EMG ELDRO EdEx Series User manual

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

Table of contents
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Table of contents
1 General........................................................................................................ 6
1.1 Information about this assembly manual ......................................................................... 6
1.2 Manufacturer........................................................................................................................ 6
1.3 Validity .................................................................................................................................. 7
1.4 Further applicable documents ........................................................................................... 7
1.5 Formal information about this assembly manual ............................................................ 7
1.6 Format conventions ............................................................................................................ 8
1.7 Structure of warning notices ............................................................................................. 9
1.8 Terms and abbreviations .................................................................................................... 10
2 Safety .......................................................................................................... 12
2.1 General ................................................................................................................................. 12
2.1.1 For use in potentially explosive areas ................................................................................... 13
2.2 Intended use ........................................................................................................................ 14
2.3 Unintended use ................................................................................................................... 16
2.4 Staff qualifications .............................................................................................................. 16
2.4.1 Qualified personnel ............................................................................................................... 17
2.4.2 Qualified electrician ............................................................................................................... 17
2.4.3 Maintenance staff .................................................................................................................. 18
2.4.4 Authorised personnel ............................................................................................................ 18
2.4.5 Qualified person .................................................................................................................... 18
2.4.6 Responsible staff ................................................................................................................... 19
2.5 Personal protective equipment.......................................................................................... 19
2.6 Electrical equipment ........................................................................................................... 20
2.7 Process media ..................................................................................................................... 21
2.8 Modifications ....................................................................................................................... 21
2.9 Spare and wear parts .......................................................................................................... 21
3 Technical data ............................................................................................ 22
3.1 Thruster identification ........................................................................................................ 22
3.2 Explosion protection identification ................................................................................... 23
3.2.1 EdEx identification ................................................................................................................. 23
3.3 Specifications on the type plate ........................................................................................ 24
3.4 Specifications on the test plate ......................................................................................... 25
3.5 Characteristics .................................................................................................................... 26
3.5.1 Short lift thrusters .................................................................................................................. 26
3.5.2 Long lift thrusters ................................................................................................................... 28
3.5.3 Setting times.......................................................................................................................... 30

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3.6 Dimensions .......................................................................................................................... 31
3.6.1 Type EdEx ............................................................................................................................. 31
3.6.2 Type EdEx-HV....................................................................................................................... 32
3.7 Electrical system ................................................................................................................. 33
3.7.1 Voltage and frequency .......................................................................................................... 33
3.8 Operating fluid ..................................................................................................................... 33
3.9 Airborne sound emissions ................................................................................................. 34
3.10 Operating conditions .......................................................................................................... 34
3.10.1 Ambient temperature ............................................................................................................. 34
3.10.2 Air humidity ............................................................................................................................ 34
3.10.3 Aggressive ambient conditions ............................................................................................. 34
3.10.4 Installation height .................................................................................................................. 34
4 Functional description............................................................................... 35
4.1 Mechanical layout ............................................................................................................... 36
4.2 Electrical equipment ........................................................................................................... 37
4.2.1 Motor ..................................................................................................................................... 37
4.2.2 Operating modes ................................................................................................................... 37
4.2.3 Junction box .......................................................................................................................... 37
4.3 Electrical and mechanical additional equipment ............................................................. 38
4.3.1 Lift, lowering or throttle valve (H, S, D) ................................................................................. 38
4.3.2 Brake spring – C-spring ........................................................................................................ 38
4.3.3 Regulating spring – R-spring ................................................................................................. 38
4.4 Function sequence ............................................................................................................. 39
5 Transport and storage ............................................................................... 40
5.1 Transport .............................................................................................................................. 40
5.1.1 Transport sketch ................................................................................................................... 41
5.2 Storage ................................................................................................................................. 42
6 Assembly and installation ......................................................................... 43
6.1 Assembly ............................................................................................................................. 43
6.1.1 Permissible installation positions .......................................................................................... 45
6.1.2 Installing the EdEx thruster ................................................................................................... 45
6.2 Electrical connection .......................................................................................................... 47
6.2.1 Junction box and terminal diagram ....................................................................................... 49
6.2.2 Earthing conductor connection.............................................................................................. 51
6.2.3 Power supply connection ...................................................................................................... 51
6.3 Adjusting the valves ........................................................................................................... 53
6.3.1 Installation location of the regulating screw .......................................................................... 54
6.3.2 Changing the set time and the reset time ............................................................................. 55
6.4 Completing assembly ......................................................................................................... 55
7 Notes on operation .................................................................................... 56

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7.1 Safety instructions .............................................................................................................. 56
7.2 Tests before commissioning ............................................................................................. 57
7.2.1 Operating conditions ............................................................................................................. 57
7.2.2 Order parameters .................................................................................................................. 58
7.2.3 Technical parameters ............................................................................................................ 58
7.3 Operating modes ................................................................................................................. 58
8 Help with malfunctions .............................................................................. 59
8.1 Faults and troubleshooting ................................................................................................ 59
9 Maintenance ............................................................................................... 61
9.1 Safety instructions .............................................................................................................. 61
9.2 Maintenance tasks .............................................................................................................. 62
9.2.1 Operating fluid ....................................................................................................................... 63
9.2.2 Intervals for renewing the operating fluid .............................................................................. 64
9.2.3 Checking the operating fluid .................................................................................................. 64
9.2.4 Seals ..................................................................................................................................... 65
9.2.5 Changing the operating fluid ................................................................................................. 66
9.3 Maintenance schedule ........................................................................................................ 67
9.3.1 Classification ......................................................................................................................... 68
10 Disassembly ............................................................................................... 69
10.1 Safety instructions .............................................................................................................. 69
10.2 Disconnecting the electrical connections ........................................................................ 70
10.3 Removal ............................................................................................................................... 70
11 Disposal ...................................................................................................... 72
11.1 Disposal consideration ....................................................................................................... 72
12 Lists ............................................................................................................ 73
12.1 Index of figures.................................................................................................................... 73
12.2 Index of tables ..................................................................................................................... 73
13 Appendix..................................................................................................... 74
13.1 EU Declaration of Conformity ............................................................................................ 74
13.2 Further applicable documents ........................................................................................... 75

1 General
1.1 Information about this assembly manual
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1 General
1.1 Information about this assembly manual
This assembly manual was prepared according to the principles of
technical editing and the minimum legal requirements of directive
2006/42/EU are used as a basis. The assembly manual enables the
safe and efficient operation of the ELDRO® EdEx electro-hydraulic
lifting thruster (subsequently referred to as EdEx thruster).
This assembly manual is part of the EdEx thruster and must be kept
in its immediate vicinity and accessible to staff at all times.
The staff must have read this assembly manual carefully and
understood it before starting any work.
Version Description Date Author
V1.0 First draft of the test version
for DEKRA EXAM GmbH
21/10/2019 CE Design
V1.1 First draft 27/03/2020 CE Design
V1.2 Declaration of conformity +
footer
14/05/2020 EMG
1.2 Manufacturer
EMG Automation GmbH
Werk Oschersleben
Am Pfefferbach 20
39387 Oschersleben / Germany
Phone [phone]
Fax [phone]
Email [e-mail]
Website www.emg-automation.com

General 1
Validity 1.3
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1.3 Validity
This manual corresponds to the technical state of the EdEx thruster at
the time of issue. 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
inaccuracies or incorrect specifications in this manual, which are
caused by content and technical changes after delivering this EdEx
thruster, as there is no obligation to update this manual continually.
1.4 Further applicable documents
All documents listed in the appendix (further applicable documents) to
this assembly manual must be observed.
1.5 Formal information about this assembly manual
Document version: V 1.1
Date: 03.2020
© Copyright, 2020
All rights reserved.
Reprinting, including excerpts, is only permissible
with the approval of EMG Automation GmbH.

1 General
1.6 Format conventions
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1.6 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
assembly manual or to further applicable
documents
(e.g
⇒
Technical data chapter)
This signal word indicates an immediate
threat of danger. If this danger is not
avoided, this will result in death or serious
injuries.
This signal word indicates a possible
danger. If this danger is not avoided, this
may result in death or serious injuries.
This signal word indicates a possibly
dangerous situation. If this dangerous
situation is not avoided, this may result in
minor or moderate injuries.
This signal word indicates actions for
preventing property damage. Observing
this information prevents damage or
destruction of the EdEx thruster.
Supplementary information

General 1
Structure of warning notices 1.7
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1.7 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
– Measures for avoidance/prohibited actions
Hazard signs
The hazard sign indicates warning information that alerts you of
personal injury hazards.
Source of danger
The source of the danger indicates the cause of the hazard.
Possible consequences of non-compliance
The possible consequences when failing to observe the warning
information are bruises, burns or other serious injuries.
Measures/prohibited actions
Measures / prohibited actions contains a list of instructions that must
be implemented in order to avoid a hazard or that are prohibited in
order to avoid a hazard.

1 General
1.8 Terms and abbreviations
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1.8 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.
Damping spring (D-spring) Spring for gentle braking. This reduces the braking force by applying the
brake shoes continuously until the stop value is reached. When bleeding
the brake, the braking force reduces continuously from the highest value
to zero (releasing the brake shoes). This function is only available in
combination with the C-spring.
ED Duty cycle
EdEx thruster Electro-hydraulic lifting thruster in explosion-proof design that converts
electrical energy into mechanical energy in a straight line movement by
hydraulic means
EN European standard
EPL Equipment Protection Level
Highest value for additional
load
Total of the forces that apply to the lifting rod head and that affect the
lifting movement and setting time, e.g. friction and mass of the connection
elements
Lifting valve H Valve to reduce the lifting speed
Throttle valve D Valves to reduce the lifting and lowering speeds
Lifting time Time from switching the motor on until the top piston limit position is
reached
Nominal operating point Operating point that is at 1/3 of the nominal lift
Nominal lift Maximum path that the extending lifting rod can take
Nominal reset force Minimum force at the nominal operating point for a machine with reset
spring C
Nominal actuating force Usable hydraulic force on the lifting rod head for a machine without reset
spring c
Regulation braking Braking to regulate three-phase motors to low speeds, virtually
independent of the load. A pump wheel with optimum adjustment
determines the hydraulic force with the nominal reset force. Thrusters for
regulation braking are equipped with reset spring C and damping spring
D.
Regulating spring (R-spring) See damping spring
Reset spring See brake spring
Lowering valve S Valve to reduce the lowering speed

General 1
Terms and abbreviations 1.8
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Table 2: Terms and abbreviations
Term/abbreviation Meaning
Lowering time Time from switching the motor off until the bottom piston limit position is
reached.

2 Safety
2.1 General
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2 Safety
EdEx thrusters are reliable electro-hydraulic machines for use in
industrial systems. They are state of the art.
The generally applicable regulations and other binding directives
regarding health and safety, accident prevention and environmental
protection must be adhered to.
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
 Test to ensure a de-energised state
 Cover or isolate adjacent live parts
2.1 General
 The EdEx thruster must be able to swivel, transverse forces must
not act on the lifting rod
 Keep the terminal box clean and close it tightly
 Ensure that the seals are correctly seated and undamaged
 Check the tightness and correct installation of the cable entry
 The intervals for renewing the operating fluid must be observed.
 The brake must not have its own spring or weight load if the
EdEx thruster has an integrated brake spring (⇒type plate,
designation C…).
 If the EdEx thruster is retrospectively painted, it is essential to
protect the lifting rod and the sealing system to prevent leakage
 The maximum permissible layer thickness (subsequent coating)
according to ATEX approval must not be exceeded (if necessary,
consult the manufacturer EMG Automation GmbH).
 Regular cleaning must be carried out to prevent dust deposits
with a layer thickness of more than 5 mm.
 The EdEx thrusters may only come into contact with substances
that do not impair the properties of the thruster materials.

Safety 2
General 2.1
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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).
 Compliance with the following important explosion protection
characteristics must be evident from the marking on the product:
– G = Gas, D = Dust; M = Mining
– Thruster category 1,2,3 in the 3 zone areas
– Gas characteristic values: Temperature class (T1..T6),
Explosion group (II A,B,C)
– Dust characteristic values: Explosion group (III A, B: not
conductive; C: conductive);
surface temperature,
glow and ignition temperature
 For work such as assembly, electrical connection, repair or
opening the housing, it must be ensured that
– no explosive atmosphere is present.
– no electrical voltage is present.
– inadvertent switching on is not possible.
 Dust deposits on EdEx thrusters must be avoided so no
dangerous temperature increase arises on the surface.
 Clean non-conductive parts (e.g. plastic) using only a damp cloth
 Ensure that all technical and organisational protective measures
are fulfilled and their function/effect is tested.
 Modifications to the EdEx thrusters are not permitted and can
cause an explosion hazard (ignition).
 The contents of the EU type examination certificate must be
observed. If there is an X after the number on the EC type
examination certificate, special conditions or deviations from the
standard conditions apply. These special notes must therefore
be checked in the certificate.
 Before any activities (e.g. assembly) are carried out in potentially
explosive areas, the operating company must issue approval for
the work.

2 Safety
2.2 Intended use
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 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. These
EdEx thrusters must not be exposed to highly charging
processes.
 Fixing screws of the end shield must have a yield strength of 640
Nm2 (quality 8.8).
 Additional non-conductive (colour) coatings must not exceed the
total coating thickness for IIA/B by more than 2 mm and for IIC
by more than 0.2 mm.
 The use of contrasting colours makes it easier to detect dust
deposits.
 When coating, care must be taken to ensure chemical resistance
to the ambient conditions.
2.2 Intended use
The EdEx thruster is partly completed machinery and must be
connected to other parts to form a complete machine. The safety of
this complete machine must prevent hazards caused by controlling
and operating the system.
EdEx thrusters are used to apply straight work movements using
electro-hydraulics. In drive technology, drives are braked or stopped
using brakes with electro-hydraulic actuation thrusters (lifting
thrusters). EdEx thrusters are mainly used in drive technology to
bleed drum and disc brakes (brake bleeder).

Safety 2
Intended use 2.2
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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
 Valves
 Couplings
 Slides
 Throttle valves
 Locking thrusters
EdEx thrusters are suitable for use in the following potentially
explosive areas.
 Gases (G) in zones 1 and 2
 Dust (D) in zones 21 and 22
 Mining (M)
Table 3: Use in zones in potentially explosive areas
Thruster
category
Thruster protection level
(EPL)
Zone
0 (20) 1 (21) 2 (22)
1 G (D) Ga (Da) X X X
2 G (D) Gb (Db) – X X
3 G (D) Gc (Dc) – – X
Intended use also includes adhering to the assembly, operating and
maintenance procedures described in this assembly manual.
The technical data and the specifications for terminal assignments
are specified on the type plate and in the manual, and must be
adhered to.
EdEx thrusters may only be operated in the permissible installation
position and operating mode. Only this intended use is permissible.
Any other use is prohibited.

2 Safety
2.3 Unintended use
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2.3 Unintended use
Reasonably foreseeable misuse
 Use of the EdEx thrusters in potentially explosive areas for which
the EdEx thrusters are not suitable
Any unintended use or impermissible operating modes constitutes
misuse of the EdEx thrusters. For safety reasons, all applications not
listed in the intended use section are strictly prohibited by the
manufacturer.
All applications as an actuator always require confirmation from the
manufacturer. Applications as actuators that cause the power supply
for retracting the lifting rod to fail are not permitted due to the
associated risk of accidents.
2.4 Staff qualifications
Authorised and qualified staff must be deployed for intended use of
the EdEx thrusters. The scope of responsibility, authority and
supervision of personnel must be precisely stipulated by the operating
company.
Qualified staff are people who, due to their training, experience and
instruction, as well as their knowledge of applicable standards,
regulations, accident prevention regulations and operating conditions,
are authorised by the person responsible for system safety to perform
the relevant required tasks and are thereby able to identify and avoid
possible hazards.
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.

Safety 2
Staff qualifications 2.4
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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.
Specialists include industrial mechanics or people who have
comparable, country-specific training and who have the following
knowledge:
 Knowledge and experience in transporting, storing, assembling
and disposing of the EdEx thrusters
 Knowledge and experience of the electrical, mechanical and
hydraulic equipment on the components of the EdEx thrusters
 Functionality of the EdEx thrusters
 Retrofitting and professional adjustment of EdEx thrusters
 Hazards on the system and suitable safety measures
 Expert knowledge of explosion protection
2.4.2 Qualified electrician
Electrical specialists include electricians who,
 due to their technical training, knowledge, and experience, as
well as knowledge of applicable standards and regulations, are
capable of carrying out work on electrical systems
 have been commissioned and trained by the operating company
to perform work on electrical systems and equipment on the
EdEx thrusters
 are familiar with the EdEx thruster functions
 can detect and avoid possible hazards by taking suitable safety
measures.
 Expert knowledge of explosion protection

2 Safety
2.4 Staff qualifications
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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:
 Knowledge and experience of the electrical, mechanical and
hydraulic equipment on the components of the EdEx thrusters
 EdEx thruster functions and maintenance points
 Hazards on the EdEx thrusters and suitable safety measures
 Lubricating, cleaning, preserving, topping up to replacing
consumables
 Expert knowledge of explosion protection
 Replacing wear parts
 Retrofitting and professional adjustment of EdEx thrusters
2.4.4 Authorised personnel
Authorised personnel are persons (usually maintenance personnel)
who have received additional training from the manufacturer EMG
Automation GmbH in handling the EdEx thrusters. This allows you
to carry out additional and complex repairs. The description of these
activities is not included in the scope of this instruction manual.
Authorised personnel possess expert knowledge of explosion
protection.
2.4.5 Qualified person
A qualified person is a person who has the specialist knowledge
required to check the work equipment (e.g. tools, devices, machines
or systems) due to their professional training, work experience and
their near-term job. They are not subject to any technical orders
during their checking work and may not be disadvantaged by this
work. The competent person possess expert knowledge of explosion
protection.

Safety 2
Personal protective equipment 2.5
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2.4.6 Responsible staff
The following table provides you with information on the staff
qualifications that are the prerequisites for the corresponding tasks.
Only people who have the corresponding qualification may perform
these tasks.
Table 4: Responsible staff
Task Responsible staff Manufacturer or
personnel
authorised by the
manufacturer
Qualified
personnel
Qualified
electrician
Maintenance
staff
Transport x
Assembly x
Electrical installation x
Starting up x
Shutting down x
Fault rectification x x x
Electrical fault
rectification
x x
Maintenance x x
Repairs x x
Electrical repairs x x
Dismantling x
Storage x
Disposal x x
Contact EMG Automation GmbH if the required staff responsibilities
are unclear.
2.5 Personal protective equipment
The operating company must prescribe personal protective
equipment according to the danger risk. Personal protective
equipment includes the following among others:
 Safety shoes, work clothing, protective clothing if required
 Protective gloves
 Hard hat
 Safety goggles
This list of personal protective equipment is not exhaustive.

2 Safety
2.6 Electrical equipment
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2.6 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
– Test to ensure a de-energised state
– Earth and short-circuit
– Cover or isolate adjacent live parts
 Perform regular checks for insulation and housing damage.
 Never operate the EdEx thruster with electrical connections that
are faulty or not ready for operation.
 If there are power supply faults, the system must be switched off
immediately.
 Before any work on electrical components, switch the mains
disconnection thruster off and secure it to prevent it being
switched on again.
 It is essential to observe the inspection and maintenance
intervals specified by the manufacturer for electrical components.
 All touchable, conductive parts of the system are connected to
the external earthing conductor system. The earthing conductor
system must be inspected after performing maintenance work
(e.g. replacing components).
 Some equipment (e.g. mains power units, servo controllers,
converters) with electrical intermediate circuits may store
residual voltage for a certain time after being disconnected.
Before starting work on these systems, check that they are de-
energised.