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Assembly manual General designation ELDRO ® electro-hydraulic lifting thrusters Type designation Ed 12 to Ed 630 standard range and special designs (three-phase voltage version) Date: 01/2020 EMG Automation GmbH, Industriestr. 1, D-57482 Wenden / Germany...
Table of contents Table of contents General......................6 Information about this assembly manual ................. 6 Manufacturer........................6 Validity ..........................7 Further applicable documents ................... 7 Formal information about this assembly manual ............7 Format conventions ......................8 Structure of warning notices ..................... 9 Terms and abbreviations ....................
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Table of contents 3.6.2 Air humidity ..........................43 3.6.3 Aggressive ambient conditions ..................... 43 3.6.4 Voltage and frequency tolerances..................43 3.6.5 Installation height ........................43 Functional description................44 Mechanical layout ....................... 45 4.1.1 Type group 1 ......................... 45 4.1.2 Type group 3 ......................... 46 4.1.3 Type group 4 .........................
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Table of contents Maintenance schedule ......................74 9.2.1 Classification ......................... 75 Disassembly ....................76 10.1 Disconnecting the electrical connections ................ 77 10.2 Removal ..........................77 Disposal ...................... 79 11.1 Disposal consideration ....................... 79 Lists ......................80 12.1 Index of figures........................80 12.2 Index of tables ........................
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.
General Format conventions 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 ⇒...
General Structure of warning notices 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 –...
General Terms and abbreviations Terms and abbreviations The following terms and abbreviations are used in the maintenance 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.
Safety Intended use Safety ® ELDRO lifting 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 ELDRO ®...
Safety Staff qualifications 2.3.1 Qualified personnel ELDRO ® 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.
Safety Staff qualifications 2.3.3 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: ...
Maintenance Repairs Electrical repairs Dismantling Storage Disposal EMG Automation GmbH Contact if the required staff responsibilities are unclear. 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 Electrical equipment 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 –...
Safety Process media 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.
Technical data Type designation and type key Technical data Type designation and type key Figure 1: Type designation and type key Ed: ELDRO ® , three-phase version Eg: ELDRO ® , direct current version Lifting force in daN Lifting path in cm Indicator for replacement and special thrusters Letters for additional equipment: brake spring (c spring)
Technical data Specifications on the type plate Specifications on the type plate Figure 2: Type plate Standard Equipment Serial number Lifting path in mm Lifting force in N Year of construction Operating mode Switching processes per hour Switch-on duration in % Voltage Switching type Voltage tolerance...
Technical data Dimensions Dimensions 3.4.1 Type Ed 12 Figure 3: Example type Ed 12/4 Ed 12 dimensions Table 10: Ed 12/4 dimensions Type Ed 12/4 – Tolerance +0.1 Tolerance +0.15 to +0.25 ELDRO-Assembly-manual-344029-EN.docx 23 / 83...
Technical data Dimensions 3.4.2 Type Ed 23 to Ed 25 Figure 4: Dimensional drawing – example: Type Ed 23/5 d spring released (thruster bled) tensioned (thruster braked) The foot attachment for Ed 23/5.1 and Ed 23/5.2 can be installed offset by 90° (not possible for thrusters with limit switches). The top thrust shackle is rotatable (not possible for thrusters with limit switches).
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Technical data Dimensions Ed 23 dimensions Table 11: Ed 23 – 1 dimensions Type Ed 23/5 – Ed 23/5.1 – Ed 23/5.2 – Ed 23/5.5 12.73 – 12.73 Table 12: Ed 23 – 2 dimensions Type Ed 23/5 – Ed 23/5.1 –...
Technical data Dimensions 3.4.3 Type Ed 30 Figure 5: Dimensional drawing – example: Type Ed 30/5 Lifting valve d spring Lowering valve released (thruster bled) tensioned (thruster braked) 26 / 83 ELDRO-Assembly-manual-344029-EN.docx...
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Technical data Dimensions Ed 30 dimensions Table 15: Ed 30 – 1 dimensions Type Ed 30/5 – Ed30/5.1 Ed 30/5.2 Table 16: Ed 30 – 2 dimensions Type Ed 30/5 Ed 30/5.1 Ed 30/5.2 Tolerance +0.1 Tolerance +0.15 to +0.25 ELDRO-Assembly-manual-344029-EN.docx 27 / 83...
Technical data Dimensions 3.4.4 Types Ed 50, Ed 80, Ed 125 Figure 6: Dimensional drawing – example: Type Ed 50/6; Ed 80/6.5; Ed 80/6.6 d spring released (thruster bled) tensioned (thruster braked) 28 / 83 ELDRO-Assembly-manual-344029-EN.docx...
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Technical data Dimensions Ed 50 dimensions – short lift thrusters Table 17: Ed 50 – 1 dimensions Type Ed 50/6 – Ed 50/6.1 Ed 50/6.2 Ed 50/6.3 69.5 Ed 50/6.5 19.13 19.13 Ed 50/7 – Table 18: Ed 50 – 2 dimensions Type Ed 50/6 Ed 50/6.1...
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Technical data Dimensions Ed 80 dimensions – short lift thrusters Table 19: Ed 80 – 1 dimensions Type Ed 80/6 – Ed 80/6.1 Ed 80/6.5 22.3 22.3 Ed 80/6.6 22.3 22.3 Ed 80/7 – Table 20: Ed 80 – 2 dimensions Type Ed 80/6 Ed 80/6.1...
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Technical data Dimensions Ed 50, Ed 80 dimensions – long lift thrusters Table 23: Ed 50, Ed 80 – 1 dimensions Type Ed 50/12 – Ed 80/12 – Ed 80/12.1 Table 24: Ed 50, Ed 80 – 2 dimensions Type Ed 50/12 Ed 80/12 Ed 80/12.1...
Technical data Dimensions 3.4.5 Types Ed 121 to Ed 501 Figure 7: Dimensional drawing – example: Type Ed 201/12.5; Ed 301/12.5 Lifting valve released (thruster bled) Lowering valve tensioned (thruster braked d spring Lift markings Markings are applied to the piston guide bushing for easier brake adjustment or inspection.
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Technical data Dimensions Ed 121 dimensions – short lift thrusters Table 25: Ed 121 – 1 dimensions Type Ed 121/6 Table 26: Ed 121 – 2 dimensions Type Ed 121/6 119.5 Tolerance +0.1 Tolerance +0.15 to +0.20 Ed 185 dimensions – short lift thrusters Table 27: Ed 185 –...
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Technical data Dimensions Ed 301 dimensions – short lift thrusters Table 31: Ed 301 – 1 dimensions Type Ed 301/6 Ed 301/6.1 Ed 301/7 Table 32: Ed 301 – 2 dimensions Type Ed 301/6 119.5 Ed 301/6.1 119.5 Ed 301/7 119.5 Tolerance +0.1 Tolerance +0.15 to +0.20...
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Technical data Dimensions Ed 450 dimensions – short lift thrusters Table 35: Ed 450 – 1 dimensions Type Ed 450/8 Table 36: Ed 450 – 2 dimensions Type Ed 450/8 – – – – – – Tolerance +0.1 Tolerance +0.15 to +0.20 Ed 500 dimensions –...
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Technical data Dimensions Ed 121 dimensions – long lift thrusters Table 41: Ed 121 – 1 dimensions Type Ed 121/12 – Ed 121/12.1 – Ed 121/20 – Table 42: Ed 121 – 2 dimensions Type Ed 121/12 179.5 Ed 121/12.1 179.5 Ed 121/20 Tolerance +0.1...
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Technical data Dimensions Ed 201 dimensions – long lift thrusters Table 45: Ed 201 – 1 dimensions Type Ed 201/12 – Ed 201/12.1 – Ed 201/12.5 25.4 25.4 Table 46: Ed 201 – 2 dimensions Type Ed 201/12 179.5 Ed 201/12.1 179.5 Ed 201/12.5 84.5...
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Technical data Dimensions Ed 400 dimensions – long lift thrusters Table 49: Ed 400 – 1 dimensions Type Ed 400/10 – Table 50: Ed 400 – 2 dimensions Type Ed 400/10 119.2 Tolerance +0.1 Tolerance +0.15 to +0.25 Ed 450 dimensions – long lift thrusters Table 51: Ed 450 –...
Technical data Dimensions 3.4.6 Type Ed 350 Ed 350/20, Ed 350/20-X01, Ed 350/20.2 dimensions Figure 8: Dimensional drawing – example: Ed 350/20, Ed 350/20-X01, Ed 350/20.2 Table 53: Ed 350 – 1 dimensions Type Ed 350/20 Ed 350/20 X01 Ed 350/20.2 1092 22.3 38.15...
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Technical data Dimensions Ed 350/20.1, Ed 350/20-X02 dimensions Figure 9: Dimensional drawing – example: Ed 350/20.1, Ed 350/20-X02 Table 55: Ed 350 – 1 dimensions Type Ed 350/20.1 – – – Ed 350/20 X02 1025.53 25.48 – – – Table 56: Ed 350 –...
Technical data Dimensions 3.4.7 Type Ed 630 Figure 10: Dimensional drawing – example: Ed 630/8, Ed 630/9, Ed 630/10 Ed 630 dimensions Table 57: Ed 630 – 1 dimensions Type Ed 630/8 Ed 630/9 Ed 630/10 Table 58: Ed 630 – 2 dimensions Type Ed 630/8 Ed 630/9...
Technical data Airborne sound emissions Airborne sound emissions ® The A-rated emission sound pressure level for all ELDRO thrusters is 55 dB (A). This value was determined using an integrated sound pressure level measuring unit in accordance with DIN 45633 under the following measurement conditions: ...
Technical data Operating conditions 3.6.2 Air humidity Up to 100 % air humidity is permitted if special measures are taken. 3.6.3 Aggressive ambient conditions Special measures (special paint) are required for use in aggressive ambient conditions (e.g. salty ambient air). 3.6.4 Voltage and frequency tolerances The permissible voltage tolerances in operation are ±10 % at the...
Functional description Operating conditions Functional description ® The ELDRO electro-hydraulic lifting thrusters are manufactured as different types. These individual types can be merged into the following type groups due to their common attributes. Table 60: Type groups ELDRO ® Type group type Ed 12/4 Ed 23/5, Ed 23/5.1, Ed 23/5.2, Ed 23/5.5...
Functional description Mechanical layout Mechanical layout ® The ELDRO thruster combines all structural elements of a complete hydraulic system in one structural unit. This comprises a three-phase asynchronous motor (direct current motor in the special version), a closed hydraulic system and the work cylinder with piston and lifting rod.
Functional description Mechanical layout 4.1.2 Type group 3 Figure 12: ELDRO ® thruster layout (example: Ed 50 – Ed 80 C-HS) Oil filling opening Two-pole three-phase asynchronous motor Double seal to the hydraulic space Motor shaft seal Lifting/lowering valve Piston Hydraulic pump Brake spring (c spring) Junction box...
Functional description Mechanical layout 4.1.3 Type group 4 Figure 13: ELDRO ® thruster layout (example: Ed 121 – Ed 301 C-HS) Piston rod Two-pole three-phase asynchronous motor Double seal to the hydraulic space Double motor shaft seal Hydraulic cylinder Piston Lifting/lowering valve Brake spring (c spring) Hydraulic pump...
Functional description Mechanical layout 4.1.4 Type group 5 ® Figure 14: ELDRO thruster layout (example: Ed 630/9) Thrust shackle Double seal to the hydraulic space Piston rod Hydraulic cylinder Piston Lifting/lowering valve Motor shaft seal Junction box Two-pole three-phase asynchronous motor Foot attachment Oil filling opening 48 / 83...
Functional description Electrical equipment Electrical equipment A three-phase asynchronous motor is used as the drive (some special version also use direct current motors). The power supply is provided via screw terminals that are located in a junction box. There is an M25 x 1.5 cable infeed for cable diameters of 10 mm to 19 mm on the junction box.
Transport and storage Transport Transport and storage Transport CAUTION The ELDRO ® thrusters weigh between 10 and 70 kg Risk of injury when lifting the load manually – Use suitable lifting equipment (e.g. crane). – Never remain below suspended loads. –...
Transport and storage Storage 5.1.1 Transport sketch Attach a suitable load carrying thruster to the attachment point to transport using lifting gear. Figure 15: Attachment point Attachment point Storage ® The ELDRO thrusters can be transported or stored upright or lying down until commissioned.
Assembly and installation Assembly Assembly and installation The following safety regulations must be adhered to before beginning ® any work on ELDRO thrusters: Ensure that the industrial system is shut down De-energise the system Safeguard the system to prevent it being switched on again ...
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Assembly and installation Assembly CAUTION Sudden power failure or switch-off due to any c springs, brake springs, brake weights that may be installed or due to other external influences Risk of crushing due to the lifting rod. – Before removing the ELDRO ®...
Assembly and installation Assembly 6.1.1 Permissible installation positions ELDRO ® thrusters may be installed vertically, horizontally and in angled positions in accordance with the following illustration. The type plate must always be at the top. This is important, as the compensation space that is below the type plate must always be at the top.
Assembly and installation Assembly ® 6.1.2 Installing the ELDRO thruster To attach the ELDRO ® thruster, there are fastening eyelets on the motor housing and holes in the lifting rod, which can be used with suitable bolts to establish the connection to the equipment to be operated (e.g.
Assembly and installation Electrical connection Electrical connection DANGER Live components Fatal electric shock or serious burns – Work on live components may only be performed by electricians. – When performing any work on electrical components, the five safety rules must be adhered to: –...
Assembly and installation Electrical connection 6.2.1 Junction box and terminal diagram 6-pin terminal board Terminal diagram: Figure 17: 6-pin terminal diagram Connection terminals for the motor Delta connection Bridge Star connection (condition as delivered) Blank plug Earthing conductor terminal M25-x-1.5 screw connection ELDRO-Assembly-manual-344029-EN.docx 57 / 83...
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Assembly and installation Electrical connection 9-pin terminal board with heating Terminal diagram: Figure 18: 9-pin terminal diagram with heating Bridge Connection terminals for the motor Connection terminals for the heating M25-x-1.5 screw connection for motor cable M25-x-1.5 screw connection for heating cable Delta connection Earthing conductor terminal Star connection (condition as delivered)
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Assembly and installation Electrical connection 9-pin terminal board without heating Terminal diagram: Figure 19: 9-pin terminal diagram without heating Bridge M25x1.5 screw connection for motor cable Blank plug Star connection (condition as delivered) Earthing conductor terminal Double star connection Connection terminals for the motor If required, the motor can also be operated with a double star connection YY by reconnecting the bridges (2).
3 times the thruster current according to the type plate. If using a quick lowering switch (capacitors) and a motor protection switch, the overcurrent trigger must be adjusted after consulting EMG Automation GmbH. 60 / 83 ELDRO-Assembly-manual-344029-EN.docx...
Assembly and installation Electrical connection Electrical power may only be supplied once the earthing conductor is connected and can be provided as a fixed cable if the thruster is arranged stationary. A pivoting arrangement requires a flexible cable. A minimum cable cross section of 1.5 mm must be provided for all thruster sizes.
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Assembly and installation Electrical connection Temperature measurement points Figure 20: Temperature measurement points Type Ed 23/5 Temperature measurement point Types Ed 30, Ed 50, Ed 80 Types Ed 121/6 – Ed 350/20 62 / 83 ELDRO-Assembly-manual-344029-EN.docx...
Assembly and installation Adjusting the valves Adjusting the valves In the condition as delivered, the ELDRO ® thrusters are set to 5 seconds of setting time and resetting time. The setting times depend on the temperature and must be adjusted when the machine is at operating temperature.
Assembly and installation Completing assembly 6.3.2 Changing the set time and the reset time Figure 21: Lifting/lowering valve adjustment parts Slotted nut Adjustment screw Sealing plug Housing edge Turning the adjustment screw (2) clockwise increases the lifting or lowering time. Turning the adjustment screw (2) anticlockwise reduces the lifting or lowering time.
Notes on operation Completing assembly Notes on operation WARNING ELDRO ® thrusters can reach housing surface temperatures of up to 100 °C in continuous mode S1 or in switching mode S3 Risk of burns on the housing surface – Avoid touching the housing surface during operation. –...
Notes on operation Checking the operating conditions prior to starting up ® Never operate the ELDRO thruster with electrical connections that are faulty or not ready for operation. The junction box must always be locked. Access must only be granted to authorised staff who have received corresponding training and safety briefings.
Help with malfunctions Faults and troubleshooting Help with malfunctions If used as intended, no typical malfunctions can occur on the ® ELDRO thruster. However, malfunctions can occur due to wear or misuse. ® Malfunctions on the ELDRO thruster may only be rectified when the system is stopped, disconnected from the power supply and the movements have come to a standstill.
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Help with malfunctions Faults and troubleshooting Table 61: Faults and troubleshooting Fault Possible cause Measure Lack of operating fluid Top up the operating fluid Operating fluid On the lifting rod seal Replace the thruster and send to the escapes manufacturer for repair Check the sealing ring, tighten the filling On the filling screw screw to a maximum of 65 Nm...
Maintenance Maintenance tasks Maintenance ® Maintenance work on the ELDRO thruster may only be performed when: the system is stopped. the system has been disconnected from the power supply and secured to prevent a restart. the movements have come to a standstill. ...
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Maintenance Maintenance tasks WARNING Pre-tensioned reset spring ® Risk of injury when opening the ELDRO thruster due to the pre- tensioned reset spring. – Never attempt to open the ELDRO ® thruster in order to access the reset spring. – The ELDRO ®...
EMG operating fluid that depends on the usage conditions and the required version. Specify the EMG operating fluid type that was filled in on the type plate. The EMG operating fluids are tuned to the components used for the ELDRO ®...
Maintenance Maintenance tasks 9.1.2 Checking the operating fluid WARNING Hot operating fluid Risk of burns due to hot oil plumes when opening the filling screw when at operational heat. – The operating fluid may only be checked, topped up or drained when switched off and cool.
Maintenance Maintenance tasks Topping up the operating fluid Figure 23: Topping up the operating fluid Filling nozzle Filling nozzle bottom edge ® Fill the ELDRO thruster with operating fluid up to the filling nozzle bottom edge. Perform several lifting movements while doing so in order to prevent air entering the system.
Maintenance Maintenance schedule Maintenance schedule Table 63: Maintenance log for ELDROclassic ® lifting thrusters ® ELDROclassic type Serial number System ID Classification Standard Higher according to section requirements requirements 3.1 (table 1) Test object Test interval according to classification Test Test Evaluation / performed...
Maintenance Maintenance schedule Test object Test interval according to classification Test Test Evaluation / performed passed measured values Proof of insulation Every 2-3 years reliability in accordance with DIN 57530 part 1 / VDE 0530 section17.1 Maintenance Recommendation: Replacing all wear parts Every 5 years (bearings, seals, or after...
Disassembly Maintenance schedule Disassembly The following safety regulations must be adhered to before beginning ® any work on ELDRO thrusters: Ensure that the industrial system is shut down. De-energise the system. Safeguard the system to prevent it being switched on again. ...
Disassembly Disconnecting the electrical connections 10.1 10.1 Disconnecting the electrical connections DANGER Live components Fatal electric shock or serious burns. – Work on live components may only be performed by electricians. – First disconnect the electrical power supply. – The earthing conductor must be disconnected after all other cables.
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Disassembly 10.2 Removal NOTE Suitable measures must be taken to prevent the ELDRO ® thrusters falling before removing them. The ELDRO ® thrusters weigh between 10 and 70 kg. NOTE The lifting rod must not be damaged or contaminated (e.g. by paint as a result of painting the entire system).
Disposal Disposal consideration 11.1 Disposal 11.1 Disposal consideration WARNING Opening the ELDRO ® thrusters Risk of injury due to tensioned c springs. – Only service partners authorised by the manufacturer are ® permitted to dismantle the ELDRO thrusters outside the manufacturer’s factory.
Lists 12.1 Index of figures Lists 12.1 Index of figures Figure 1: Type designation and type key ..................18 Figure 2: Type plate ........................19 Figure 3: Example type Ed 12/4 ....................23 Figure 4: Dimensional drawing – example: Type Ed 23/5 ............24 Figure 5: Dimensional drawing –...
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Lists Index of tables 12.2 Table 19: Ed 80 – 1 dimensions ....................30 Table 20: Ed 80 – 2 dimensions ....................30 Table 21: Ed 125 – 1 dimensions ....................30 Table 22: Ed 125 – 2 dimensions ....................30 Table 23: Ed 50, Ed 80 –...