EMG ELDROclassic Ed 23/5 User manual

Assembly Instructions
General description
Electro-Hydraulic ELDROclassic®Thrusters
Type designation
Standard Series Ed 23 to Ed 630 (alternating current model)
Status:
01.2019
EMG Automation GmbH, Industriestr. 1, D-57482 Wenden / Germany

Table of contents
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Table of contents
1General remarks......................................................................................... 6
1.1 Information about these Assembly Instructions ............................................................. 6
1.2 Manufacturer........................................................................................................................ 6
1.3 Validity.................................................................................................................................. 7
1.4 Additional applicable documents...................................................................................... 7
1.5 Formal information about these Assembly Instructions ................................................ 7
1.6 Typographical conventions ............................................................................................... 8
1.7 Structure of warnings......................................................................................................... 9
1.8 Definitions and abbreviations............................................................................................ 10
2Safety.......................................................................................................... 11
2.1 Use as intended................................................................................................................... 11
2.2 Improper use........................................................................................................................ 12
2.3 Qualification of personnel.................................................................................................. 12
2.3.1 Trained personnel ................................................................................................................. 13
2.3.2 Trained electrician................................................................................................................. 13
2.3.3 Maintenance personnel......................................................................................................... 14
2.3.4 Responsible personnel.......................................................................................................... 15
2.4 Personal protective equipment.......................................................................................... 16
2.5 Electrical operating equipment.......................................................................................... 16
2.6 Operating materials and supplies ..................................................................................... 17
2.7 Alterations............................................................................................................................ 17
2.8 Spare and wear parts.......................................................................................................... 17
3Technical data............................................................................................ 18
3.1 Type designations and type codes ................................................................................... 18
3.2 Information on the rating plate .......................................................................................... 19
3.3 Key data ............................................................................................................................... 20
3.4 Dimensions.......................................................................................................................... 22
3.4.1 Type Ed 23/5......................................................................................................................... 22
3.4.2 Type Ed 30/5......................................................................................................................... 24
3.4.3 Types Ed 50/6, Ed 80/6, Ed 50/12, Ed 80/12........................................................................ 25
3.4.4 Types Ed121, Ed185, Ed201, Ed301, Ed350, Ed450, Ed630, Ed500.................................. 28
3.5 Airborne noise emission .................................................................................................... 35
3.6 Operating conditions.......................................................................................................... 35
3.6.1 Ambient temperature............................................................................................................. 35
3.6.2 Humidity ................................................................................................................................ 36
3.6.3 Aggressive environmental conditions ................................................................................... 36
3.6.4 Voltage and frequency tolerances......................................................................................... 36

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3.6.5 Altitude of setup site.............................................................................................................. 36
4Function description ................................................................................. 37
4.1 Mechanical layout ............................................................................................................... 38
4.1.1 Type groups 1, 2 and 4 ......................................................................................................... 38
4.1.2 Type groups 3, 5 and 6 ......................................................................................................... 39
4.2 Electrical equipment........................................................................................................... 40
4.3 Function description........................................................................................................... 40
5Transport and storage............................................................................... 41
5.1 Transport.............................................................................................................................. 41
5.1.1 Transport sketch ................................................................................................................... 42
5.2 Storage................................................................................................................................. 42
6Assembly and installation......................................................................... 43
6.1 Assembly ............................................................................................................................. 43
6.1.1 Permissible installation positions .......................................................................................... 45
6.1.2 Installation of the ELDRO®device ........................................................................................ 46
6.2 Electrical connection.......................................................................................................... 47
6.2.1 Terminal box and terminal diagram ...................................................................................... 48
6.2.2 Connecting the earth conductor............................................................................................ 51
6.2.3 Connecting the energy supply............................................................................................... 51
6.2.4ELDRO®devices with installed trace heating ....................................................................... 52
6.3 Valve adjustment................................................................................................................. 54
6.3.1 Installation point of adjustment screws ................................................................................. 54
6.3.2 Change manipulating and reset time .................................................................................... 55
6.4 Assembly completion......................................................................................................... 55
7Notes on operation .................................................................................... 56
7.1 Check of operating conditions before commissioning................................................... 57
8Help for failures.......................................................................................... 58
8.1 Failures and their correction.............................................................................................. 58
9Maintenance............................................................................................... 60
9.1 Maintenance work............................................................................................................... 60
9.1.1 Operating liquid..................................................................................................................... 62
9.1.2 Check of the operation liquid................................................................................................. 63
9.1.3 Seals ..................................................................................................................................... 64
9.2 Maintenance table............................................................................................................... 65
9.2.1 Classification......................................................................................................................... 66
10 Disassembly............................................................................................... 67

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10.1 Disconnect electrical connections.................................................................................... 68
10.2 Deinstallation....................................................................................................................... 68
11 Disposal...................................................................................................... 70
11.1 Notes on disposal ............................................................................................................... 70
12 Directories.................................................................................................. 71
12.1 List of figures....................................................................................................................... 71
12.2 List of tables........................................................................................................................ 71
13 Annex.......................................................................................................... 73
13.1 EC Declaration of Incorporation........................................................................................ 73
13.2 Additional applicable documents...................................................................................... 74

1
General remarks
1.1
Information about these Assembly Instructions
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1 General remarks
1.1 Information about these Assembly Instructions
These Assembly Instructions have been drafted in accordance with
the principles of the technical editorial board and the minimum legal
requirements of Directive 2006/42/EC that have been used as the ba-
sis for this document. The Assembly Instructions enable the safe and
efficient handling of the Electro-Hydraulic ELDRO®Thruster (hereinaf-
ter referred to as the ELDRO®device).
These Assembly Instructions are part of ELDRO®device and they
must be retained within reach at the device in a place that is accessi-
ble to the personnel at all times.
The personnel must have read and understood these Assembly In-
structions before starting any work.
Version
Description
Date
Author
V1.0
Date created
18/01/2019
CE Design
1.2 Manufacturer
EMG Automation GmbH
Industriestr. 1
D-57482 Wenden / Germany
Phone [phone]
Fax [phone]
Email [e-mail]
Internet www.emg-automation.com

General remarks
1
Validity
1.3
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1.3 Validity
These Instructions conform to the state of the art of the ELDRO®de-
vice at the time of publication. The content of these Instructions is not
subject of a contract but serves for information.
EMG Automation GmbH reserves making substantive and technical
changes compared to the information in these Instructions, without
being required to publish such changes. The company EMG Automa-
tion GmbH cannot be held accountable for any inaccuracies or inap-
plicable information in these Instructions that result from substantive
and technical changes after delivery of this ELDRO®device, because
there is no obligation to continuously update these Instructions.
1.4 Additional applicable documents
All documents (additional applicable documents) listed in these As-
sembly Instructions must be observed.
1.5 Formal information about these Assembly Instructions
Document version: V 1.0
Date: 01.2019
© Copyright, 2019
All rights reserved.
Reprint, even in excerpts, is permitted only with approval from EMG
Automation GmbH.

1
General remarks
1.6
Typographical conventions
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1.6 Typographical conventions
Table 1: Typographical conventions
Typography
Meaning
1. Action
Step in a sequence of actions
▪
Step / User instruction
−
Enumeration
"ABC"
indicates special terms in the text
⇒
Reference to chapters or sections in the
Assembly Instructions or to additional
applicable documents
#(e.g. ⇒Chapter Technical data)
This signal word denotes a directly
impending danger. If this danger is not
avoided, this will result in death or serious
physical injuries.
This signal word denotes a potential
danger. If this danger is not avoided, this
will result in death or serious physical
injuries.
This signal word denotes a potential
dangerous situation. If this dangerous
situation is not avoided, this can result in
minor or modest physical injuries.
This signal word denotes actions to prevent
property damages. Observation of this
information prevents damages to or
destruction of the ELDRO®device.
Supplementary Information

General remarks
1
Structure of warnings
1.7
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1.7 Structure of warnings
Warnings, if observed, protect against potential physical injuries and
property damages, and they rate the extent of the danger by means
of the signal word.
WARNING = signal word
Source of danger
Potential consequences if not observed
–Measures for avoidance/prohibitions
Danger sign
The danger sign denotes warnings that warn of physical injuries.
Source of danger
The source of the danger indicates the cause of the danger.
Potential consequences if not observed
The potential consequences in case the warnings are not observed
are, e.g. bruises, burns and other serious injuries.
Measures/Prohibitions
Under measures/prohibitions, actions are listed that must be carried
out to avoid a danger or actions that are prohibited so as to avoid a
danger.

1
General remarks
1.8
Definitions and abbreviations
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1.8 Definitions and abbreviations
The following terms and abbreviations are used in the Assembly In-
structions.
Table 2: Definitions and abbreviations
Term/Abbreviation
Meaning
Brake spring
Cylindrical pressure spring that counteracts the hydraulic force. In
consequence, only the difference in force works on the lift rod as throw
force.
Absorption spring (d-spring)
Spring for soft braking. It reduces the brake force continuously down to
the hold value as soon as the brake shoes engages. When the brake is
released, the braking force continuously decreases from the maximum
value to zero (lifting of the brake shoes).
ELDRO®device
Electro-hydraulic thruster that converts electrical into mechanical energy
of rectilinear motion in a hydraulic process
Maximum value of the
permissible load
Total of forces working on the lifting rod head and which influence the
lifting movement and manipulation time, e.g. friction and mass of
connection elements
Lifting valve H
Valve to reduce the lifting speed
Lifting and lowering valve HS
Valves to reduce the lifting and lowering speed
Lifting time
Time from starting the motor until reaching the upper piston end position
Nominal operating point
Operating point that is at 1/3 of the nominal stroke
Nominal stroke
Maximum path that the extending lifting rod can travel
Nominal reset force
Minimum force in the nominal operating point for a device with return
spring c
Nominal throw force
Hydraulic force usable at the lifting rod head of a device without return
spring c
Regulating brake
Brake to regulate alternating current motors down to low rotation speeds
largely independent of the load. By means of an optimally adjusted pump
wheel, the hydraulic force is adjusted to the nominal reset force. For
regulating braking, devices are equipped with return spring c and damper
spring d.
Regulating spring
See damper spring
Return spring c
See brake spring
Lowering valve S
Valve to reduce the lowering speed
Lowering time
Time from stopping the motor until reaching the lower piston end-position.

Safety
2
Use as intended
2.1
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2 Safety
ELDRO®Thrusters are operationally safe electro-hydraulic devices
for use in industrial plants. They conform to the present state of the
art.
The generally applicable legal regulations and other binding guide-
lines on work safety, accident prevention and environmental protec-
tion must be observed.
Before starting any work on ELDRO®devices, the following safety
rules must be observed:
−Ensure the industrial plant is at a complete standstill
−Disconnect the plant from the power supply
−Secure the plant from restarting
−Ensure voltage-free condition
−Cover or shield neighbouring parts that are under voltage
2.1 Use as intended
The ELDRO®device is an incomplete device and it must be con-
nected with other parts into one unit as a device. The safety of this
unit must preclude any hazards that are caused by the control and
operation of the system.
ELDRO®devices serve the purpose of applying rectilinear operating
motions by means of electro-hydraulics. In propulsion technology,
drives are braked or stopped by means of brakes using electro-hy-
draulic operating units (thrusters). ELDRO®devices are primarily
used in drive propulsion to release drum brakes and disc brakes
(brake thrusters).
But the ELDRO®devices can also be used in many other areas of
production, transport technology, warehouse management and han-
dling technology where a rectilinear operating motion is required and
an individual drive is desired. Such applications for use as a regulat-
ing unit are, for example, the activation of
−valves,
−couplings,
−sliders,
−throttle flaps,
−arrester devices.
The use as intended also includes the observation of the method de-
scribed in these Assembly Instructions for assembly, operation and
maintenance.

2
Safety
2.2
Improper use
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The technical data and information on connector occupations can be
found on the rating plate and in these Instructions and they should be
observed in all cases.
ELDRO®devices may be operated only in the permitted installation
position and operating mode. Only this intended use is permissible.
Any other use is prohibited.
2.2 Improper use
Reasonably expectable incorrect use
Any use not intended or any impermissible mode of operation repre-
sent improper use of the ELDRO®devices. For safety reasons, all ap-
plications not listed in the Section "Use as intended" are strictly pro-
hibited by the manufacturer.
All application cases for use as a regulating unit always require con-
sultation with the manufacturer. Application cases for use as regulat-
ing unit in the course of which an outage of the voltage supply leads
to the lifting rod being retracted are prohibited due to the associated
risk of accidents.
2.3 Qualification of personnel
Qualified personnel must be assigned with the intended use of the
ELDRO®devices. The area of responsibility, competency and super-
vision of the personnel must be defined in detail by the operator.
Qualified personnel are persons, who, based on their training, experi-
ence and instruction, as well as their knowledge of relevant stand-
ards, regulations, accident prevention rules and operating conditions
have been authorised by the person responsible for the safety of the
system to carry out the respectively required activities and are able to
recognise and avoid potential hazards in the process.
Work on or with the ELDRO®devices may be carried out only by
qualified personnel trained who are instructed and assigned specifi-
cally to the system for this purpose and who have specialised know-
how and experience in the respective technical field.
Consult with EMG Automation GmbH if the required qualification of
the personnel is unclear.

Safety
2
Qualification of personnel
2.3
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2.3.1 Trained personnel
ELDRO®devices may be transported, set up, connected, taken into
operation and serviced only by trained personnel. All work must be
conducted with intact tools, devices, test equipment and consumable
materials intended for this purpose and all work must be checked by
responsible trained personnel. The trained personnel must be author-
ised for the required work by the person responsible for the safety of
the industrial plant.
Trained personnel includes industrial mechanics or persons, who
have completed comparable country-specific occupational training
and the following know-how:
−Know-how and experience in transport, storage, assembly and
disposal of ELDRO®devices
−Know-how and experience relating to electrical, mechanical and
hydraulic equipment on the components of the ELDRO®devices
−Mode of operation of the ELDRO®devices
−Retrofitting and professional readjustment of the ELDRO®devices
−Hazards arising on the device and suitable protection measures
2.3.2 Trained electrician
Trained electrical engineering personnel includes trained electricians,
who,
−based on their occupational training, know-how and experience, as
well as their knowledge of relevant standards and regulations, are
able to conduct work on electrical equipment,
−have been assigned and trained by the operator to conduct work
on electrical devices and equipment of the ELDRO®devices,
−are familiar with the mode of operation of the ELDRO®devices and
the plant,
−are able to recognise occurring hazards and prevent these through
suitable protection measures.

2
Safety
2.3
Qualification of personnel
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2.3.3 Maintenance personnel
Maintenance personnel includes industrial mechanics or persons with
comparable country-specific occupational training. Maintenance per-
sonnel is assigned by the operator with the servicing of the plant and
they have the following know-how:
−Know-how and experience relating electrical, mechanical and hy-
draulic equipment on the components of the ELDRO®devices
−Mode of operation of the ELDRO®devices
−Hazards arising on the device and suitable protection measures
−Lubricating, cleaning, preserving, refilling or replacing operating
liquids
−Replacement of wear parts
−Retrofitting and professional readjustment of the ELDRO®devices

Safety
2
Qualification of personnel
2.3
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2.3.4 Responsible personnel
The table below specifies the qualification of the personnel, which are
prerequisites for the corresponding activities. Only persons with the
relevant qualification may conduct these activities.
Table 3: Responsible personnel
Activity
Zuständiges Personal
Manufacturer or ser-
vice partner author-
ised by the manu-
facturer
Trained
personnel
Trained
electrician
Maintenance
personnel
Transport
x
Assembly
x
Electrical installation
x
Commissioning
x
Decommissioning
x
Correcting failures
x
x
x
Correcting electrical
failures
x
x
Servicing
x
x
Repair
x
x
Electrical repairs
x
x
Disassembly
x
Storing
x
Disposal
x
x
Consult with EMG Automation GmbH if the required competencies of
the personnel are unclear.

2
Safety
2.4
Personal protective equipment
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2.4 Personal protective equipment
Personal protective equipment must be prescribed by the operator
depending on the risk of hazard.
Personal protective equipment includes, e.g.:
−Safety shoes, professional clothing, protective clothing if neces-
sary
−Protective gloves
−Hard hat
This list of personal protective equipment is not exhaustive.
2.5 Electrical operating equipment
−Work on electrical operating equipment may be carried out only by
trained electricians.
−For all work on electrical components, the five safety rules must be
observed:
–Disconnect from power
–Secure against restarting
–Ensure voltage-free condition
–Ground and short-circuit
–Cover or shield neighbouring parts that are under voltage
−Regular inspections for damages on insulation and housing must
be conducted.
−The ELDRO®device must never be operated with defective or in-
operable electrical connections.
−In case of failures of the energy supply, the device must be shut off
immediately.
−For all other work on electrical components, the line disconnector
must be switched off and be secured against reactivation
−The inspection and maintenance intervals for electrical compo-
nents specified by the manufacturers must be observed.
−All exposed, conductive parts of the system are connected to the
external protective system. After maintenance work (e.g. replace-
ment of components), the protective conductor system must be
checked

Safety
2
Operating materials and supplies
2.6
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−Some operating equipment (e.g. mains adapters, servo controllers,
inverters) with intermediate electrical circuit can still store hazard-
ous residual voltages for a certain time after disconnection from
the power supply. Before beginning with the work on these sys-
tems, it must be checked for the absence of voltage.
2.6 Operating materials and supplies
−The information on the safety datasheets of the manufacturer must
be observed.
−Contact with the eyes or skin must be avoided.
−Inhaling vapours or mists must be avoided.
−Spilled or leaked operating media and auxiliary supplies must be
absorbed immediately using a binding agent and be disposed of.
−Containers with flammable materials and compressed, liquefied
gases must be kept away from heat sources.
2.7 Alterations
Modifications, extensions and alterations of ELDRO®components
that might compromise safety or function may not be made without
the written approval from the manufacturer.
2.8 Spare and wear parts
The use of spare and wear parts of third party manufacturers can en-
tail risks. Only original parts or spare and wear parts approved by the
manufacturer may be used.
Spare parts orders for ELDRO®types that are no longer deliver-
able, see the list "Information for orders of replacement de-
vices".

3
Technical data
3.1
Type designations and type codes
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3 Technical data
3.1 Type designations and type codes
Figure 1: Type designations and type codes
1
Ed: ELDRO®, alternating current model
Eg: ELDRO®, direct current model
2
Lifting force in daN
3
Length of stroke in cm
4
Symbols of replacement and special devices
5
Letters for additional equipment:
c Brake spring (c-spring)
d Absorption spring (d-spring)
H Lifting valve
S Lowering valve
6
Nominal voltage

Technical data
3
Information on the rating plate
3.2
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3.2 Information on the rating plate
Figure 2: Rating plate
1
Standard
12
Equipment
2
Serial number
13
Length of stroke mm
3
Lifting force in N
14
Year built
4
Operating mode
15
Switching operations per hour
5
Start-up time in %
16
Voltage
6
Switching operation type
17
Voltage tolerance
7
Frequency
18
Power input
8
Power consumption
19
Weight
9
ISO class
20
Operating liquid
10
IP rating
21
Temperature range
11
Device type

3
Technical data
3.3
Key data
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3.3 Key data
Short-stroke thrusters
Table 4: Key data –Short-stroke thrusters Ed23/5-Ed301/6
ELDRO®-type
Ed
23/5
30/5
50/6
80/6
121/6
185/6
201/6
301/6
Lifting force [N]
220
300
500
800
1.250
1.850
2.000
3.000
Length of stroke [mm]
50
50
60
60
60
60
60
60
Lifting force [Ncm]
1,100
1,500
3,000
4.800
7,500
11,100
12,000
18,000
Brake spring force (c-spring)1) [N]
180
270
460
750
1,200
1,900
1,900
2,700
Power consumption [W]
165
200
210
330
330
450
450
550
Power intake at 400 V2) [A]
0,5
0,5
0,5
1,2
1,2
1,3
1,3
1,4
Frequency of switching operations at
S3-60% ED3) [c/h]
2,000
2,000
2,000
2,000
2,000
2,000
2,000
1,500
Weight [kg]
10
14
23
24
39
39
39
40
Table 5: Key data –Short-stroke thrusters Ed400/6-Ed630/10
ELDRO®-type
Ed
400/6
400/8
400/10
450/8
500/8
500/10
630/8
630/9
630/10
Lifting force [N]
4,000
4,000
4,000
4,500
5,000
5,000
6,300
6,300
6,300
Length of stroke [mm]
60
80
100
80
80
100
80
90
100
Lifting force [Ncm]
24,000
32,000
40,000
36,000
40,000
50,000
50,400
56,700
63,000
Brake spring force (c-spring)1) [N]
–
–
–
–
–
–
–
–
–
Power consumption [W]
550
550
550
600
700
700
700
700
700
Power intake at 400 V2) [A]
1,3
1,3
1,3
1,3
1,6
1,6
1,8
1,8
1,8
Frequency of switching operations at
S3-60% ED3) [c/h]
600
600
600
600
400
400
400
400
400
Weight [kg]
39
39
39
39
50
50
70
70
70
1)
Values of braking force apply at 1/3 the nominal length of stroke
2)
Values of the mechanical end position of the piston. The specified values increase during the lifting process. At a working
temperature of -25°C of the devices, the power intake is about 1.5-times the power intake at +20°C.
3)
Continuous operation S1 and intermittent duty S3 permitted up to +50°C ambient temperature
All technical data are mean values based on +20°C device
working temperature.