Table of Contents
Summary of Contents for EMG ELDRO EdEx Series
- Page 1 Assembly manual General designation Electro-hydraulic lifting thruster ELDRO ® EdEx Type designation Series EdEx 32 to EdEx 320 (three-phase version) Explosion-proof design Date: 03.2020 EMG Automation GmbH, Industriestr. 1, D-57482 Wenden / Germany...
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Page 3: Table Of Contents
Table of contents Table of contents General......................6 Information about this assembly manual ................. 6 Manufacturer........................6 Validity ..........................7 Further applicable documents ................... 7 Formal information about this assembly manual ............7 Format conventions ......................8 Structure of warning notices ..................... 9 Terms and abbreviations .................... - Page 4 Table of contents Dimensions .......................... 31 3.6.1 Type EdEx ..........................31 3.6.2 Type EdEx-HV........................32 Electrical system ......................... 33 3.7.1 Voltage and frequency ......................33 Operating fluid ........................33 Airborne sound emissions ....................34 3.10 Operating conditions ......................34 3.10.1 Ambient temperature ......................
- Page 5 Table of contents Safety instructions ......................56 Tests before commissioning ..................... 57 7.2.1 Operating conditions ......................57 7.2.2 Order parameters ........................58 7.2.3 Technical parameters ......................58 Operating modes ......................... 58 Help with malfunctions ................59 Faults and troubleshooting ....................59 Maintenance ....................
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Page 6: General
DEKRA EXAM GmbH V1.1 First draft 27/03/2020 CE Design V1.2 Declaration of conformity + 14/05/2020 footer Manufacturer EMG Automation GmbH Werk Oschersleben Am Pfefferbach 20 39387 Oschersleben / Germany Phone +49 3949 928 500 +49 3949 928 513 Email info@emg-automation.com Website www.emg-automation.com 6 / 75 ELDRO-EdEx-Montageanleitung-607338-EN.docx... -
Page 7: Validity
The contents of this manual are not contractually binding but are provided as information. EMG Automation GmbH reserves the right to make content and technical changes compared to this manual without having to specify these. EMG Automation GmbH cannot be held responsible for any... -
Page 8: Format Conventions
General Format conventions Format conventions Table 1: Format conventions Format Meaning 1. Action Action step with a sequence Action step / user instruction List "ABC" Highlighting of special terms in the text Reference to chapters or sections of this ⇒... -
Page 9: Structure Of Warning Notices
General Structure of warning notices Structure of warning notices If observed, warning notices protect against possible personal injury and property damage and classify the extent of the danger by the signal word. WARNING = Signal word Source of danger Possible consequences of non-compliance –... -
Page 10: Terms And Abbreviations
General Terms and abbreviations Terms and abbreviations The following terms and abbreviations are used in the assembly manual. Table 2: Terms and abbreviations Term/abbreviation Meaning ATEX ATmosphere EXplosible Brake spring (C-spring) Cylindrical pressure spring that counteracts the hydraulic force. As a result, only the force difference on the lifting rod is effective as the actuating force. - Page 11 General Terms and abbreviations Table 2: Terms and abbreviations Term/abbreviation Meaning Lowering time Time from switching the motor off until the bottom piston limit position is reached. ELDRO-EdEx-Montageanleitung-607338-EN.docx 11 / 75...
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Page 12: Safety
The maximum permissible layer thickness (subsequent coating) according to ATEX approval must not be exceeded (if necessary, EMG Automation GmbH consult the manufacturer Regular cleaning must be carried out to prevent dust deposits with a layer thickness of more than 5 mm. -
Page 13: For Use In Potentially Explosive Areas
Safety General 2.1.1 For use in potentially explosive areas It is essential to observe the applicable regulations, plant-specific provisions and the requirements for the test personnel. Installation, commissioning and recurring tests may only be carried out by suitably qualified personnel (competent person). ... -
Page 14: Intended Use
Safety Intended use The specification of the maximum surface temperature is only valid for dust deposits up to a maximum of 5 mm. Clean only using a damp cloth (ESD danger) For dusts of group IIIA/IIIB/IIIC it is necessary to prevent electrostatic charges on the housing surface, which can lead to propagating brush discharges, through suitable measures. - Page 15 Safety Intended use However, EdEx thrusters can also be used in many other areas of production, transport technology, warehousing and handling technology, wherever a straight work movement is required and a single drive is wanted. Applications as an actuator include actuating ...
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Page 16: Unintended Use
Work on or with EdEx thrusters may only be performed by trained and qualified staff who have received system-specific instructions, who are authorised to do so and who have special knowledge and experience within the corresponding field. Contact EMG Automation GmbH if the required staff qualifications are unclear. 16 / 75 ELDRO-EdEx-Montageanleitung-607338-EN.docx... -
Page 17: Qualified Personnel
Safety Staff qualifications 2.4.1 Qualified personnel EdEx thrusters may only be transported, set up, connected, operated and maintained by specialists. All work must be performed with the intended, intact tools, equipment, test equipment and consumables, and must be inspected by the specialists responsible. The specialists must be authorised to perform the required tasks by the person responsible for the industrial system’s safety. -
Page 18: Maintenance Staff
Safety Staff qualifications 2.4.3 Maintenance staff Maintenance staff include industrial mechanics or people who have comparable, country-specific training. Maintenance staff are people who have been commissioned by the operating company to maintain the system and who have the following knowledge: ... -
Page 19: Responsible Staff
Maintenance Repairs Electrical repairs Dismantling Storage Disposal EMG Automation GmbH Contact if the required staff responsibilities are unclear. Personal protective equipment The operating company must prescribe personal protective equipment according to the danger risk. Personal protective equipment includes the following among others: ... -
Page 20: Electrical Equipment
Safety Electrical equipment Electrical equipment Work on electrical equipment must be carried out exclusively by electricians. When performing any work on electrical components, the five safety rules must be adhered to: – Disconnect from the electrical supply – Safeguard to prevent a restart –... -
Page 21: Process Media
Safety Process media Check the voltage supply using the data on the type plate and then establish the electrical connection according to the terminal diagram on the inside of the terminal box frame. The phase sequence is arbitrary. The earthing must maintain an earth leakage resistance of <... -
Page 22: Technical Data
Technical data Thruster identification Technical data Thruster identification Figure 1: Thruster identification EdEx type Brake/reset spring Regulating spring (R-spring) Lifting valve Lowering valve Throttle valve Identification of installation position Corrosion protection class Sensors, limit switches Adaptors, special series 22 / 75 ELDRO-EdEx-Montageanleitung-607338-EN.docx... -
Page 23: Explosion Protection Identification
Technical data Explosion protection identification Explosion protection identification Figure 2: Explosion protection identification EU Directive 2014/34 Thruster group Thruster category Ignition protection type for non-electrical thrusters "Liquid encapsulation" Ignition protection type for electrical equipment "Pressure-proof encapsulation" Explosion protection group Temperature class EPL mark (thruster protection level) 3.2.1 EdEx identification... -
Page 24: Specifications On The Type Plate
Technical data Specifications on the type plate Specifications on the type plate Figure 3: Type plate Serial number, date of manufacture Explosion protection identification Actuating force in N Lifting path in mm Operating mode S, switching / h with duty Reset force in N cycle in % Voltage... -
Page 25: Specifications On The Test Plate
Technical data Specifications on the test plate Specifications on the test plate Figure 4: Test plate EU type examination certificate IECEx certificate number Thruster type Explosion protection identification Serial number, date of manufacture ELDRO-EdEx-Montageanleitung-607338-EN.docx 25 / 75... -
Page 26: Characteristics
Technical data Characteristics Characteristics 3.5.1 Short lift thrusters General characteristics All technical data are mean values relating to +20 °C thruster temperature. Table 6: Characteristics – short lift thrusters EdEx 32/50-EdEx 150/75 EdEx EdEx type 32/50 50/50 80/60 80/75 125/60 125/60 125/75 150/60... - Page 27 Technical data Characteristics C-spring characteristics All technical data are mean values relating to +20 °C thruster temperature. Table 8: C-spring characteristics – short lift thrusters EdEx 32/50-EdEx 125/75 EdEx EdEx type 32/50 32/50 50/50 50/50 50/50 80/60 80/60 80/75 125/60 C-spring –...
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Page 28: Long Lift Thrusters
Technical data Characteristics 3.5.2 Long lift thrusters General characteristics All technical data are mean values relating to +20 °C thruster temperature. Table 11: Characteristics – long lift thrusters EdEx 80/160-EdEx 320/120 EdEx EdEx type 80/160 125/160 150/160 200/160 250/160 320/120 Nominal actuating force [N] 1,250 1,500... - Page 29 Technical data Characteristics C-spring characteristics All technical data are mean values relating to +20 °C thruster temperature. Table 12: C-spring characteristics – long lift thrusters EdEx 80/160-EdEx 150/160 EdEx EdEx type 80/160 80/160 125/160 125/160 125/160 150/160 150/160 150/160 C-spring C125 C125 Brake/reset force...
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Page 30: Setting Times
With integrated lowering valve Lowering time Adjustable lowering time in [s] min. in [s] max. in [s] EdEx 32/50… 0.45 For data refer to delivery documents, consult with EMG Automation GmbH if necessary EdEx 50/50… 0.36 EdEx 80/60… 0.48 EdEx 80/75… 0.62 EdEx 125/60…... -
Page 31: Dimensions
Technical data Dimensions Dimensions 3.6.1 Type EdEx Figure 5: Type EdEx All dimensions in the following table are in mm. Table 16: Dimensions type EdEx D L N X Type EdEx 32/50 21.5 EdEx 50/50 EdEx 80/60 EdEx 125/60 27.5 EdEx 150/60... -
Page 32: Type Edex-Hv
Technical data Dimensions 3.6.2 Type EdEx-HV Figure 6: Type EdEx-HV All dimensions in the following table are in mm. Table 17: Dimensions type EdEx-HV D L N X Type EdEx 80/60 EdEx 125/60 27.5 EdEx 150/60 EdEx 80/160 EdEx 125/160 27.5... -
Page 33: Electrical System
Technical data Electrical system Electrical system 3.7.1 Voltage and frequency All EdEx thrusters are switched to star (Y) when delivered. Table 18: Electrical voltage and frequency (basic version) Values Name 3/N/PE AC 230 up to 690 V Operating voltage 3/N/PE AC 660/1140 V (HV) Voltage tolerance, ±5 % permissible... -
Page 34: Airborne Sound Emissions
Technical data Airborne sound emissions Airborne sound emissions The A-rated emission sound pressure level for all EdEx thrusters is 55 dB (A). This value was determined using an integrated sound pressure level measuring unit in accordance with DIN 45633 under the following measurement conditions: ... -
Page 35: Functional Description
Functional description Operating conditions 3.10 Functional description The EdEx electro-hydraulic lifting thrusters are manufactured in different type groups. Due to common characteristics, the EdEx thrusters can be summarised in the following type groups. Table 21: Classification of EdEx thrusters/type groups Type group Type EdEx 32/50... -
Page 36: Mechanical Layout
Functional description Mechanical layout Mechanical layout The EdEx thruster combines all structural elements of a complete hydraulic system in one structural unit. This comprises a three-phase asynchronous motor (direct current motor in the special version), a closed hydraulic system and the work cylinder with piston and lifting rod. -
Page 37: Electrical Equipment
Functional description Electrical equipment Electrical equipment 4.2.1 Motor Three-phase asynchronous motor, 2-pin Standard insulation according to insulation material class F 4.2.2 Operating modes Continuous operation S1 and intermittent operation S3 – max. 240 c/h, up to 60 % ED (duty cycle) standard 4.2.3 Junction box ... -
Page 38: Electrical And Mechanical Additional Equipment
Functional description Electrical and mechanical additional equipment Electrical and mechanical additional equipment 4.3.1 Lift, lowering or throttle valve (H, S, D) With a built-in lifting, lowering or throttle valve, the lifting or lowering times as well as both times together can be extended continuously. -
Page 39: Function Sequence
Functional description Function sequence Function sequence The hydraulic pump driven by the motor conveys the hydraulic medium into the space below the piston. This generates hydraulic pressure that acts outwards via the piston and lifting rod. The piston and lifting rod move backwards after the motor is switched off either due to a force acting from the outside (brake weight, brake spring) or due to the integrated reset spring. -
Page 40: Transport And Storage
Transport and storage Transport Transport and storage Transport CAUTION The EdEx thrusters weigh between 30 and 90 kg Risk of injury when lifting the load manually – Use suitable lifting equipment (e.g. crane). – Never remain below suspended loads. – Use a transport aid (e.g. lifting carriage) with sufficient load bearing capacity. -
Page 41: Transport Sketch
Transport and storage Transport 5.1.1 Transport sketch Attach a suitable load carrying thruster to the attachment point to transport using lifting gear. Figure 8: Attachment point Attachment point ELDRO-EdEx-Montageanleitung-607338-EN.docx 41 / 75... -
Page 42: Storage
Transport and storage Storage Storage The EdEx thrusters can be transported or stored upright or lying down until commissioned. If stored for more than 6 months, we recommend storing the EdEx thrusters upright. Even though the thrusters are basically suitable for installation outdoors, we recommend taking protective measures against the effects of weather while storing. -
Page 43: Assembly And Installation
Assembly and installation Assembly Assembly and installation The following safety regulations must be adhered to before beginning any work on EdEx thrusters: Ensure that the industrial system is shut down De-energise the system Safeguard the system to prevent it being switched on again ... - Page 44 Assembly and installation Assembly CAUTION Sudden power failure or switch-off due to any C-springs, brake springs, brake weights that may be installed or due to other external influences Risk of crushing due to the lifting rod. – The downstream drive must be secured before removing the EdEx thrusters, because the lifting rod retracts automatically.
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Page 45: Permissible Installation Positions
Assembly and installation Assembly 6.1.1 Permissible installation positions Vertical and intermediate positions up to 60° deviation from the vertical position (marking "II"): – Lifting rod acting upwards without restrictions – Lifting rod acting downwards is not permissible. Horizontal and intermediate positions up to 30° deviation from the horizontal position (marking "I"): –... - Page 46 Assembly and installation Assembly Process To attach the EdEx thruster, there are fastening eyelets on the motor housing and holes in the lifting rod, which can be used with suitable bolts to establish the connection to the equipment to be operated (e.g.
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Page 47: Electrical Connection
Assembly and installation Electrical connection Electrical connection DANGER Live components Fatal electric shock or serious burns – Work on live components may only be performed by electricians. – When performing any work on electrical components, the five safety rules must be adhered to: –... - Page 48 Assembly and installation Electrical connection The cable gland and the screws of the housing cover must be firmly tightened to ensure that the IP protection class is maintained. Excessive tightening damages the seal and affects the IP protection class. ...
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Page 49: Junction Box And Terminal Diagram
Assembly and installation Electrical connection 6.2.1 Junction box and terminal diagram EdEx thrusters Terminal diagram Figure 9: Terminal diagram EdEx thruster – 3-pin Connection L1 Connection L3 Connection L2 Protective conductor terminal (red) The torque for tightening the threaded connection is 0.8 Nm. ELDRO-EdEx-Montageanleitung-607338-EN.docx 49 / 75... - Page 50 Assembly and installation Electrical connection EdEx HV thrusters Terminal diagram Figure 10: Terminal diagram EdEx-HV thrusters – 6-pin Jumper 5–6 Connection L1 Jumper 4-5 Connection L2 Earthing conductor terminal Connection L3 Jumper 1–6 Delta connection Jumper 2-5 Star connection (condition as delivered) Jumper 3-4 The torque for tightening the threaded connection is 0.8 Nm.
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Page 51: Earthing Conductor Connection
Assembly and installation Electrical connection 6.2.2 Earthing conductor connection NOTICE The connection of the external protective conductor must take the swivel movement of the EdEx thruster and the surface temperature into account! Always connect the earthing conductor before all other cables There is one earthing conductor connection in the junction box (⇒Junction box and terminal diagram section) and one in the immediate vicinity of the junction box on the outside of the EdEx... - Page 52 Assembly and installation Electrical connection A pivoting arrangement requires a flexible cable. A minimum cable cross section of 1.5 mm must be provided for all thruster sizes. The connection terminals permit a maximum cable cross section of 2.5 When selecting the cables, the ambient conditions (e.g. temperature, humidity) at the installation location must also be considered.
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Page 53: Adjusting The Valves
Assembly and installation Adjusting the valves Cable entry There is a cable entry on the terminal box depending on the version: EdEx-Standard: M25 x 1.5 for conductor cross-section 7 x 2.5 EdEx-HV: M32 x 1.5 for conductor cross-section 7 x 2.5 mm ... -
Page 54: Installation Location Of The Regulating Screw
Assembly and installation Adjusting the valves The versions with lifting and/or lowering valves enable the lifting rod’s set or reset speed (setting or resetting time) to be adjusted infinitely within a specific range. The type designation specifies whether an EdEx thruster is equipped with valves (see type plate; ⇒Type designation and type key section). -
Page 55: Changing The Set Time And The Reset Time
Assembly and installation Completing assembly 6.3.2 Changing the set time and the reset time The integrated valve system allows the stepless extension of the setting and/or resetting times. Adjustment takes place with a regulating screw. The regulating screw is located inside the thruster and is accessible after removing the outer screw plug. -
Page 56: Notes On Operation
Notes on operation Safety instructions Notes on operation Safety instructions Never operate the EdEx thruster with electrical connections that are faulty or not ready for operation. The EdEx thruster must be operated exclusively with the hydraulic medium specified on the type plate. (Depending on the hydraulic medium used, operation of the EdEx thruster is limited to the specified ambient temperatures.) ... -
Page 57: Tests Before Commissioning
Notes on operation Tests before commissioning WARNING Cylinder movements Risk of crushing between surrounding hindrances and the cylinder or connected components as a result of the cylinder retracting automatically due to the reset spring with a hydraulic pressure drop, or if the power supply is interrupted. –... -
Page 58: Order Parameters
Notes on operation Operating modes 7.2.2 Order parameters Check whether the EdEx thrusters used comply with all safety- relevant parameters (e.g. thruster category, surface temperature) Check whether the documentation is complete and comprehensive (e.g. approvals, conditions, certificates, tests to be carried out) 7.2.3 Technical parameters... -
Page 59: Help With Malfunctions
Help with malfunctions Faults and troubleshooting Help with malfunctions If used as intended, no typical malfunctions can occur on the EdEx thruster. However, malfunctions can occur due to wear or misuse. Malfunctions on the EdEx thruster may only be rectified when the system is stopped, disconnected from the power supply and the movements have come to a standstill. - Page 60 Help with malfunctions Faults and troubleshooting Table 23: Faults and troubleshooting Fault Possible cause Measure Lack of operating fluid Top up the operating fluid Operating fluid On the lifting rod seal Replace the EdEx thruster and send to escapes the manufacturer for repair Check the sealing ring, tighten the filling On the filling screw screw to a maximum of 65 Nm...
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Page 61: Maintenance
Maintenance work must be carried out by qualified maintenance personnel only. Repairs may only be carried out by the manufacturer EMG Automation GmbH, by authorised personnel or by a recognised body. The EdEx thruster and the connections may only be opened if no explosive atmosphere is present. -
Page 62: Maintenance Tasks
Maintenance Maintenance tasks Maintenance tasks WARNING Hot surface Stored residual heat poses a risk of burns if you touch the housing surface – EdEx thrusters can reach housing surface temperatures of up to 100 °C in continuous mode S1 or in very high switching mode S3. -
Page 63: Operating Fluid
Maintenance Maintenance tasks WARNING Cylinder movements Risk of crushing between surrounding hindrances and the cylinder or connected components as a result of the cylinder retracting automatically due to the reset spring with a hydraulic pressure drop, or if the power supply is interrupted. –... -
Page 64: Intervals For Renewing The Operating Fluid
Maintenance Maintenance tasks EdEx thrusters are filled with Pentosin operating fluid (hydraulic oil) of class HL10 DIN 51524 for the temperature range of -25 °C to +40 °C when delivered. Special operating fluids are required for other temperature ranges (⇒ Technical data chapter, Operating fluid section). -
Page 65: Seals
Maintenance Maintenance tasks Check the fill level according to the EdEx type and top up if required. Figure 12: Adjustment parts, lifting/lowering/throttle valve Fill level Screw plug Filling opening Regulating screw Topping up the operating fluid Fill the EdEx thruster with operating fluid up to the filling nozzle bottom edge. -
Page 66: Changing The Operating Fluid
Maintenance Maintenance tasks 9.2.5 Changing the operating fluid WARNING Hot operating fluid Risk of burns due to hot oil plumes upon opening the filling screw when at operational temperature. – The operating fluid may only be checked, topped up or drained when switched off and cool. -
Page 67: Maintenance Schedule
Maintenance Maintenance schedule Maintenance schedule Table 25: Maintenance log for EdEx thrusters EdEx type Serial number System ID Classification Standard Higher according to section requirements requirements 3.1 (table 1) Test object Test interval according to classification Test Test Evaluation / performed... -
Page 68: Classification
Maintenance Maintenance schedule Test object Test interval according to classification Test Test Evaluation / performed passed measured values Proof of insulation Every 2-3 years reliability in accordance with DIN 57530 part 1 / VDE 0530 section17.1 Maintenance Recommendation: Replacing all wear parts Every 5 years (bearings, seals,... -
Page 69: Disassembly
Disassembly Safety instructions 10.1 Disassembly 10.1 Safety instructions The following safety regulations must be adhered to before beginning any work on EdEx thrusters: Ensure that the industrial system is shut down. Disassembly may only be carried out if no explosive atmosphere is present. -
Page 70: Disconnecting The Electrical Connections
Disassembly 10.2 Disconnecting the electrical connections 10.2 Disconnecting the electrical connections DANGER Live components Fatal electric shock or serious burns. – Work on live components may only be performed by electricians. – First disconnect the electrical power supply. – The earthing conductor must be disconnected after all other cables. - Page 71 Disassembly Removal 10.3 NOTICE Suitable measures must be taken to prevent the EdEx thrusters falling before removing them. The EdEx thrusters weigh between 30 and 90 kg. NOTICE The lifting rod must not be damaged or contaminated, e.g. by paint as a result of painting the entire system. A failure to observe this will destroy the lifting rod.
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Page 72: Disposal
Disposal 11.1 Disposal consideration Disposal 11.1 Disposal consideration WARNING Opening the EdEx thrusters Risk of injury due to tensioned C-springs. – Only service partners authorised by the manufacturer are permitted to dismantle the EdEx thrusters outside the manufacturer’s factory. The manufacturer can dispose of EdEx thrusters for a charge in accordance with the applicable terms and conditions after they have been dismantled properly. -
Page 73: Lists
Lists Index of figures 12.1 Lists 12.1 Index of figures Figure 1: Thruster identification ..................... 22 Figure 2: Explosion protection identification ................. 23 Figure 3: Type plate ........................24 Figure 4: Test plate ........................25 Figure 5: Type EdEx........................31 Figure 6: Type EdEx-HV ....................... -
Page 74: Appendix
Appendix 13.1 EU Declaration of Conformity Appendix 13.1 EU Declaration of Conformity Figure 13: EU Declaration of Conformity 74 / 75 ELDRO-EdEx-Montageanleitung-607338-EN.docx... -
Page 75: Further Applicable Documents
Appendix Further applicable documents 13.2 13.2 Further applicable documents Table 27: Further applicable documents Document Designation EC Declaration of Incorporation EU Declaration of Conformity EU type examination certificate System and zone plan Maintenance documents for tests to be performed Cable gland assembly manual ELDRO-EdEx-Montageanleitung-607338-EN.docx 75 / 75...