
3 Complete rotor 6 Flange

4 Hub 15 End shield
1. Push the complete rotor (3) onto the hub (4) and check whether it can be moved by hand. Do not use
any lubricant! (Exception: rotor with toothing that has been sprayed by the manufacturer.)
In the following sections, only assembly for the versions with flange will be described.
Assembly of the complete stator
Abb. 8 Mounting the complete stator
1 Stator, complete 15 End shield

6 Flange 17 Transport safety bolt
10 Cylinder head bolt
1. Push the complete stator (1) onto the shaft.

2. Screw the complete stator (1) into the bearing shield (15) using the bolts (10)
3. Remove the transport safety bolts (17) (discard).
INTORQ | BA 14.0197 | 04/2016 25

4.4.3 Check the air gap
Abb. 9 Checking "sL"
A Air gap, sL
1.1 Stator 6 Flange 10 Cylinder head bolt

2 Armature plate 9 Sleeve bolt 15 End shield
1. Check the air gap "sL" near the bolts (10) using a feeler gauge and compare the 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 "sL" ( 16) is not within the tolerance, readjust the air gap.
INTORQ | BA 14.0197 | 04/2016 26

4.4.4 Adjusting the air gap
WARNING
Danger: rotating parts!

Switch off the voltage. The drive system must be free of loads.
Abb. 10
1. 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).
2. 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.
3. Tighten the bolts (10), (for torques, see table 17).
4. Check the air gap "sL" near the bolts (10) with a feeler gauge, ("sLN" 16).
5. Repeat the adjustment procedure if the deviation of "sLN" is too large.
NOTICE
Only for brakes with manual release

❚ Additionally check the dimension "s" and adjust if necessary 30.
INTORQ | BA 14.0197 | 04/2016 27

DANGER
Brake may fail

If the manual release is not adjusted correctly the brake may fail.
Possible consequences:
❚ Severe injuries or material damage.
Protective measure:
❚ Ensure that the dimension "s" is observed.
4.4.5 Cover ring assembly
NOTICE
Brakes without flange require a groove in the bearing shield for the lip of the cover ring.
Abb. 11 Cover ring assembly
1 Stator, complete 6 Flange 13 Cover ring

2 Armature plate 10 Cylinder head bolt
1. Pull the cable through the cover ring (13).

2. Push the cover ring (13) over the complete stator (1).
3. Press the lips of the cover ring (13) into the grove of the complete stator (1) and flange (6) or the bearing
shield.
NOTICE
Cover ring with condensation drain hole:
Fit the cover ring so that condensation can drain through the hole.
INTORQ | BA 14.0197 | 04/2016 28

4.4.6 Manual release assembly (optional)
NOTICE
The assembly of the manual release is done to the spring-applied brake which is already fitted
to the bearing shield 24. The air gap of the brake is set to the rated air gap, 16.
Abb. 12 Assembly of the manual release
12.1 Lever 12.6 Cup springs 12.8 Nuts

12.4 Stud bolts 12.7 Sleeves 14 Brake
1. Insert four stud bolts (12.4) into the bore holes of the transport safety bolts which have been removed.
Tighten with a screwdriver.
2. Put the lever (12.1) onto the brake (14).
3. Place four cup springs (12.6) in alternate directions in each of the four sleeves (12.7). Finally, insert the
sleeves into the holes in the lever (12.1).
INTORQ | BA 14.0197 | 04/2016 29

4. Screw self-locking nuts (12.8) onto the stud bolts and tighten them until the dimension "s" has been set.
NOTICE
Before setting the dimension "s", it is imperative that the air gap "sL" is checked, and adjusted
to "sLN" ( 16), if required. The brake is not energised during adjustment.
Abb. 13 Dimension "s"
1.1 Stator, complete 6 Flange 12.1 Lever

2 Armature plate
Type sLN+0.05 [mm] s+0.1 [mm]
BFK464-17S
BFK464-18S
BFK464-18S.2
5.3
BFK464-19S
BFK464-20S 0.4
BFK464-20S.1
BFK464-22S 6.5
BFK464-25S
5.3
BFK464-25S.1
BFK464-28S 0.5 6.5
DANGER
Brake may fail

If the manual release is not adjusted correctly the brake may fail.
Possible consequences:
❚ Severe injuries or material damage.
Protective measure:
❚ Ensure that the dimension "s" is observed.
INTORQ | BA 14.0197 | 04/2016 30

Electrical installation
5 Electrical installation
5.1 Electrical connection
5.1.1 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 name plate.
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 energisation when switching on, it is also neces-
sary 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 ( 32).
INTORQ | BA 14.0197 | 04/2016 31

5.1.2 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
Abb. 14 INTORQ BFK464 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
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. Depending on the design of the load, an improvement of the switching be-
haviour or a reduction in performance is possible.
INTORQ | BA 14.0197 | 04/2016 32

5.2.1 Assignment: Bridge/half-wave rectifier – brake size
Rectifier type Supply voltage Coil voltage Assigned brake

Release / holding
[V AC] [V DC]
BFK464-17S
BFK464-18S
BFK464-18S.2
BFK464-19S
BFK464-20S
BEG-561-255-130 230 ±10% 205 / 103
BFK464-20S.1
BFK464-22S
BFK464-25S
BFK464-25S.1
BFK464-28S
BFK464-17S
BFK464-18S
BFK464-18S.2
BFK464-19S
BFK464-20S
BEG-561-440-130 400 ±10% 360 / 180
BFK464-20S.1
BFK464-22S
BFK464-25S
BFK464-25S.1
BFK464-28S
NOTICE
The BFK464-20S.1 and -25S.1 brake versions in the voltage versions 103 / 72 V are operated
using switching devices provided by the customer which reduce the coil voltage from 103 V
DC to 72 V DC.
INTORQ | BA 14.0197 | 04/2016 33

Dimensions Fastening options
Abb. 15 Dimensions and possible installations of bridge/half-wave rectifier
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 Overexcitation 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
INTORQ | BA 14.0197 | 04/2016 34

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

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.
INTORQ | BA 14.0197 | 04/2016 35

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.
❚ 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.
❚ Check the braking torque if the brake is inserted on the customer's friction surfaces.
❚ If the brake is used as a pure holding brake without dynamic load, the friction lining must be reactivated
regularly.
6.2 Function checks before commissioning
6.2.1 Functional checks

Brake with microswitch
DANGER

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

Live connections must not be touched.
INTORQ | BA 14.0197 | 04/2016 36

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 disconnect the supply voltage for the brake. Apply DC voltage 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.
6. Measure the DC voltage at the brake:
- The measured DC voltage after the over-excitation time (see bridge/half-wave rectifier, 34)
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 microswitch (see table 6).
9. Open the switching contact for the brake.
- The brake is applied.
10. Check the switching status of the microswitch (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 Microswitch closed

yes no
NC contact black / grey
no yes
yes yes
NO contact black / blue
no no
Tab. 6: Switching status of the microswitch
INTORQ | BA 14.0197 | 04/2016 37

6.2.2 Test that the manual release functions
NOTICE
❚ The manual release is designed for activation via a Bowden cable.
❚ Releasing an individual brake circuit is only possible electrically.
DANGER

The drive system must be free of loads. The motor must not run!
Abb. 16 Turning direction of the lever

Motor and brake are de-energised.
14. Suspend Bowden cable (not included in the delivery package) and pull with approx. 800 N.
- The drive must be able to be turned freely. A low residual torque is permitted.
15. Release the lever.
- Torque must be available!
The preparations for commissioning are completed.
6.3 Commissioning
1. Switch on drive system.

2. Carry out a braking test.
INTORQ | BA 14.0197 | 04/2016 38

6.4 During operation
DANGER

The running rotor must not be touched.
DANGER

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

- unusual noises or temperatures
- loose fixing elements
- the condition of the electrical cables
❚ The armature plate must be attracted 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, 34)
must correspond to the holding voltage (see 33). A deviation of ±10 % is permissible.
❚ If faults occur once, go through the troubleshooting table in 46. If the fault cannot be fixed or elim-
inated, please contact your customer service.
INTORQ | BA 14.0197 | 04/2016 39

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 41.
NOTICE
Braking torque reduction

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 that the prescribed maintenance intervals can be specified accurately. The most important fac-
tors in this context are the applied friction energy, the initial speed of rotation of braking and the operating
frequency. If several of the causes of friction lining wear occur in an application at the same time, the influ-
encing factors should be added together when the amount of wear is calculated. The calculation of the ser-
vice interval can be supported by the design program INTORQ-Select.
Component Cause Effect Influencing factors

Friction lining Braking during operation Wear of the friction lining Friction work
Emergency stops
Overlapping wear during start and stop of
drive
Active braking via the drive motor with sup-
port of brake (quick stop)
Starting wear in case of motor mounting Number of start-stop
position with vertical shaft, even when the cycles
brake is not applied
Armature plate and Rubbing of brake lining Run-in of armature plate and Friction work
counter friction counter friction face
face
Gear teeth of Relative movements and shocks between Wear of gear teeth (primarily Number of start-stop
brake rotor brake rotor and brake shaft on the rotor side) cycles
Brake support Load reversals and jerks in the backlash Breaking of armature plate, Number of start/stop
between armature plate, adjustment tubes adjustment tubes and guide cycles, braking
and guide pins pins torque
Springs Axial load cycle and shear stress of springs Reduced spring force or Number of switching
through radial backlash on reversal of arma- fatigue failure operations of brake
ture plate
Tab. 7: Causes for wear
INTORQ | BA 14.0197 | 04/2016 40

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, 40. 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:

BFK464 - ❚ according to service life cal- ❚ at least every two years
S/S.1/S.2 culation ❚ after 1 m cycles at the latest
❚ or else every six months
❚ after 4000 operating hours
at the latest
Maintenance
Inspections with assembled brake: Inspections after the brake has been
removed:
❚ Check release function and 43 ❚ Check the play of the rotor 43
control toothing (replace worn-out ro-
tors)
❚ Measure the air gap (adjust 26 ❚ Check for breaking out of the
if required) torque support at the sleeve
bolts and the armature plate
❚ Measure the rotor thickness 43 ❚ 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
INTORQ | BA 14.0197 | 04/2016 41

7.3 Maintenance
NOTICE
Brakes with defective armature plates, socket head cap screws, springs or counter friction
faces must always be replaced completely.
Generally observe the following for inspections and maintenance works:
❚ Contamination by oils and greases should be removed using brake cleaner, or the brake
should be replaced after determining the cause. Dirt and particles in the air gap between
the stator and the armature plate endanger the function and should be removed.
❚ After replacing the rotor, the original braking torque will not be reached until the run-in op-
eration for the friction surfaces has been completed. After replacing the rotor, the run-in ar-
mature plates and counter friction faces have an increased initial rate of wear.
7.3.1 Check the rotor thickness
DANGER

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 calliper gage.
4. Compare the measured rotor thickness against the minimal permitted rotor thickness ( 16).
5. If required, replace the rotor completely. Refer to 43 for the description.
7.3.2 Check the air gap
DANGER

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 the rotor completely. Refer to 43 for the description.
INTORQ | BA 14.0197 | 04/2016 42

7.3.3 Release / voltage

1. Start motor and control system!
DANGER
The running rotor must not be touched.
DANGER
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, 33), the measured DC voltage
must correspond to the holding voltage ( 34). A deviation of ±10 % is permissible.
7.3.4 Replacing the rotor
DANGER
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 toothing 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 calliper 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 stator and armature plate is
reached.
12. Install and adjust the new complete rotor and stator, 25.
13. Reconnect the connection cable.
INTORQ | BA 14.0197 | 04/2016 43

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
Abb. 17 Spring-applied brake BFK464- S / S.1 / S.2
Item Designation Variant

1 Stator, complete Voltage
3 Complete rotor
Rotor, complete noise-reduced
4 Hub Bore diameter
6 Flange
10 Set of fastening screws for mounting to the motor
Cylinder head screw DIN912 for flange with through hole
12 Complete manual release
13 Cover ring
18 Noise reducer
INTORQ | BA 14.0197 | 04/2016 44

7.5 Ordering spare parts
INTORQ BFK464- S / S.1 / S.2, stator, complete
Size 17 18 19 20 22 25 28
Design S S.1 S.2
Voltage 103 V / 51.5 V

103 V / 72 V
205 V / 103 V
360 V / 180 V
Braking torque ________ Nm
Cable length Standard (600 mm)

________ mm (from 100-1000 mm in 100 mm steps, from 1000-
2500 mm in 250 mm steps)
Manual release mounted
Armature plate Standard
Microswitch Monitoring the switching function
Switching noises Damped
Accessories
Rotor Aluminium
Noise-reduced (rotor with sleeve)
Hub mm (for hole diameter, see dimensions)
Flange
Fixing screw set for mounting to the motor
for mounting to the flange with pass-through holes
Sealing Cover ring
Shaft seal ring (shaft diameter on request)
Cap
Noise reduction Noise reducer set
Electrical accessories
Rectifier type: Selection see 33
Rectifier BEG-561-255-130
BEG-561-440-130
INTORQ | BA 14.0197 | 04/2016 45

Troubleshooting and fault elimination
8 Troubleshooting and fault elimination
If any malfunctions should occur when operating the braking system, 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 service.
Brake malfunction
Fault Cause Remedy

Brake does not release Coil interruption ❚ Measure the coil resistance using a multimeter:
- If resistance is too high, replace the complete stator.
Coil has contact to earth or ❚ Measure the coil resistance using a multimeter:
between windings - Compare the measured resistance with the nominal
resistance. Refer to 16 for the values. If resist-
ance is too low, replace the complete stator.
❚ Check the coil for short to ground using a multimeter:
- If there is a short to ground, replace the complete
stator.
❚ Check the brake voltage (see Defective rectifier, volt-
age too low).
Wiring defective or wrong ❚ Check and correct
❚ cable for continuity using a multimeter
- Replace defective cable.
Rectifier defective or incorrect ❚ Measure rectifier DC voltage using a multimeter.
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
- Diode is defective; use a suitable new rectifier
❚ Check the coil for winding short or ground short.
❚ 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 error may only occur on
warming up.
INTORQ | BA 14.0197 | 04/2016 46

Troubleshooting and fault elimination
Fault Cause Remedy

Brake does not release Microswitch incorrectly wired Check the wiring of the microswitch and correct it.
Microswitch incorrectly set Replace the complete stator and make a complaint about
the setting of the microswitch to the manufacturer.
Air gap too big Adjust the air gap ( 27)
Measure the rotor thickness and compare against the min-
imum rotor thickness ( 16). If required, replace the
rotor.
Rotor cannot rotate freely Wrong setting of manual Check the dimension "s+sL" with the brake energised. The
release dimension must be the same on both sides. Correct if
required.
Air gap "sL" too small Check air gap "sL" and adjust it if necessary ( 27).
Rotor thickness too small Rotor has not been replaced Replace the rotor ( 43).
in time
Voltage is not zero during Microswitch incorrectly wired Check and correct the wiring of the microswitch.
the functional test Microswitch defective or Replace the complete stator and send the complete
( 36) incorrectly set stator to the manufacturer.
Voltage too high Brake voltage does not match Adjust rectifier and brake voltage to each other.
the rectifier
Voltage too low Brake voltage does not match Adjust rectifier and brake voltage to each other.
the rectifier
AC voltage is not mains Fuse is missing or defective Select a connection with proper fusing.
voltage Microswitch incorrectly wired Check and correct the wiring of the microswitch.
Microswitch defective or Replace the complete stator and return the defective com-
incorrectly set plete stator to the manufacturer.
INTORQ | BA 14.0197 | 04/2016 47

Notes
Notes
INTORQ | BA 14.0197 | 04/2016 48

 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
 [email protected]
 ᓊᤉḥ࡬ࣞಞ δр⎭εᴿ䲆䍙Ա‫ޢ‬ਮ
INTORQ (Shanghai) Co., Ltd.
р⎭ᐸ⎜ђ᯦॰⌛ค䭽᯦‫ݹ‬঍䐥 ਭ
ਭᾲжᾲ % ᓝ
No. 600, Xin Yuan Nan Road,
Building No. 6 / Zone B
Nicheng town, Pudong
201306 Shanghai
 +86 21 20363-810
 +86 21 20363-805
 INTORQ US Inc.
USA
300 Lake Ridge Drive SE
Smyrna, GA 30082, USA
 +1 678 236-0555
 +1 678 309-1157
 INTORQ India Private Limited

India
Plot No E-7/3
Chakan Industrial Area, Phase 3
Nighoje, Taluka - Khed
33002149 | BA 14.0197 | EN | 6.0 | © 04/2016 | SC |
Pune, 410501, Maharashtra

 +91 2135625500
www.intorq.com

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EN

Gearless Lift Machine Code GM.8.003277.EN

Gearless Lift Machines

Translation of the Original Operating Instructions

WITTUR Holding GmbH

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

These operating instructions are

WSG - S1.2 - ....

WITTUR Electric Drives GmbH reserves the right to correct or

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

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

1.2. Intended use

1.3. Scope of delivery

1.4. Warranty and liability

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

2.2. Format of the safety instructions

Risk of electric shock Property damage

General danger Information

2.3. Safety precautions

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

Type code of lift

Item Part WSG-S1

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

3.2. Transport and storage

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

Securing the machine

üok üok üok üok

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

temperature, the reduction factors k shown in the dia-

4.2. Electrical connection

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

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

4.2.2. Motor connection / Winding protection

Screw plugs 2 x M 16 and 1 x M 20

As an option, the electrical connection of the

D tor provided on the motor. A type B ST A 078

C temperature Pin contacts of flanged

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

Cable cross-section required:

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

exceed 2.5 V DC. 3 x 1330

Short-circuiting the motor terminals

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

4.2.3. Speed/Position measuring system

The measuring system of WSG lift machines with a

Measuring system Sendix 8.5873 Measuring system ECN 413

Core Signal Pin Signal

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

Note on the use of DC/AC side switching:

AC side switching DC side switching

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

Monitoring the brakes

Connection of the brakes

Screw plugs 2 x M 16 and 1 x M 20

1st. partial 2nd. partial M 20 Cable gland

Stripping length required: 9-10 mm

„release“ 1st. partial brake „release“ 2nd. partial brake

Option: terminal box

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