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Schaeffler EWELLIX EMA-100 Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
EMA-100
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Summary of Contents for Schaeffler EWELLIX EMA-100

  • Page 1 CATEGORY MAX 2 LINES INSTALLATION, OPERATION AND MAINTENANCE MANUAL EMA-100 3. Heading_cover max 2 lines Subheading max 2 lines...
  • Page 2 EMA-100 Contents 1. General information ............3 7.6.1 Parallel mounting .............20 1.1 Information about this manual ........3 7.6.2 Tools needed ............21 7.6.3 Step-by-step instructions ........21 1.2 Explanation of symbols and signal words ....3 1.3 Limitation of liability ............4 7.7 Centrifugal brake mounting......... 31 1.4 Spare parts ..............4 7.8 Motor N11 connector and pinning ......
  • Page 3 EMA-100 1. General information 1.1 Information about this DANGER Indicates a dangerous situation, which will lead to death or manual serious personal injury, if the precautionary measures are ignored. This manual provides important information on how to work  with the actuator safely and efficiently. WARNING The manual is part of the device, must always be kept in the  Indicates a dangerous situation, which can lead to minor or device’s direct proximity and should be available for person- moderate injury or property damage, if the precautionary nel to read at any time. All personnel working with the device ...
  • Page 4 EMA-100 1.3 Limitation of liability 1.5 Warranty terms All information and notes in this manual were compiled un- The applicable and effective warranty terms are those con- der due consideration of valid standards and regulations,  tained in the manufacturer’s terms and conditions of sale. the present status of technology and our years of knowledge and experience. The manufacturer will not be liable for damage resulting from: • ...
  • Page 5 EMA-100 2. Safety This chapter provides an overview of all important safety  In addition to following the safety instructions in this manual, precautions for protection of personnel as well as safe and the owner or processor must do the following concerning trouble-free operation. the safety and accident prevention guidelines and environ- mental protection regulations applicable to the site of the Disregarding this manual and the safety precautions speci- system’s installation: fied therein may result in increased risk of serious injury or ...
  • Page 6 EMA-100 2.3 Personnel requirements NOTE The processor must decide which applications require the installation of an emergency shut-off system. WARNING Improper installation, operation and maintenance can result in serious injury, death or property damage. 2.5 Modifications to the Use only qualified, trained personnel (as described below) who  device have read, understand and follow these instructions. To avoid hazardous situations and to ensure optimal perfor- 2.3.1 Qualifications mance, do not make any changes or modifications to the de- The following qualifications are specified for different areas ...
  • Page 7 EMA-100 3. Technical data NOTE 3.2 Product labels The technical data (dimensions, weight, output, connection values, etc.) can be found in the drawings and data sheets at the  3.2.1 Linear unit label 11. Appendix, page 42). end of this manual (see chapter 3.1 Operating conditions Environment Information Value Unit Temperature range –20 to +50 °C Relative atmospheric humidity, maximum (no build up of condensation) The product label provides the following information:...
  • Page 8 EMA-100 4. Structure and function 4.1 Product and option 4.2 Brief description overview The EMA-100 is a mechanical drive designed to work in vari- ous types of machines. The drive is used exclusively for dy- namic center compression or traction movement. The linear unit (7) is powered thru a coupling (5) by a motor (6). The motor (6) sets in motion either a ball or a roller screw system.
  • Page 9 EMA-100 4.3 Direction of motor during 4.4 Overview extension of the cylinder 4.4.1 EMA-100 linear unit accessories overview GB-100-GI; inline gearbox GB-100-GS; Spur gearbox EMA-100 accessories GB-100-GB; Belt gearbox 1. Linear unit 2. Proximity sensor 3. Foot mount 4. Pivot pin (pair) 5a.
  • Page 10 EMA-100 5. Delivery, packaging and storage 5.1 Safety information for 5.3 Returning actuator to the transport manufacturer Proceed as follows for the return transport: NOTICE 1. Dismantle the device if necessary (see chapter  Damage due to improper transporting 10. Dismantling, page 41). Significant material damage can occur in conjunction with  2. Pack device in its original packaging. Follow storage  improper transport. 5.5 Storage, page 11).
  • Page 11 EMA-100 5.5 Storage Pack the actuator in its original packaging for storage. •  Do not store outside. •  Storage should be dry and dust-free. •  Keep away from any aggressive media. •  Protect from UV radiation. •  Avoid mechanical vibrations. •  Storage temperature: –40 to 50 °C. • ...
  • Page 12 EMA-100 6. Installation and initial operation Authorized personnel The EMA-100 Linear actuator (see image below) is attached to two elements via the push tube and the mounting  The installation and initial operation may only be conducted accessories. by qualified personnel. 1. Assemble the gearbox and motor onto the linear unit if 7.5 Final in- the product is not premounted (see chapter WARNING...
  • Page 13 EMA-100 WARNING Risk of injury and material damage due to insufficient fastening! Only use fastening bolts and secure them adequately. Do not use screws to install. Never loosen or remove screws on the actuator. 6. During installation, ensure that the applied force is al- ways directed on the center of the actuator. WARNING Risk of injury and material damage due to incorrect installation!
  • Page 14 EMA-100 7. Operation NOTICE 7.1 Safety Material damage through overheating. An overheating of the device can cause damage. Therefore: DANGER Only use control integrated thermal switch. Risk of crushing While moving onto solid objects, the force of the device may  cause injuries. NOTICE Therefore: Actuator may be damaged if chemical substances penetrate Ensure that there are no persons in the stroke area of the device  the  actuator or get in touch with the actuator’s surface. Keep  while in operation. chemical substances away. Take note of maximum permissible operating parameters for the device (see chapter 11.
  • Page 15 EMA-100 7.5 Final installation instruction of actuator 7.5.1 Motor adapter The motor adapter is to install a motor with an axially de- 7.5.2 Recommended motors, signed shaft (see chapter page 15) to a EMA-100 linear unit. 7.5.2 Recommended motors The Siemens motors provided by Ewellix come with a differ- ential resolver or multi-turn encoder, a shaft-end with key- way (1FK7044 without) and a holding brake.
  • Page 16 EMA-100 7.5.4 Synchronous Servo Motors Inline mounting •  Attach the coupling (C1) on the linear unit (LU) using screw (S4) as described in 7.5.3. •  Fit the inline gearbox (GB) on the linear unit (LU) by insert- ing the gasket (G1) between the two components and tightening the housing using four screws (S1).
  • Page 17 EMA-100 Parallel mounting - Spure gearbox - Servo motor •  Fit the linear unit (LU) onto the gearbox (GB) by inserting the gasket (G3) between the two components and tighten the screws (S1). •  Attach the coupling (C1) to the motor (M) using screw (S4) as described in 7.5.3.
  • Page 18 EMA-100 7.5.5 Asynchronous Motors Inline mounting G2 SM3* *These screws depend on the motor type they do not correspond to the same indices as in table 1 •  Attach the coupling (C1) to the motor (M) using screw (S4) as described in 7.5.3. • ...
  • Page 19 EMA-100 Parallel mounting - Spure gearbox •  Attach the coupling (C1) to the motor (M) using screw (S4) as described in 7.5.3. •  Put the sealing (G1) into the groove in the motor flange  (MF) and tighten the flange with four screws (SM3). •  Fit the linear unit (LU) onto the gearbox (GB) by inserting the gasket (G3) between the two components and tighten the screws (S1).
  • Page 20 EMA-100 7.6 Belt gearbox mounting 7.6.1 Parallel mounting Delivery scope – Complete actuator with Figure 1 Belt gearbox mounted and without motor Belt gear with linear unit, with motor adapter kit and without motor. Start at step 2 Delivery scope - Belt gearbox only Figure 2 Belt gear without linear unit, without motor kit and without motor.
  • Page 21 EMA-100 Figure 4 7.6.2 Tools needed Not included in kit from Ewellix 1. Torque wrench 0-81 Nm with Allen key sockets 3, 4, 5, 6, 7, 8, 10 mm 2. T10 torx. 3. Allen keys, 3, 4, 5, 6, 7, 8 and 10mm. 4.
  • Page 22 EMA-100 Step 2: Mount motor adapter kit, AC-motor. Step 3: Mount motor flange, AC-motor. Only valid for AC-motor, if Servo motor skip to step 4. Only valid for AC-motor4. WARNING WARNING Ingoing parts can vary depending on motor kits and motor type Ingoing parts can vary depending on motor kits and motor type 1. Insert spider element (C1) in the coupling (C2). 2. Mount coupling on the motor (M). 1. Mount motor adapter kit to the belt gear housing. The kit 3.
  • Page 23 EMA-100 Step 4: Mount servo motor Only valid for servo motor. WARNING Ingoing parts can vary depending on motor kits and motor type C2 C3 1. Mount spider element (C1) into the coupling (C2). 2. Secure the coupling (C2) to the motor (M) using coupling screw (M6x20) (C3) and torque the screw to 15 Nm. 3.
  • Page 24 EMA-100 Figure 8 Figure 9 Step 5: Mount belt pulley and taper bushing on linear unit. 1. Place belt pulley with the side plates removed, around  the spline shaft. The pulley will only fit one way. 2. Mount taper lock bushing with spline all the way up against the linear unit spline and nut. 3. Take the setscrews and degrease the screws using Loctite SF 7063.
  • Page 25 EMA-100 Step 7: Mount belt pulley and belt on shaft. Figure 13 Figure 14 1. For belt gear 1:1 do not install the sleeve. On belt gear  For gear ratio 1:1 For gear ratio 2:1 2:1, install sleeve on the shaft (see figure 14). 2. Place belt pulley around shaft. 3. Place belt around both pulleys. 4. Take 1x taper bushing and push it on to the shaft. Use Taper bushing mounting tool and a plastic mallet to gen- tly tap the bushing all the way on to the shaft.
  • Page 26 EMA-100 Step 8: Secure belt pulley on shaft Figure 19 Figure 20 1. The bushing has 3 or 4 holes depending on the bushing type, 2 of them has threads. Insert the set screws in the threaded ones to tighten the bushing. The hole that is threaded in the pulley is used for loosening the bushing.
  • Page 27 EMA-100 Step 9: Mount interface adapter. Figure 23 Figure 24 Only valid for thick cover, if thin cover skip to step  1. Apply Loctite 243 to the first 10 threads of 1x  screw (M4x25). 2. Insert adapter in the shaft. 3. Torque the screw to 2,9 Nm using a torque wrench Figure 25 Figure 26 Figure 27 Step 10: Mount interface cover on thick cover.
  • Page 28 EMA-100 Step 11: Fit rubber seal on thick cover. Figure 29 Figure 30 1. Mount Seal in the cover.  2. Orient the seal with the flat part of the seal facing down  in the groove like the picture shows (see figure 31). 3. Make sure that it sits in the intended groove all the way  around (see figure 29). Figure 31 Figure 32 Figure 33 Step 12: Mount set screws on thick cover, if no rear attachment.
  • Page 29 EMA-100 Step 13: Mount casted cover Figure 35 Figure 36 1. Place 2x pins in their designated holes marked with red on the figure 35 in the belt gear housing. If the pin will not go in easily, use a plastic mallet and gently tap it in. 2.
  • Page 30 EMA-100 Step 15: Mount rear attachment. Figure 41 Figure 42 1. EMA-100-#-xx-0100-Axxxxxx-xxxx00-GB-Cxx-0x-MA- B=0° C=90° xx-xxx-xx-000 0= No rear attachment, B= 0° and C= 90° 2. Apply Loctite 243 to the first 10 threads all the way  around 4x screws (M12x25). 3. Study the order key to check the orientation of the attachment.
  • Page 31 EMA-100 Connecting U V W power wires 7.7 Centrifugal brake mounting Assembly sequence for washers, spring-washer and M6 nut: 3x M6 tightening torque 4.6 - 5.6Nm Figure 46 Install cable, install washer •  Remove cover from gearbox (1) and insert key (2) into groove in gearbox input shaft. • ...
  • Page 32 EMA-100 7.9 Detection of mechanical This sensor placement allow for a usable sensor field of  40 mm (+20/-20mm) from centre of sensor field and leaves  end stops 10 mm on both ends unused for tolerance stack-ip to be covered. •  Preferably the actuator is driven manually for the end stop  detection. If not possible, the speed and the torque of the NOTE screw must be lower than 125 mm/s respectively 20 Nm  Instructions to install the sensor can be found on the supplier’s  (input torque at linear unit). Higher speed or torque could website.
  • Page 33 EMA-100 7.11 Accessories NOTICE T-bar can rotate to aid assembly. The rotation feature is for 7.11.1 Linear unit accessories installation purpuse only. Constant rotation during regular operation should be prevented. Rod End Front Attachment T-Bar Type Screw MS Torque Type Screw MS Torque ZBE-377900 M10×25 48 Nm...
  • Page 34 Stroke + ZA EMA-100 Ø80 -0,02 -0,07 Spline DIN 5480 W 30x1,25x22x8f Pivot housing relubricant PL2 PL3 ventilation Recommended Type Bushing diameter EMA-100-1-xx-xxxx-xxxE1xx Ø38.1 +0,02 Ø38,23-38,48 –0,03a 7.11.2 Gearbox accessories Rear Attachment Recommended Type Gearbox type Screw MS Torque Secure it with shaft tolerance: ZBE-377921 Spur gearbox...
  • Page 35 EMA-100 8. Maintenance Personnel •  Daily maintenance work described herein can be per- formed by the operator. •  Some maintenance tasks should only be performed by specially trained, qualified personnel employed by the  product owner, or exclusively by personnel of the manu- facturer; specific reference will be made in each case in  the description of the respective maintenance task. •  Only professional electrician. 8.1 Maintenance plan Maintenance tasks that are required for optimal and trou- ble-free operation are described in the sections below.
  • Page 36 EMA-100 8.2 Maintenance work 8.2.3 Check of visual condition To be performed by qualified personnel. 8.2.1 Cleaning 1. Separate the device from the energy supply. To be performed by operator. 2. Check the following structural components for visual ex- ternal damage: NOTICE •  Check profile and housing for cracks and gaps (1) Damage due to incorrect cleaning. Therefore: •  Check centrifugal brake housing for damage. In case of Do not use any aggressive cleaning agents. Water used for ...
  • Page 37 EMA-100 WARNING Risk of injury and material damage! Only open the relubrication bore when the actuator is stopped and powered off. Table 7 EMA-100 linear actuator relubrication interval Type Relubrication position Relubrication interval Amount of lubricant Screw type Nominal stroke: 40 mm EMA-100-1-BA-…...
  • Page 38 EMA-100 8.5.4 Instructions for replacing the Figure 50 belt Casted cover 4×M6 Step 1: Remove the rear cover of the belt gear. 1. Remove the two bolts holding the label plate. 2. Remove all bolts holding the belt cover (4x M6 and 4x  Washer M10). 3. Leave the 4x bolts holding the brake cover. Brake cover 4. Remove the belt cover from the belt gear housing.  Label plate Step 2: Remove the upper belt pulley and the belt 1.
  • Page 39 EMA-100 9. Malfunctions The following chapter describes potential causes for disrup- tions and the work that is necessary to restore operation. In the event of more frequent malfunctions, shorten the  maintenance intervals. Contact the manufacturer concerning malfunctions which are not solved by the repair suggestions in the table below;  see service address on the back cover.  Personnel •  Unless indicated otherwise, the work described herein to solve malfunctions may be performed by the operator.
  • Page 40 EMA-100 9.1 Malfunction table Malfunction Possible cause Repair malfunction To be repaired by Linear actuator Obstacle in the stroke area of the linear Remove all obstacles in the stroke area. Operator. doesn’t move actuator. Measure static and dynamic load and compare with information concerning the product label. If Incorrect load.
  • Page 41 EMA-100 10. Dismantling Personnel 10.2 Disposal •  The dismantling may only be carried out by specifically  To the extent that no take-back or disposal agreement has qualified personnel. been put in place, disassembled components should be •  Work on the electric system may only be performed by recycled. professional electricians. • ...
  • Page 42 EMA-100 11. Appendix A complete description of the actuator’s performance can  be found in the following document: Technical data PUB IL-07016 EN Electric cylinder EMA-100 For further technical information please contact Ewellix. For quick reference, the most relevant performane parame- ters are shown in the following section. 11.1 Liner Unit 11.1.1 Ingress Protection The following position in the type key defines the rated in- gress protection: EMA-100-#-##-####-#######-X####-…...
  • Page 43 EMA-100 Buckling load [kN] EMA-100-1-BA EMA-100-1-BB / EMA-100-1-CB EMA-100-1-RA 0 200 1 000 1 400 1 800 2 200 Stroke [mm] Depending on front and rear attachments used there can be additional limitations Front housing attachment [Y] Rear housing attachment [Z] Load C, D, E See fig. “Housing Attachment Lifetime Chart”...
  • Page 44 EMA-100 11.2 Gearbox 11.2.1 Output Torque If a gearbox is selected, the following maximum output torques must be respected: EMA-100-#-##-####-#######-######-GX-YY#-##-… Gearbox Type [X] Gear ratio [YY] Nominal output torque Max. Output Torque I - Inline 75 Nm 150 Nm S - Spur CB (4:1), CC (10:1), CD (25:1) 100 Nm 300 Nm...
  • Page 46 Due to continuous improvements being made in our products, the product’s appearance and specifications are subject to change without notice. PUB TC-08001/8-EN-November 2024 Certain image(s) used under license from Shutterstock.com. Schaeffler and the Schaeffler logo are trademarks of the Schaeffler Group.