ELECTRO HYDRAULIC

THRUSTERS
THE ORIGINAL. BE SAFE.

.moving ahead.
2
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

WELCOME

For 70 years, EMG Automation GmbH has been de-

veloping and producing drive systems for industrial
brakes in a wide range of industrial applications, from
low ambient temperatures to extremely harsh environ-
ments.
The customer benefit arises due to the combination
of long-term experience with industrial strength, effi-
cient solutions, outstanding logistics and top quality
standards.
EMG offers its customers uncompromising reliabili-
ty coupled with intelligent innovation. In production,
EMG greatly values the highest possible manufactur-
ing Quality in order to ensure its high quality stand-
ards. Nearly all components are manufactured by
EMG in house, thus the customers can be sure:
If EMG is what you see, then EMG is what you get.
The electrohydraulic thrusters ELDRO and ELHY,
patented by EMG, ensure safe and soft braking in
combination with modern drum and disc brakes. Ad-
ditionally they ensure safety for man and machine
when braking and in general use as well as for inter-
ruptions such as power failures.
As an independent manufacturer of linear industrial
drive systems, the most important application fields
for EMG products comprise ports, steel and metal-
lurgy, as well as mining and raw material extraction.
To date, more than 2 million electro hydraulic thrust-
ers have been supplied in many thousands of design
variants.
Founded in 1946 in Wenden, Germany, EMG as part
of the elexis Group currently employs around 1,260
employees worldwide and covers the market with
18 subsidiary companies and more than 50 partners
around the globe. Based on a deep understanding
of the market requirements, as a partner to our cus-
tomers we prepare the way for new applications and
business fields of the future.

THE ORIGINAL. BE SAFE.

3
HIGHEST QUALITY, MAXIMUM SAFETY

In addition to the requirements arising from standards, Consistent compliance with our quality assurance
laws, etc., the quality demands of EMG Automation system in accordance with DIN EN ISO 9001 and
GmbH are oriented in particular towards our custom- the legal requirements
ers expectations, as well as a responsibility for the en- Verification and validation of the
vironment and the technically and financially feasible prototypes
optimum.
One-Piece-Flow assembly concept
All employees along the added value chain take respon-
sibility for the quality of our products and processes. Menu-controlled operating media filling with
Through internal and external audits, we regularly scru- automated test routines
tinize existing processes and procedures, with the aim 100 % testing of all series devices from the
of finding and utilising improvement potentials. ELDRO and ELHY range, including
We expand the knowledge and awareness of our em- High voltage insulation test
ployees through regular training and development, Function test
and enhance the quality of our processes and proce- 12 hour endurance test
dures. Test data acquisition and evaluation
Traceability of the test data per
Alongside our decades of experience in the produc-
brake thruster
tion of brake thrusters, EMG quality is guaranteed
through: Continuous Improvement Process (CIP)

On request, we furnish you with EC declarations of conformity (CE mark) and test certificates per DIN EN IEC 17050-1 or
DIN EN 10204.

4
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

CERTIFICATE
The Certification Body
of TV SD Management Service GmbH
certifies that

EMG Automation GmbH

Industriestrae 1, 57482 Wenden
Germany

EMG Automation GmbH

Werk ELTMA
Am Pfefferbach 20, 39387 Oschersleben
Germany

has established and applies

a Quality Management System for

Development, manufacture, sale and

service of metal strip guiding control systems,
quality assurance systems, ELDRO-/ELHY brake lifting devices,
hydraulic compact units and linear actuators,
electronic controls for the
BRAKEMATIC braking system, valve gearboxes,
electromechanical actuators, magnetic particle couplings
and machining of metal products.

An audit was performed, Report No. 70002967.

Proof has been furnished that the requirements
according to

ISO 9001:2008
are fulfilled. The certificate is valid from 2014-06-13 until 2017-06-02.
Certificate Registration No. 12 100 16893 TMS

Product Compliance Management

Munich, 2014-06-16

5
DESIGN, FUNCTION AND ADVANTAGES

PRESSURE STRAP

REDUNDANT
PISTON ROD PROTECTIVE TUBE DUST PROTECTION SEAL

PISTON ROD

OIL FILLER OPENING

REDUNDANT SEAL TO
THE HYDRAULIC CHAMBER BRAKE SPRING
(C-SPRING) 1)

HYDRAULIC CYLINDER

PISTON
OIL GUIDE RING

HYDRAULIC PUMP

REDUNDANT MOTOR
SHAFT SEAL

TERMINAL BOX

THREE-PHASE
ASYNCHRONOUS MOTOR, 2-POLE

BASE FASTENING

1)
Auxiliary equipment

6
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

ADVANTAGES
Use of robust asynchronous
motors
Use of high quality mate-
rials
Use of the proven hydro-
dynamic principle
Broad standard tempera-
ture range from 25 C to
+50C, expandable to
45 C to + 80 C with
additional equipment, e.g.
heating and use of special
operating media
Mains voltage fluctuations
only have a limited influ-
ence on the function of the
devices, because the motor
speed is predominantly de-
Hydraulic assembly Pump system Motor assembly
pendent on frequency and
less on voltage
No thermal protective cir-
cuit required
MODE OF OPERATION

Automatic driving back of All elements of a hydraulic actuation system are combined in the ELDRO to
the piston to the default po- produce a compact assembly. When switched off, the hydraulic piston with
sition when switched off the piston rod is located in its bottom limit position.

Linear lifting and lower-
ing speeds (exception: mo-
tor start-up and run-down
range)
No sensitive electronic and
sensory installation parts
needed for the operating
principle
Long service intervals
When switched on, the hydraulic pump pumps the operating fluid beneath
the piston and in doing so generates the hydraulic pressure here. This moves
the piston up to the maximum stroke path. When doing so, the counter-
force which is generated through an integrated brake or return spring, or
an external load (e.g. a brake) must be safely overcome.
The maximum stroke path of the ELDRO device, e.g. 60 mm, can be exter-
nally arbitrarily limited. This can be the case if the brake to be actuated only
requires a stroke path of 40 mm for example, for complete opening.
In the respective piston limit position, the power consumption of the mo-
tor reduces in comparison to the power consumed during the lifting process
due to the laws of hydraulics. The pressure in the device reaches its maxi-
mum value here. The drive motor is therefore relieved in the resting position
of the piston. Mechanical overloading of the ELDRO device is not possible.

7
ED DEVICE OVERVIEW

CHARACTERISTIC FEATURES
The electro hydraulic system of the ELDRO devices,
in conjunction with the straightforward integration in
brake systems and the simple electrical start-up, re-
sult in the following features under the diverse appli-
cation conditions:
High operational safety
Long service life due to wear-free work under
constant self-lubrication
Soft and impact-free mode of operation, as a
systemic result of the hydraulic working principle
Short actuating times
Approved continuous operation S1
High switching frequency of up to 2,000
cycles per hour in switching operation S3
Reversing operation without limitations
Easy to install and de-install
Arbitrary direction of motor rotation, meaning no
changeover contactors required
Overloading not possible during operation
Arbitrary external limiting of the stroke path
Stepless extension of the lifting and/or lowering
times through the installation of valves
The fill level of the operating medium is optimised
according to the application conditions and re-
quires no further checking.

Three-phase current version

Current Switching
Power
Type Lifting force Stroke path** consumption at frequency with Weight
consumption
400 V/50 Hz S3 operation
Ed 12/... 120 N 40 mm 120 W 0.36 A 2,000 c/h 8 kg
Ed 23/... 220 N 50 mm 165 W 0.50 A 2,000 c/h 10 kg
Ed 25/... 300 N 50 mm 165 W 0.50 A 2,000 c/h 10 kg
Ed 30/... 300 N 50 mm 200 W 0.50 A 2,000 c/h 14 kg
Ed 50/... 500 N 60 120 mm 210 W 0.50 A 1,200 2,000 c/h* 23 26 kg*
Ed 80/... 800 N 60 120 mm 330 W 1.20 A 1,200 2,000 c/h* 24 27 kg*
Ed 121/... 1,250 N 60 200 mm 330 W 1.20 A 400 2,000 c/h* 39 kg
Ed 125/... 1,250 N 70 mm 330 W 1.20 A 2,000 c/h 24 kg
Ed 185/... 1,850 N 60 155 mm 450 W 1.30 A 400 2,000 c/h* 40 kg
Ed 201/... 2,000 N 60 120 mm 450 W 1.30 A 1,200 2,000 c/h* 39 kg
Ed 301/... 3,000 N 60 150 mm 500 W 1.40 A 400 1,500 c/h* 40 50 kg*
Ed 350/... 3,500 N 200 mm 550 W 1.40 A 400 c/h 50 kg
Ed 400/... 4,000 N 80 200 mm 550 W 1.40 A 400 600 c/h* 50 kg
Ed 450/... 4,500 N 80 200 mm 600 W 1.40 A 400 600 c/h* 40 50 kg*
Ed 500/... 5,000 N 80 mm 700 W 1.80 A 400 c/h 50 kg
Ed 630/... 6,300 N 80 120 mm 700 W 1.80 A 400 c/h 70 kg

DC current version
Current Switching
Power
Type Lifting force Stroke path** consumption at frequency with Weight
consumption
220 V DC S3 operation
Eg 50/... 500 N 60 120 mm 350 W 1.60 A 600 1,000 c/h* 27 31 kg*
Eg 80/... 800 N 60 120 mm 330 W 1.50 A 600 1,000 c/h* 27 31 kg*
Eg 121/... 1,250 N 60 120 mm 330 W 1.50 A 500 1,000 c/h* 43 44 kg*
Eg 201/... 2,000 N 60 120 mm 430 W 2.00 A 500 1,000 c/h* 43 44 kg*
Eg 301/... 3,000 N 60 120 mm 470 W 2.20 A 400 800 c/h* 43 44 kg*

* depending on stroke path ** further on request Stroke work (N cm) = Lifting force x stroke path

8
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

Ed 12/4 Ed 23/5 Ed 30/5 Ed 80/6

VERSIONS WITH BRAKE SPRING

Brake spring force

Type
(c-spring)
N

Three-phase current version

Ed 23/5 180
Ed 30/5 270
Ed 50/6 460
Ed 80/6 750
Ed 121/6 1,200
Ed 185/6 1,900
Ed 201/6 1,900
Ed 301/6 2,700

DC current version

Eg 50/6 460
Eg 80/6 750
Ed 301/6 Ed 630/9
Eg 121/6 1,200
Eg 201/6 1,900
Eg 301/6 2,700

9
ED 12

F
B D
E
K
C

A
O

N P G

Ed 12

ED 23 TO ED 25

B F K
D E1
E

G
N P

Ed 23 / Ed 25

10
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

ED 30 TO ED 80 AND ED 125

F
B D
E

K
C

G
Ed 30 N P

Type A C D E E1 F G H K L M N O P R

Ed 12/ 265 20 10 12 20 12 12 110 55 45 25 178 14 100

Ed 23/ 286 26 12 12 16 20 16 20 160 80 80 40 200 16 92

Ed 25/ 286 26 12 12 16 20 16 20 160 80 80 40 200 16 92

Type A C D E E1 F G H K L M N O P R

Short stroke thrusters

Ed 30/ 370 34 15 16 25 16 18 160 80 80 40 197 16 80

Ed 50/ 435 36 18 20 30 20 23 195 97 120 60 254 22 90

Ed 80/ 450 36 18 20 30 20 23 195 97 120 60 254 22 90

Ed 125/ 450 36 18 20 30 20 23 195 97 120 60 254 22 90

Long stroke thrusters

Ed 50/ 515 36 18 20 30 20 23 195 97 120 60 254 22 90

Ed 80/ 530 36 18 20 30 20 23 195 97 120 60 254 22 90

B = stroke path (variable) | E convertible to E1 by removing the clamping bush

11
ED 121 TO ED 630

B F
D
E
K
C

N G
P
M
Ed 301

Type A C D E F G H K L M N O P R

Short stroke thrusters

Ed 121/ 645 38 25 25 40 25 35 240 112 90 40 260 25 -

Ed 185/ 600 42 25 25 40 27 44 240 112 160 80 260 25 -

Ed 201/ 645 38 25 25 40 25 35 240 112 90 40 260 25 -

Ed 301/ 645 38 25 25 40 25 35 240 112 90 40 260 25 -

Long stroke thrusters

Ed 121/ 705 38 25 25 40 25 35 240 112 90 40 260 25 -

Ed 185/ 700 42 25 25 40 27 44 240 112 160 80 260 25 -

Ed 201/ 705 38 25 25 40 25 35 240 112 90 40 260 25 -

Ed 301/ 705 38 25 25 40 25 35 240 112 90 40 260 25 -

Ed 301/* 880 38 25 25 40 27 44 250 117 160 80 265 25 -

Ed 350/ 880 38 25 25 40 27 44 250 117 160 80 265 25 -

Ed 400/ 645 42 25 25 40 25 34 240 112 90 40 265 25 -

Ed 450/ 645 42 25 25 40 25 34 240 112 90 40 265 25 -

Ed 500/ 665 52.5 25 25 40 25 35 250 117 90 40 265 25 -

Ed 630/ 705 38 25 25 40 25 35 274 127 90 40 328 30 -

B = stroke path (variable) | * from 130 mm stroke path

12

ELECTRICAL VERSION
MOTOR
Three-phase asynchronous motor, 2-pole
For power data see technical values
Standard insulation per insulation class F
Special version in insulation class H
VOLTAGES AND FREQUENCIES
S
 tandard:
230/400 V, 50 Hz, 3 ~
290/500 V, 50 Hz, 3 ~
400/690 V, 50 Hz, 3 ~
Special versions 110 V to 690 V, 3 ~,
50 Hz and 60 Hz possible
All devices are star (Y) connected on delivery
Alternating current versions (with capacitor for
Steinmetz circuit) on request
DC current version possible from device type Eg 50
CABLE INLET
Threaded cable gland M 25 x 1.5 for cable
cross-sections to 4 x 2.5 mm2 ( 12 18 mm)
MECHANICAL VERSION
INSTALLATION VARIANTS
In case of types from Ed 50, the base fastening
can be mounted offset through 90.
With the types Ed 23/5 and Ed 30/5, the base
fastening is cast on the motor.
Here, 90 offset installation is possible with a
special motor housing.
The pressure strap at the top rotates in all types.
In case of versions with a limit switch, minor mod-
ifications are required in order to rotate the pres-
sure strap or fasten the base as required.
OPERATING FLUID
Mineral hydraulic oil or silicone oil
depending on the operating conditions, e.g.
ambient temperature, factory-filled
ELECTRO HYDRAULIC
THRUSTERS ELDRO
OPERATING MODES
Continuous operation S1 and intermittent duty
S3 60 % ED standard
With temperatures > 50 C deviating
technical values
TERMINAL BOX
Terminal board 6-pole, with devices with heating
the terminal board is 9-pole
Supply line connection M4
Internal protective conductor connection: M4
External protective conductor connection: M6
MOTOR CIRCUIT BREAKER
With device protection through motor circuit
breaker, the trigger value must be set to at least
2-times the nominal device current.
ENCLOSURE
Standard IP 65, in special version up to IP 68
PAINT APPLICATION PER DIN EN ISO 12944
Standard for corrosion load C1,
layer thickness 70 m
Special paint up to corrosion load C5-M,
coating thickness to 280 m
Standard colour RAL 7022 (umbra grey)
PROTECTIVE MEASURES
Redundant dust protection seal
Redundant seal with the hydraulic chamber
Piston rod chromium plated to dimension
With Ed 121, Ed 201, Ed 301, Ed 350, Ed 630 addi-
tional piston rod protective tube against external
mechanical influences
13
ELECTRICAL & MECHANICAL AUXILIARY EQUIPMENT

LIFTING AND/OR LOWERING VALVE (H, S, HS) HEATING

The lifting and lowering times can be steplessly ex-
tended with an integrated lifting and/or lowering
valve. The adjustable minimum values attain 10 to
20-times the normal values.
Integrated valves in open position result in an ex-
tension of the lifting and lowering times with short
stroke thrusters of up to approx. 0.1 to 0.2 seconds,
and with long stroke thrusters of up to approx. 0.2
to 0.4 seconds.
The desired lifting or lowering time is set externally
on the device.
With ambient temperatures below 25 C
and use of the standard operating fluid, the
ELDRO devices must be equipped with low
temperature heating.
The task of the heating lies in keeping the opera-
ting fluid within the liquid range.
In order to avoid condensation in the motor, the
ELDRO devices can be equipped with parking
heaters. The temperature of the ELDRO device is
kept slightly above the ambient temperature and
the formation of condensation is thereby avoided.

BRAKE SPRING (C-SPRING) INCREASED CORROSION PROTECTION

Integrated c-spring for generating the brake Increased corrosion protection is necessary with
force. The specified brake force of the c-spring is the use of ELDRO devices in environments of ag-
reached at 1/3 of the nominal stroke. gressive media and/or high relative humidity with
the resultant formation of condensation.
Increased protection in the motor:
DAMPING SPRING (D-SPRING)
Vacuum full potting of the stator or the use of a
Damping of the load change when closing and parking heater
opening the brake.
Increased external protection:
The d-spring is only effective in conjunction with a Through special paint application, see Mechanical
c-spring. version
With the installation of the d-spring, it is not possi-
ble to fit a limit switch.
The installation length A of the device does not
change.
When specifying the working point of the brake,
dimension z must be taken into account (see
separate datasheet).
Main application: ELDRO control brake

QUICK LOWERING SWITCHING

The lowering times are shortened through the
use of three-phase motor capacitors, or by short-
circuiting the stator winding via a contactor.
The lowering times reduce by approx. 15 %. d-spring

14
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

POSITIONING MEASURING SYSTEMS

Analogue measuring systems for monitoring the
entire stroke path
Version dependent on the stroke path

LIMIT SWITCHES
All ELDRO devices can be fitted with mechanical
ANALOGUE or inductive limit switches for the electrical display
of the air and brake setting.
Detailed information is available in the data sheet
for the limit switches

INDUCTIVE

MECHANICAL

15
GENERAL INFORMATION

For device key data see device type plate
The devices are delivered ready for operation,
filled with operating fluid
Do not open the filler plug unless authorised to do
so, because oil losses change the technical values
or cause inoperability

INSTALLATION POSITION

15

90

15 15

Base fastening of device types from Ed 50

can be mounted offset by 90 respectively
Device pivoting must be ensured, transverse
forces must not act on the piston rod

16
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

ELECTRICAL CONNECTION

Establish connection in the terminal box cover Tightly close terminal box
according to the connection diagram
To ensure the protection class (e.g. IP65) a proper
Motor is voltage interchangeable for delta () or cable entry must be ensured
star (Y) switching
The devices exhibit star (Y) switching when deliv-
ered. Phase sequence arbitrary with connection
With auxiliary heating observe connection diagram
in the terminal box cover
Keep terminal box clean
Ensure integrity and correct seating of the seals at
the terminal box cover

TERMINAL BOX COVER

CONNECTION DIAGRAM

17
FURTHER DELIVERY SPECTRUM

ELECTROHYDRAULIC ELECTROHYDRAULIC
THRUSTERS ELHY IN DIN THRUSTERS ELHY IN TGL

ELECTROHYDRAULIC ELECTROHYDRAULIC
ACTUATORS EDC 100/30 COMPACT THRUSTERS IN EX-VERSION EDEX

18
 ELECTRO HYDRAULIC
THRUSTERS ELDRO

HYDRAULIC COMPACT DRIVE HYDRAULIC COMPACT DRIVE

AGGREGATE HKA-A LINEAR HKA-L

ELECTRO LIFT CYLINDER ELECTRO SERVO CYLINDER

EHZ ESZ

19
EMG Automation GmbH
Industriestrae 1 57482 Wenden, Germany
Phone: +49 27 62 6 12 - 0 Fax: +49 27 62 6 12 - 320
www.emg-automation.com eldro@emg-automation.com Group
oup
EMG / P-E / ELDRO / EN / Revision 00 / 06.2016 / Printed in Germany / Subject to modification