Ace Sdh38eu Service manual

ACE Stoßdämpfer GmbH · Postfach 1510 · D-40740 Langenfeld · T +49 (0)2173 - 9226-10 (Technik -20) · F +49 (0)2173 - 9226-19 · [email protected] · www.ace-ace.comStand 03.2021 ACE Stoßdämpfer GmbH · www.ace-ace.com21_22_0019 Issue 05.2022

Table of contents Page

General instructions................................. 2

Safety information ................................... 2

Intended use........................................... 2

Description and function........................... 2

Calculation and design ............................. 2

Delivery and storage ................................ 2

Maintenance and care.............................. 2

Disassembly and disposal......................... 2

Mounting instructions........................... 3 - 5

Warranty ................................................. 6

Expected service life ................................. 6

Technical data.......................................... 6

SDH38EU

SDH50EU

SDH63EU

SDH38 to SDH63

Safety Shock Absorbers

Low reacting forces with long strokes

High rack damper, optimised characteristic

Energy capacity 3,600 Nm/cycle to 229,100 Nm/cycle

Stroke 50 mm to 800 mm

The identiﬁcation numbers listed are the

respective standard units of the corresponding

shock absorber series. Special types can have

deviating identiﬁcation numbers.

Operating and mounting instructions

General instructions and technical details

Piston Rod

Gas Accumulator

Positive Stop

Rod Button

Seals

Piston

Outer Body

Main Bearing

Pressure Chamber with

Metering Oriﬁces

Membran

General instructions

This manual is for the disruption-free use of the product

types listed on page 1; its compliance is a prerequisite

for the fulﬁlment of any warranty claims.

Therefore, make sure to read this manual before use.

Please always maintain the speciﬁed limits from the per-

formance table (technical data). Take into account the

predominant environmental conditions and restrictions.

Note the regulations of the trade association, TÜV or

corresponding national, international and European reg-

ulations. Installation and commissioning only according

to mounting instructions.

Intended use

ACE safety shock absorbers are machine elements to brake moving

masses in a deﬁned end position in emergency stop situations

for axial forces. The safety shock absorbers are not designed for

regular operational usage.

Description and function

The ACE safety shock absorbers SDH38 to SDH63 are mainte-

nance-free, ready-to-install hydraulic components with numerous

metering oriﬁces. During the slowing down process the moving

mass moves with kinetic energy and, if necessary, an additional

drive energy in the axial direction of the piston rod with a deﬁned

impact velocity against the rod end button of the shock absorber.

Alternatively, numerous shock absorbers can also be used in

parallel. During the initiated slowing down process the piston

rod is pushed into the shock absorber. The hydraulic oil located

before the piston is displaced through all metering oriﬁces at the

same time. The number of effective metering openings reduces

in proportion to the driven stroke. The retraction speed reduces.

The dynamic pressure applied in front of the piston corresponds

to the counterforce applied by the shock absorber and remains

approximately constant over the entire stroke. A requirement for a

constant rate of deceleration is the correct calculation of the safety

Delivery and storage

- After delivery please check the shock absorber for any damage.

- The shock absorber can become damaged if it falls. Carefully

remove shock absorber from the packaging.

- Shock absorbers can generally be stored in any position.

- Storage in the original packaging is preferred.

- Always store shock absorbers in a dry place in order to avoid

oxidation.

- The recommended maximum storage time is three years.

Maintenance and care

Safety shock absorbers are enclosed systems and therefore

do not need special maintenance. Safety shock absorbers that

are not regularly started up (e.g. emergency stop devices) are

checked at least once per year as part of the normal safety

check of the plant. Check that the return of the piston rod is in

the initial position, the damper is not leaking and the mounting

elements are properly secured. The piston rod must not exhibit

any damage. For safety shock absorbers that are regularly

operated, these checks should take place at intervals of no more

than three months.

Disassembly and disposal

Take account of environmental protection (recovery of problematic

substances) during disposal of the shock absorber. The SDH38

to SDH63 safety shock absorbers are ﬁlled with HLP 46. The

corresponding data sheet is available on request.

The SDH38 to SDH63 safety shock absorbers are repairable.

Faulty dampers can be sent to our service department for

determination of the cause of failure.

WARNING

If ACE safety shock absorbers are used where a failure of

the product could lead to personal injuries and/or material

damage, additional safety elements must be implemented.

Free-moving masses can lead to injuries by crushing

during installation of the shock absorber. Secure moving

masses against inadvertent starting with suitable safety

precautions before installing the shock absorbers.

Safety information

Calculation and design

In order to ensure an optimum, fault-free and durable function of

the safety shock absorbers they must be correctly dimensioned

and designed. The following parameters must be known and used

in the calculation:

- Moving mass [kg]

- Impact velocity of the mass into the shock absorber(s) [m/s]

- Additionally acting propelling force, propelling power or propel-

ling torque [N, kW, Nm]

- Number of shock absorbers acting in parallel [n]

- Number of strokes or cycles per hour [1/h]

The correct size of the safety shock absorbers can be determined

with the ACE online calculation programme at www.ace-ace.de.

You can also send us the completed online form via e-mail for

checking.

Or make use of our free calculation service by phoning: +49

(0)2173 - 9226-20.

General Function

F = Force (N) p = Internal pressure (bar) s = Stroke (m)

t = Deceleration time (s) v = Velocity (m/s)

* The load velocity reduces continuously as you travel through the stroke due to the

reduction in the number of metering oriﬁces (*) in action. The internal pressure remains

essentially constant and thus the Force vs. stroke curve remains linear.

*4 *3

p = 400 bar

v = 2 m/s

*2 *1 *0

p = 400 bar

v = 1,5 m/s

p = 400 bar

v = 1 m/s

p = 400 bar

v = 0,5 m/s

p = 0 bar

v = 0 m/s

F/p

s/t

shock absorber and therefore the correct selection of the right

metering oriﬁce pattern or the right hardness level of the shock

absorber.

WARNING

The dampers must be dimensioned in such a way that the

calculated values do not exceed the maximum values of the

respective performance table (technical data):

W3[Nm/cycle]

Effective weight me

Max. side load angle [°]

The calculation and design of the suitable safety shock

absorber should be undertaken by or checked by ACE.

For a correct damping design the safety shock absorber

must represent the only braking system in an emergency

stop.

Manual

Safety Shock Absorbers SDH38 to SDH63 (high rack damper, optimised characteristic)

Installation instructions

Before installation and use check whether the identiﬁcation num-

ber on the damper or on the packaging matches the respective

designation on the delivery note.

Operating temperature range: -20 °C to +60 °C

Mounting: As required but always in such a way that the entire

damper stroke is used. The dampers must always be mounted

in such a way that the forces are introduced centrally over the

piston rod in the damper. The maximum side load angle must

not be exceeded. Safety dampers must not be exchanged from

one installation site to another if the conformity of the throttle

characteristic curve is not ensured.

Packaging disposal

Please dispose of the transportation packaging in an environ-

mentally-friendly manner. Recycling packaging materials saves

raw materials and reduces waste. The packaging materials do not

contain any prohibited materials.

Emergency stop application: After an emergency stop, check

that the piston rod returns to the initial position, the damper is not

leaking and the mounting elements are properly secured. Make

sure that no damage has occurred to the piston rod, the body, or

the mounting hardware.

Regular start-up: Safety shock absorbers can be regularly

started up with 100 % stroke utilisation with a creep speed of 1/10

of the max. impact velocity.

Checking: A regular check should take place at an interval of no

more than three months.

Commissioning

First impacts on the shock absorber should only be tried after

correctly mounting and with reduced impact velocity and – if

possible – with reduced load. Differences between calculated and

actual operating data can then be detected early on, and damage

to the system can be avoided. If the safety dampers were selected

on calculated data that does not correspond to the maximum

possible loading (i.e. selection based on drive power being

switched off or at reduced impact velocity) then these restricted

impact conditions must not be exceeded during initial testing

or subsequent use of the system. Otherwise you risk damaging

the shock absorbers and/or machine by overstressing materials.

After the initial trial, check that the piston rod fully extends again

and that there are no signs of oil leakage. Also check that the

mounting hardware is still securely tightened. Make sure that no

damage has occurred to the piston rod, the body, or the mounting

hardware.

Performance data and dimensions

Mounting type

TYPES

1Energy capacity

Nm/cycle

1Reacting force

Return Force min.

Return Force max.

Stroke

A max.

E max.

F and R

Weight

SDH38-50EU 3,600 80,000 600 700 50 270 204 165 84 14.0 13.7

SDH38-100EU 7,300 80,000 600 700 100 370 254 215 13 4 15.5 15.7

SDH38-150EU 10,900 80,000 600 700 150 470 304 265 184 17.0 17.2

SDH38-200EU 14,500 80,000 600 700 200 585 369 330 234 20.0 19.7

SDH38-250EU 18,200 80,000 600 700 250 685 419 380 284 22.0 21.7

SDH38-300EU 21,800 80,000 600 700 300 800 484 445 334 24.0 23.7

SDH38-350EU 25,500 80,000 600 700 350 900 534 495 384 26.0 25.7

SDH38-400EU 29,100 80,000 600 700 400 1,015 599 560 434 28.0 28.2

SDH38-500EU 36,400 80,000 600 700 500 1,230 714 675 534 32.0 32.2

SDH38-600EU 43,600 80,000 600 700 600 1,445 829 790 634 36.0 36.2

SDH38-700EU 50,900 80,000 600 700 700 1,660 944 905 734 40.0 40.2

SDH38-800EU 58,200 80,000 600 700 800 1,875 1,059 1,020 834 44.0 44.2

1The values apply to mounting style Front Flange and Foot Mounting. For mounting style Rear Flange, please consult ACE.

In case of an existing side load angle, please consult ACE.

BStroke

A max

120

160

115

BStroke

A max

120

160

115

D ± 1 E max

Stroke

A max

160

190

115

SDH38-R Rear Flange

SDH38-S Foot Mount

SDH38-F Front Flange

WARNING

Take particular care that the customer-speciﬁc

identiﬁcation number at the end of the damper designation

matches the number on the delivery note. The ﬁeld data

to be read from the type plate, such as moving mass and

maximum impact velocity, must be compared with the

technical design. This ensures that the damper is the right

size for its use. Otherwise you risk damaging the shock

absorbers and/or machine by overstressing materials.

The gas accumulators of the SDH38 to SDH63 safety shock

absorbers are ﬁlled with nitrogen ex works. The respective

ﬁlling pressure (5 bar) can be found on the damper

label. The dampers may only be operated with this ﬁlling

pressure. A reduced ﬁlling pressure can lead to serious

malfunctions.

During installation of the dampers, moving masses can

lead to injuries due to inadvertent starting. Secure moving

masses against inadvertent moving.

The dampers may be unsuitable for use and have an

insufﬁcient damping effect. Check the speciﬁc suitability

of the dampers before installation.

If operated outside of the operating temperature range,

the damper can lose its function. Operating temperature

range must be maintained. Do not paint dampers due to

heat emission.

Fluids, gases and dirt particles in the surrounding area can

attack or destroy the seal system of the damper and cause

it to fail. Protect or encapsulate piston rod and seal system

from external materials in the surrounding area.

Damage to the piston rod surface can destroy the seal

system. Do not grease, oil piston rod etc. and protect

against dirt particles.

The piston rod can be torn from the damper. Do not load

the piston rod with tensile stress.

Damper can tear off upon impact. Always lay out the

connection structure in such a way that the maximum

occurring forces can be absorbed with sufﬁcient safety.

Safety shock absorber check after a damper impact.

Check that the piston rod returns to the initial position,

the damper is not leaking and the mounting elements are

properly secured.

Mounting accessories

If using accessory parts and mounting elements, note the respec-

tive separate mounting instructions for accessories.

Mounting instructions and mounting accessories

Safety Shock Absorbers SDH38 (high rack damper, optimised characteristic)

Performance data and dimensions

Mounting type

TYPES

1Energy capacity

Nm/cycle

1Reacting force

Return Force min.

Return Force max.

Stroke

A max.

E max.

F and R

Weight

SDH50-100EU 14,500 160,000 1,000 1,200 100 416 297 258 139 23.5 25.0

SDH50-150EU 21,800 160,000 1,000 1,200 150 516 347 308 189 26.0 27. 5

SDH50-200EU 29,100 160,000 1,000 1,200 200 616 397 358 239 28.5 30.0

SDH50-250EU 36,400 160,000 1,000 1,200 250 731 462 423 289 32.0 33.5

SDH50-300EU 43,600 160,000 1,000 1,200 300 831 512 473 339 34.5 36.0

SDH50-350EU 50,900 160,000 1,000 1,200 350 931 562 523 389 37.0 38.5

SDH50-400EU 58,200 160,000 1,000 1,200 400 1,046 627 588 439 40.0 41.5

SDH50-500EU 72,700 160,000 1,000 1,200 500 1,261 742 703 539 46.0 47. 5

SDH50-600EU 87,300 160,000 1,000 1,200 600 1,476 857 818 639 52.0 53.5

SDH50-700EU 101,800 160,000 1,000 1,200 700 1,691 972 933 739 58.0 59.5

SDH50-800EU 116,400 160,000 1,000 1,200 800 1,906 1,087 1,048 839 64.0 65.5

SDH50-1000EU 145,500 160,000 1,000 1,200 1,000 2,336 1,317 1,278 1,039 75.0 76.5