EMG ELHY EB 630 User manual

Assembly manual
General designation
ELHY® electro-hydraulic lifting devices
Type designation
EB 12 to EB 630 (TGL 35868) and EB 220 to EB6300 (DIN 15430)
(three-phase version)
Status:
08.2021
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 Intended use ........................................................................................................................ 12
2.2 Unintended use ................................................................................................................... 13
2.3 Staff qualifications .............................................................................................................. 13
2.3.1 Qualified personnel ............................................................................................................... 14
2.3.2 Qualified electrician ............................................................................................................... 14
2.3.3 Maintenance personnel ......................................................................................................... 15
2.3.4 Responsible staff ................................................................................................................... 15
2.4 Personal protective equipment.......................................................................................... 16
2.5 Electrical operating equipment.......................................................................................... 16
2.6 Process media ..................................................................................................................... 17
2.7 Modifications ....................................................................................................................... 17
2.8 Spare and wear parts .......................................................................................................... 17
3 Technical data ............................................................................................ 18
3.1 Type designation and type key .......................................................................................... 18
3.2 Specifications on the type plate ........................................................................................ 19
3.3 Characteristics .................................................................................................................... 20
3.4 Dimensions .......................................................................................................................... 21
3.4.1 Type EB (TGL 35868) ........................................................................................................... 21
3.4.2 Type EB (DIN 15430) ............................................................................................................ 23
3.5 Electrical system ................................................................................................................. 26
3.5.1 Voltages and frequencies ...................................................................................................... 26
3.5.2 Follow-up training .................................................................................................................. 26
3.6 Operating fluid ..................................................................................................................... 27
3.7 Airborne sound emissions ................................................................................................. 27
3.8 Operating conditions .......................................................................................................... 28
3.8.1 Ambient temperatures ........................................................................................................... 28

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3.8.2 Air humidity ............................................................................................................................ 28
3.8.3 Aggressive ambient conditions ............................................................................................. 28
3.8.4 Voltage and frequency tolerances......................................................................................... 28
3.8.5 Installation height .................................................................................................................. 28
4 Functional description............................................................................... 29
4.1 Mechanical layout ............................................................................................................... 30
4.1.1 Type group up to EB 2500 .................................................................................................... 30
4.1.2 Type group from EB 3000 ..................................................................................................... 31
4.1.3 Mechanical equipment .......................................................................................................... 32
4.1.4 Protective measures ............................................................................................................. 32
4.2 Electrical equipment ........................................................................................................... 33
4.2.1 Motor ..................................................................................................................................... 33
4.2.2 Operating modes ................................................................................................................... 33
4.2.3 Junction box .......................................................................................................................... 33
4.3 Additional mechanical and electrical equipment............................................................. 34
4.3.1 Lift, lowering or throttle valve (H, S, D) ................................................................................. 34
4.3.2 Regulating/damping spring (R/D-spring) ............................................................................... 35
4.3.3 Brake spring (C-spring) ......................................................................................................... 36
4.3.4 Heating .................................................................................................................................. 36
4.4 Position indicators .............................................................................................................. 37
4.4.1 Sensors ................................................................................................................................. 37
4.4.2 Limit switches ........................................................................................................................ 38
4.5 Function sequence ............................................................................................................. 39
5 Transport and storage ............................................................................... 40
5.1 Transport .............................................................................................................................. 40
5.1.1 Transport sketch ................................................................................................................... 41
5.2 Storage ................................................................................................................................. 41
6 Assembly and installation ......................................................................... 42
6.1 Assembly ............................................................................................................................. 42
6.1.1 Permissible installation positions .......................................................................................... 44
6.1.2 Installing the ELHY® thruster ................................................................................................. 45
6.2 Electrical connection .......................................................................................................... 46
6.2.1 Junction box and terminal diagram ....................................................................................... 47
6.2.2 Earthing conductor connection.............................................................................................. 48
6.2.3 Power supply connection ...................................................................................................... 49
6.3 Adjusting the valves ........................................................................................................... 50
6.3.1 Setting times.......................................................................................................................... 51
6.3.2 Adjustment screw installation location .................................................................................. 51
6.3.3 Changing the set time and the reset time ............................................................................. 52
6.4 Completing assembly ......................................................................................................... 52
7 Notes on operation .................................................................................... 53

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7.1 Checking the operating conditions prior to starting up ................................................. 54
8 Help with malfunctions .............................................................................. 55
8.1 Faults and troubleshooting ................................................................................................ 55
9 Maintenance ............................................................................................... 57
9.1 Maintenance tasks .............................................................................................................. 57
9.1.1 Operating fluid ....................................................................................................................... 59
9.1.2 Checking the operating fluid .................................................................................................. 60
9.1.3 Replacing the operating fluid ................................................................................................. 63
9.1.4 Seals ..................................................................................................................................... 63
9.2 Maintenance schedule ........................................................................................................ 64
9.2.1 Classification ......................................................................................................................... 65
10 Disassembly ............................................................................................... 66
10.1 Disconnecting the electrical connections ........................................................................ 67
10.2 Removal ............................................................................................................................... 67
11 Disposal ...................................................................................................... 69
11.1 Disposal consideration ....................................................................................................... 69
12 Lists ............................................................................................................ 70
12.1 Index of figures.................................................................................................................... 70
12.2 Index of tables ..................................................................................................................... 70
13 Appendix..................................................................................................... 71
13.1 Further applicable documents ........................................................................................... 71

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 ELHY® electro-hydraulic lifting
thruster (subsequently referred to as ELHY® thruster).
This maintenance manual is part of the ELHY® 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 12/08/2021 CE Design
1.2 Manufacturer
EMG Automation GmbH
Am Pfefferbach 20
D-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 ELHY® 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 ELHY®
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: V1.0
Date: 08.2021
© Copyright, 2021
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 ELHY® 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
Brake 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.
CSA Canadian Standards Association
Damping spring R (DIN) 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).
DIN devices Installation dimensions according to DIN 15430
Throttle valve D Valve to reduce the lifting and lowering speeds
EAC Eurasian Conformity mark
ED Duty cycle
ELHY® thruster Electro-hydraulic lifting thruster that converts electrical energy into
mechanical energy in a straight line movement by hydraulic means
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
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 (TGL) See damping spring
Reset spring c See brake spring
Lowering valve S Valve to reduce the lowering speed
Lowering time Time from switching the motor off until the bottom piston limit position is
reached.

General 1
Terms and abbreviations 1.8
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Table 2: Terms and abbreviations
Term/abbreviation Meaning
TGL thrusters Installation dimensions according to TGL 35868
X devices Special installation dimensions

2 Safety
2.1 Intended use
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2 Safety
ELHY® 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 ELHY® 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 Intended use
The ELHY® 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.
ELHY® 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).
The ELHY® electro-hydraulic lifting devices are used to activate a
mechanical device (e.g. industrial brakes)
However, ELHY® thrusters can also be used in 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
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.

Safety 2
Unintended use 2.2
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ELHY® thrusters may only be operated in the permissible installation
position and operating mode. Only this intended use is permissible.
Any other use is prohibited.
2.2 Unintended use
Reasonably foreseeable misuse
Any unintended use or impermissible operating modes constitutes
misuse of the ELHY® 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.
2.3 Staff qualifications
Qualified staff must be used for the ELHY® thruster's intended use.
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 ELHY® 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 with the corresponding field.
Contact EMG Automation GmbH if the required staff qualifications are
unclear.

2 Safety
2.3 Staff qualifications
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2.3.1 Qualified personnel
ELHY® 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 ELHY® thrusters
 Knowledge and experience of the electrical, mechanical and
hydraulic equipment on the components for the ELHY® thrusters
 ELHY® thruster functions
 Modifying the ELHY® thrusters and re-adjusting them properly
 Hazards on the system and suitable safety measures
2.3.2 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
 who have been commissioned and trained by the operating
company to perform work on electrical systems and equipment
on the ELHY® thrusters
 are familiar with the ELHY® thruster functions
 can detect and avoid possible hazards by taking suitable safety
measures.

Safety 2
Staff qualifications 2.3
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2.3.3 Maintenance personnel
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 for the ELHY® thrusters
 ELHY® thruster functions and maintenance points
 Hazards on the system and suitable safety measures
 Lubricating, cleaning, preserving, topping up to replacing
consumables
 Replacing wear parts
 Modifying the ELHY® thrusters and re-adjusting them properly
2.3.4 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 3: Responsible staff
Task Responsible staff Manufacturer or
service partner
authorised by the
manufacturer
Qualified
personnel
Qualified
electrician
Maintenance
personnel
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

2 Safety
2.4 Personal protective equipment
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Contact EMG Automation GmbH if the required staff responsibilities
are unclear.
2.4 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.
2.5 Electrical operating 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 ELHY® 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.

Safety 2
Process media 2.6
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 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.
2.6 Process media
 The instructions on the manufacturer’s material safety data
sheets must be followed.
 Contact with eyes or the skin should be avoided.
 Avoid inhaling vapours or mist.
 Soak up any spilled or leaking process media immediately with a
binding agent and dispose of it properly.
 Keep containers with flammable substances and compressed,
liquefied gases away from sources of heat.
2.7 Modifications
Changes, attachments and modifications to ELHY® components,
which could impair safety or functions may not be performed without
written approval from the manufacturer.
2.8 Spare and wear parts
The use of spare and wear parts from third-party manufacturers may
lead to risks. Only original parts or spare and wearing parts approved
by the manufacturer may be used.
For information regarding replacement part orders for ELHY®
types that can no longer be supplied, see the “Ordering notes
for replacement thrusters” list.

3 Technical data
3.1 Type designation and type key
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3 Technical data
3.1 Type designation and type key
Figure 1: Type designation and type key
1 ELHY® type
2 Brake/reset spring
3 Regulating spring, version for control braking
4 Lift, lowering, throttle valve
5 Design (depending on installation position and fastening)
6 Protective cover, special scraper
7 Temperature class, low temperature version
8 Corrosion protection class
9 Sensors, limit switches
10 Adaptors, special series
11 Connection data (motor voltage / frequency)

Technical data 3
Specifications on the type plate 3.2
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3.2 Specifications on the type plate
Figure 2: Type plate
1 CE or CSA or CE EAC 12 Switching type
2 Thruster type 13 Current consumption
3 Equipment 14 Frequency
4 Year of manufacture/serial number 15 Weight
5 Lifting path in mm 16 Power consumption
6 Lifting force in N 17 Additional text 1
7 Switching processes per hour 18 ISO class
8 Operating mode 20 Protection category
9 Voltage 21 Temperature range
10 Switch-on duration in % 22 Return force
11 Voltage tolerance

3 Technical data
3.3 Characteristics
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3.3 Characteristics
Type EB (TGL 35868)
Table 4: Identification data - Types TGL 35868 - EB 12-EB 630
ELHY® type
EB
12 20 50 80 125 150 250 320 630
Lifting force [N] 220 300 500 800 1,250 1,500 2,500 3,200 6,300
Lifting path [mm] 50 50 50–100 60–160 60–160 60–160 60–160 100 120
Power consumption [W] 160 180 200 300 400 400 500 600 850
Current consumption at 400 V 50 Hz [A] 0.4 0.4 0.4 0.5 0.7 0.7 0.9 1.1 1.6
Switching frequency at S3-60% ED3) [c/h] 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 240
Weight [kg] 12 11 14–151) 19–261) 19–261) 19–261) 33–401) 40 45
1) Depending on the lifting path
Type EB (DIN 15430)
Table 5: Identification data - Types DIN 15430 - EB 220-EB 6300
ELHY® type
EB
220 300 500 800 1250 2000 3000 6300
Lifting force [N] 220 300 500 800 1,250 2,000 3,000 6,300
Lifting path [mm] 50 50 60–120 60–120 60–120 60–120 60–120 120
Power consumption [W] 160 180 200 300 400 500 600 850
Current consumption at 400 V 50 Hz [A] 0.4 0.4 0.4 0.5 0.7 0.8 0.9 1.6
Switching frequency at S3-60% ED3) [c/h] 2000 2,000 2,000 2,000 2,000 2,000 2,000 240
Weight [kg] 12 11 14–151) 19–251) 26 33–401) 40 45
1) Depending on the lifting path