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Summary of Contents for EMG ELHY EB 630
- Page 1 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...
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Page 3: Table Of Contents
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 .................... - Page 4 Table of contents 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 Functional description................29 Mechanical layout ....................... 30 4.1.1 Type group up to EB 2500 ....................30 4.1.2 Type group from EB 3000 .....................
- Page 5 Table of contents Checking the operating conditions prior to starting up ..........54 Help with malfunctions ................55 Faults and troubleshooting ....................55 Maintenance ....................57 Maintenance tasks ......................57 9.1.1 Operating fluid ........................59 9.1.2 Checking the operating fluid ....................60 9.1.3 Replacing the operating fluid ....................
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Page 6: General
Version Description Date Author V1.0 First draft 12/08/2021 CE Design Manufacturer EMG Automation GmbH Am Pfefferbach 20 D-39387 Oschersleben / Germany Phone +49 (0)3949 928 500 +49 (0)3949 928 513 Email info@emg-automation.com Website www.emg-automation.com 6 / 71 ELHY-Montageanleitung_2021_EN.docx... -
Page 7: Validity
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... -
Page 8: Format Conventions
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 ⇒... -
Page 9: Structure Of Warning Notices
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 –... -
Page 10: Terms And Abbreviations
General Terms and abbreviations 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. - Page 11 General Terms and abbreviations Table 2: Terms and abbreviations Term/abbreviation Meaning TGL thrusters Installation dimensions according to TGL 35868 X devices Special installation dimensions ELHY-Montageanleitung_2021_EN.docx 11 / 71...
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Page 12: Safety
Safety Intended use 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 ®... -
Page 13: Unintended Use
Contact EMG Automation GmbH if the required staff qualifications are unclear. ELHY-Montageanleitung_2021_EN.docx 13 / 71... -
Page 14: Qualified Personnel
Safety Staff qualifications 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. -
Page 15: Maintenance Personnel
Safety Staff qualifications 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: ... -
Page 16: Personal Protective Equipment
Safety Personal protective equipment Contact EMG Automation GmbH 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: ... -
Page 17: Process Media
Safety Process media 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. -
Page 18: Technical Data
Technical data Type designation and type key Technical data Type designation and type key Figure 1: Type designation and type key ELHY ® type Brake/reset spring Regulating spring, version for control braking Lift, lowering, throttle valve Design (depending on installation position and fastening) Protective cover, special scraper Temperature class, low temperature version Corrosion protection class... -
Page 19: Specifications On The Type Plate
Technical data Specifications on the type plate Specifications on the type plate Figure 2: Type plate CE or CSA or CE EAC Switching type Thruster type Current consumption Equipment Frequency Year of manufacture/serial number Weight Lifting path in mm Power consumption Lifting force in N Additional text 1 Switching processes per hour... -
Page 20: Characteristics
Technical data Characteristics Characteristics Type EB (TGL 35868) Table 4: Identification data - Types TGL 35868 - EB 12-EB 630 ELHY ® type Lifting force [N] 1,250 1,500 2,500 3,200 6,300 Lifting path [mm] 50–100 60–160 60–160 60–160 60–160 Power consumption [W] Current consumption at 400 V 50 Hz [A] Switching frequency at S3-60% ED [c/h]... -
Page 21: Dimensions
Technical data Dimensions Dimensions 3.4.1 Type EB (TGL 35868) Figure 3: Types EB (TGL 35868) - Example EB 50/50 The foot attachment can be mounted offset by 90°. The thrust shackle at the top can be turned. For limit switches, a desired swivelling of the foot attachment or the thrust shackle/lifting rod head must be taken into account. - Page 22 Technical data Dimensions Table 6: EB 12 – EB 630 (TGL 35868) dimensions Size Type +0.1 +/-1 +/-1 EB 12-1 – – 16.1 – – EB 12-2 16.1 EB 12-3 16.1 EB 20 21.5 20.2 EB 50 21.5 20.2 EB 50 21.5 20.2 EB 80...
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Page 23: Type Eb (Din 15430)
Technical data Dimensions 3.4.2 Type EB (DIN 15430) Figure 4: Types EB DIN 15430 - Example EB 500-60 ELHY-Montageanleitung_2021_EN.docx 23 / 71... - Page 24 Technical data Dimensions Table 7: EB 120 – EB 6300 (DIN 15430) dimensions Size Type +0.1 +/-1 +/-1 EB 120-2 12.1 EB 120-3 16.1 EB 220-1 – – 16.1 – – EB 220-2 16.1 EB 220-3 16.1 EB 300 16.1 EB 500 20.1 EB 500...
- Page 25 Technical data Dimensions Special versions based on DIN 15430 Table 8: Dimensions of special versions EB 320 - EB 3200 Size Type +0.1 +/-1 +/-1 EB 320 16.1 EB 320 16.1 EB 500 20.1 EB 500 20.1 EB 800 20.1 EB 1250 25.1 EB 1500...
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Page 26: Electrical System
Technical data Electrical system Electrical system 3.5.1 Voltages and frequencies All thrusters are switched to star (Y) when delivered. AC versions (with condenser for Steinmetz circuit) on request. Standard Table 9: Electrical voltages and frequency (standard) Values Name Electrical power supply 3/N/PE AC 400/230 V Frequency 50 Hz... -
Page 27: Operating Fluid
Technical data Operating fluid Operating fluid The operating fluid used depends on the ambient temperatures at the place of installation. For information on the dependence of the operating fluid on the ambient temperatures, see the section Operating conditions (⇒ section Ambient temperatures). Airborne sound emissions The A-rated emission sound pressure level for all ELHY ®... -
Page 28: Operating Conditions
Technical data Operating conditions Operating conditions 3.8.1 Ambient temperatures With suitable operating fluids, the ELHY ® devices can be operated at the following ambient temperatures: Table 12: Different ambient temperatures and required operating fluids Ambient temperature range Operating fluid Remark The lifting times may extend by up to Standard range Transformer oil... -
Page 29: Functional Description
Functional description Operating conditions Functional description ® The ELHY electro-hydraulic lifting thrusters are manufactured as different sizes (types). These individual types can be merged into the following type groups due to their common attributes. Table 13: Type groups Size ELHY ®... -
Page 30: Mechanical Layout
Functional description Mechanical layout Mechanical layout ® The ELHY thruster combines all structural elements of a complete hydraulic system in one structural unit. This comprises a three-phase asynchronous motor, a closed hydraulic system and the work cylinder with piston and lifting rod. The hydraulic system’s operating fluid is used to generate the force. -
Page 31: Type Group From Eb 3000
Functional description Mechanical layout 4.1.2 Type group from EB 3000 The ELHY ® thrusters (type groups from EB 3000) are equipped with a two-stage hydraulic pump. Figure 6: ELHY ® thruster layout - type groups from EB 3000 Lifting rod Regulating plug Brake spring (C-spring) Guide cylinder... -
Page 32: Mechanical Equipment
Installation position Vertical Lifting rod, upwards: without restrictions Lifting rod, downwards: Note the operating mode Vertically suspended If necessary, consult EMG Automation GmbH Horizontal and Device type plate on the side! intermediate If necessary, consult EMG Automation GmbH positions 4.1.4 Protective measures ... -
Page 33: Electrical Equipment
ED (duty cycle) standard Differing technical values for ambient temperatures > 40 °C For further information on the deviating technical values, please contact EMG Automation GmbH. 4.2.3 Junction box Information on the connections can be found in the technical data (⇒... -
Page 34: Additional Mechanical And Electrical Equipment
Functional description Additional mechanical and electrical equipment Additional mechanical and electrical equipment 4.3.1 Lift, lowering or throttle valve (H, S, D) With a built-in lifting, lowering or throttle valve, the lifting or lowering times as well as both times together can be extended continuously. -
Page 35: Regulating/Damping Spring (R/D-Spring)
Functional description Additional mechanical and electrical equipment 4.3.2 Regulating/damping spring (R/D-spring) Assembly mounted on the head of the lifting rod for damping the aperiodic transient oscillation of the brake (special application: Regulation braking). Figure 7: Regulating/damping spring (R/D-spring) R-spring (TGL 35868) D-spring (DIN 15430) ... -
Page 36: Brake Spring (C-Spring)
(hydraulic medium: silicone oil), heating of the ELHY thruster is not necessary. For extreme operating temperatures (below -50 °C), preheating can be implemented via the motor winding. EMG Automation GmbH must be contacted for further information. 36 / 71 ELHY-Montageanleitung_2021_EN.docx... -
Page 37: Position Indicators
2xSG, lifting rod extended + lifting rod retracted 2xSG, lifting rod extended + function-dependent intermediate position 2xSG, lifting rod retracted + function-dependent intermediate position For detailed information and availability of the respective sensor version, please contact EMG Automation GmbH. ELHY-Montageanleitung_2021_EN.docx 37 / 71... -
Page 38: Limit Switches
2xSG, lifting rod extended + lifting rod retracted 2xSG, lifting rod extended + function-dependent intermediate position 2xSG, lifting rod retracted + function-dependent intermediate position For detailed information and availability of the respective limit switch version, please contact EMG Automation GmbH. 38 / 71 ELHY-Montageanleitung_2021_EN.docx... -
Page 39: Function Sequence
Functional description Function sequence Function sequence The hydraulic pump driven by the motor conveys the hydraulic medium into the space below the piston. This generates hydraulic pressure that acts outwards via the piston and lifting rod. The piston and lifting rod move backwards after the motor is switched off either due to a force acting from the outside (brake weight, brake spring) or due to the integrated reset spring. -
Page 40: Transport And Storage
Transport and storage Transport Transport and storage Transport CAUTION The ELHY ® thrusters weigh between 8 and 45 kg Risk of injury when lifting the load manually – Use suitable lifting equipment (e.g. crane). – Never remain below suspended loads. –... -
Page 41: Transport Sketch
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 8: Attachment point Attachment point Storage ® The ELHY thrusters can be transported or stored upright or lying down until commissioned. -
Page 42: Assembly And Installation
Assembly and installation Assembly Assembly and installation 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 ... - Page 43 Assembly and installation Assembly CAUTION ® The ELHY thrusters weigh between 8 and 45 kg. Risk of injury when lifting the load manually. – Use suitable lifting equipment (e.g. crane). – Never remain below suspended loads. – Use a transport aid (e.g. lifting carriage) with sufficient load bearing capacity.
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Page 44: Permissible Installation Positions
Assembly and installation Assembly 6.1.1 Permissible installation positions ELHY ® 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. -
Page 45: Installing The Elhy ® Thruster
Assembly and installation Assembly ® 6.1.2 Installing the ELHY thruster To attach the ELHY ® 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. -
Page 46: Electrical Connection
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: –... -
Page 47: Junction Box And Terminal Diagram
Assembly and installation Electrical connection 6.2.1 Junction box and terminal diagram There is a connection diagram in the terminal box cover. The motor is voltage switchable for delta connection (Δ) or star connection (Y). On delivery, the devices are connected in star connection (Y). The phase sequence for the connection is arbitrary. -
Page 48: Earthing Conductor Connection
Assembly and installation Electrical connection Terminal board 3-pole with position indicator Lk/La Terminal diagram: Figure 11: 3-pin terminal diagram (single voltage) Screwed connection for motor cable M25 x 1.5 PE earthing conductor terminal 6.2.2 Earthing conductor connection NOTICE If the external earthing conductor connection is used, the thruster’s pivoting ability and the surface temperature must be considered. -
Page 49: Power Supply Connection
If using a quick lowering switch (capacitors) and a motor protection switch, the overcurrent trigger must be adjusted after consulting EMG Automation GmbH. A pivoting arrangement requires a flexible cable. A minimum cable cross section of 1.5 mm must be provided for all thruster sizes. -
Page 50: Adjusting The Valves
Assembly and installation Adjusting the valves Unless ordered differently, all three-phase motors are wired for a star connection as delivered from the factory. If required, the user can reconnect the bridges (⇒ Junction box and terminal diagram section) to also operate the motors in delta connection. The motor’s phase sequence and therefore its direction of rotation do not matter. -
Page 51: Setting Times
Assembly and installation Adjusting the valves Examples for the version with valves: Lowering valve (S): e.g. EB 50/50 S Lifting valve (H): e.g. EB 800-60 H Throttle valve (D): e.g. EB 125/60 D All thrusters can be equipped or modified with valves retrospectively by the manufacturer. -
Page 52: Changing The Set Time And The Reset Time
Assembly and installation Completing assembly 6.3.3 Changing the set time and the reset time Figure 12: Lifting/lowering valve adjustment parts Screw plug Cylinder casing Regulating plug Guide cylinder Turning the regulating plug (3) clockwise increases the lifting or lowering time. Turning the regulating plug (3) anticlockwise reduces the lifting or lowering time. -
Page 53: Notes On Operation
Notes on operation Completing assembly Notes on operation WARNING ELHY ® thrusters can reach housing surface temperatures of up to 100 °C in continuous mode or in switching mode S3. Risk of burns on the housing surface – Avoid touching the housing surface during operation. –... -
Page 54: Checking The Operating Conditions Prior To Starting Up
Notes on operation Checking the operating conditions prior to starting up ® Never operate the ELHY 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. -
Page 55: Help With Malfunctions
Help with malfunctions Faults and troubleshooting Help with malfunctions ® If used as intended, no typical malfunctions can occur on the ELHY thruster. However, malfunctions can occur due to wear or misuse. ® Malfunctions on the ELHY thruster may only be rectified when the system is stopped, disconnected from the power supply and the movements have come to a standstill. - Page 56 Help with malfunctions Faults and troubleshooting Table 21: 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 On the filling screw Check sealing ring, tighten filler plug At the separation level between...
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Page 57: Maintenance
Maintenance Maintenance tasks Maintenance ® Maintenance work on the ELHY 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. ... - Page 58 Maintenance Maintenance tasks WARNING Pre-tensioned reset spring ® Risk of injury when opening the ELHY thruster due to the pre- tensioned reset spring. – Never attempt to open the ELHY ® thruster in order to access the reset spring. – The ELHY ®...
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Page 59: Operating Fluid
Maintenance Maintenance tasks 9.1.1 Operating fluid ELHY ® thrusters are delivered from the factory with operating fluid that depends on the usage conditions and the required version. The type of operating fluid that the thruster was filled with is specified on the type plate. -
Page 60: Checking The Operating Fluid
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. - Page 61 Maintenance Maintenance tasks Fill level height ® The ELHY thrusters are filled correctly if the operating fluid level reaches the lower edge within the filling opening when the thruster is upright and the lifting rod is retracted. Figure 13: Operating fluid fill height Filler opening with screw plug Fill level ELHY-Montageanleitung_2021_EN.docx...
- Page 62 Maintenance Maintenance tasks Topping up the operating fluid Figure 14: Topping up the operating fluid Screw plug EB 12-50 Fill level EB 50-50 EB 120-40 ® Fill the ELHY 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.
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Page 63: Replacing The Operating Fluid
Maintenance Maintenance tasks 9.1.3 Replacing the operating fluid On the ELHY ® thruster, the filler opening for the operating fluid is also the drain opening. Figure 15: Drain opening with screw plug Drain opening with screw plug NOTICE Observe the safety data sheet issued by the oil manufacturer. The type of operating fluid already in the thruster must always be used to replace it. -
Page 64: Maintenance Schedule
Maintenance Maintenance schedule Maintenance schedule Table 23: Maintenance log for ELHY ® thrusters ® ELHY 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 /... -
Page 65: Classification
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, etc.) -
Page 66: Disassembly
Disassembly Maintenance schedule Disassembly 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. ... -
Page 67: Disconnecting The Electrical Connections
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. - Page 68 Disassembly 10.2 Removal NOTICE Suitable measures must be taken to prevent the ELHY ® thrusters falling before removing them. The ELHY ® thrusters weigh between 8 and 45 kg. NOTICE The lifting rod must not be damaged or contaminated, e.g. by paint as a result of painting the entire system. A failure to observe this will destroy the lifting rod.
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Page 69: Disposal
Disposal Disposal consideration 11.1 Disposal 11.1 Disposal consideration WARNING Opening the ELHY ® thrusters Risk of injury due to tensioned c springs. – Only service partners authorised by the manufacturer are ® permitted to dismantle the ELHY thrusters outside the manufacturer’s factory. -
Page 70: Lists
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: Types EB (TGL 35868) - Example EB 50/50 ..............21 Figure 4: Types EB DIN 15430 - Example EB 500-60 ..............23 Figure 5: ELHY ®... -
Page 71: Appendix
Appendix Further applicable documents 13.1 Appendix 13.1 Further applicable documents Table 25: Further applicable documents Document Designation EC Declaration of Original EC Declaration of Incorporation for partly completed machinery Incorporation Maintenance manual ELHY ® Electrohydraulic Lifting Units - Maintenance Manual, EB Series Maintenance manual_EB1.0 (EN) 4.2006.pdf ELHY-Montageanleitung_2021_EN.docx 71 / 71...
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