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1. Internal Magnets IS j Sensors ele 11 2 Phillips Head Dimensions A and B are approximate end of 0 44 Screw stroke locations for the position sensors TC Series Pim Dim B ei RL mm in mm in lg A I ts TC2 73 3 2 90 48 3 1 90 0 39 T t TC3 77 0 3 03 56 6 2 23 295 H TC4 137 0 5 39 63 0 2 48 pe i TC5 137 0 5 39 63 0 2 48 Side View of TC Cylinder Sensor to Controller Connections The sensor connection diagrams below show wiring color codes and controller inputs for connecting each type of position sensor 2 Conductor Controller PSR Shielded Gable D Note The black wire in Quick Disconnect cables is Reed x Ge not used with any version of the PSR Reed sensor Sensor t Brown Inupt S K In the above drawing only the blue wire brown wire WM and shield are connected Blue COM 8 Sensor Reed 3 Conductor Controller Shielded Cable DC Suppl PSN 12 24V pply Hall Effect Controller AG Sensor 5 Brown Input Q E 3 Black E Blue COM a Shield elen Sensor Hall Effect 3 Conductor Controller Shielded a 12 24V 00 surely PSP Brown Con
2. MD ri TIL 5 1 Motor may be customer supplied 2 Drive Housing 3 Drive Train belt drive shown 4 Thrust Bearings 5 Leadscrew 6 Drive Nut 7 ee 10 11 9 5 8 Internal Guide Flange including magnets Rod End Bearing Rod End Wiper Thrust Tube Guide Cylinder TC Electric Cylinder User s Manual 2 Cylinder Part Numbers Identifying a Cylinder Your new TC cylinder will arrive with an Thomson factory label attached as shown below The factory label provides a detailed breakdown of the cylinder model with all of its mechanical characteristics This section can be used to 1 identify a cylinder s mechanical characteristics based on the factory label or 2 order a new TC cylinder with different mechanical characteristics Label Location Locations of Labels on Different Motor Mounting Configurations Label THOMSON men Label TEL 800 544 8466 www linearactuators com e al Parallel Inline lt TC3 P32 15 05B 50 MS2 MT1E SE L Voltage XXX V Rated Current XX A Model Number Example Base Model Number Stroke Cylinder Rod Options Rod Type M tor Drive Screw Length Mounting End Cylinder Type Ratio Pitch Type TC3 Product Series MS2 Side Lugs Mounting B23 NEMA 23 Frame Brushless Servo Motor MT1E Male Threaded Rod End English Threads 15 1 5 to 1 Drive Ratio Bel
3. TV D i ie UPDILMY LET Lubricating TC2 TC3 ACME Screws and All TC4 TC5 Ballscrews 1 Remove lube plug 2 M li t t troke oye cylmder to center stroke 5 Caution Do Not Overfill the Leadscrew with Grease Pump only 2 3 to 2 8 grams 08 to 1 0 oz of grease per 304 8 mm 12 inches of cylinder travel 4 Insert lube nozzle through lube opening and onto the into the leadscrew grease fitting 3 Install the Thomson supplied lube nozzle on your lube dispenser aka grease gun 27 TC Electric Cylinder User s Manual Checking Adjusting Drive Belt Tension 1 2 3 Ensure power to the motor is OFF and the load is removed from the thrust tube Remove rear cover plate s as necessary for your particular TC cylinder Using finger pressure push the drive belt inward The belt should not deflect more than 3 17 mm 125 inch from a stationary centerline If the drive belt deflects more than 3 17 mm 125 inch proceed to the following section that applies to your motor Adjusting Belt Tension on D and H Motors 1 Loosen two 2 motor adjustment screws inside drive housing shown below left just enough to allow the motor to move Both screws are in slots which allow up down movement of the motor to change belt tension Move the motor up or down to adjust belt tension While maintaining proper tension by hand tighten both screws Check belt tension again and reassemble unit
4. Adjusting Belt Tension on P22 P32 S32 S42 B23 B32 and B41 Motors 1 Loosen four 4 external motor mounting adjustment screws shown below right just enough to allow the motor to move All screws are in clearance holes which allow just enough up down movement to adjust the belt tension 2 Move the motor up or down to adjust belt tension While maintaining proper tension by hand tighten all screws Check belt tension again and reassemble unit D H H4 Motors P22 P32 S32 S42 B23 B32 B41 Motors Fe og C Motor Motor EEN 6 Adjustment SES Screw IN Motor Motor Mounting Adjustment Screw 4 28 3 17 mm 125 V Maximum Belt Deflection TC Electric Cylinder User s Manual Lubricating Gears Recommended Lubricant NLGI Grade 2 Synthetic Base Lithium Complex EP Grease 1 Remove rear cover plate s as necessary for your particular TC cylinder Note Cylinder with BS Brake on Leadscrew option requires removal of the top cover plate only on TC2 cylinders Remove as much of the old grease from the gears as possible With the gears exposed apply an ample amount of lubricant 6 35 mm 25 in or more to all surface contact areas of gear train as shown in the illustration below Reassemble unit 29 TC Electric Cylinder User s Manual Aligning Moto
5. Drive Ratios NN NN NONA Q N Pe ENN GED EG AR st N Bx O m 42 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Parallel Motor Mounting H Motor A SS 34 X ae 55 x2 54 B23 Motor IIe Lei Ba Va f Ca lt p af JR 18 x2 53 43 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Inline Motor Mounting 44 20 x4 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Inline Motor Mounting 45 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Inline Motor Mounting 46 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Inline Motor Mounting 47 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Parallel Motor Mounting 48 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Parallel Motor Mounting id 18 x4 49 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Parallel Motor Mounting H4 Motor P32 Motor 1 1 1 5 1 2 1 5 1 10 1 Drive Ratios Drive Ratios 50 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Parallel Motor Mounting 51 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Inline Motor Mounting 52 TC Electric Cylinder User s
6. l TC M Dimension A Series otors mm in TC2 D H P22 S32 B23 NEMA 23 34 11 63 0 458 TC3 D H P32 S32 B23 32 NEMA 23 34 13 08 0 515 TC4 H4 P32 S32 B32 NEMA 34 42 18 06 0 711 TC5 H4 P32 532 42 B32 41 NEMA 34 42 18 06 0 711 lg TC Dimension B Series Motors mm in TC2 32 P22 NEMA 23 34 9 40 0 370 B23 3 68 0 145 SS TC3 D P32 S32 B23 32 NEMA 23 34 3 30 0 130 TC4 H4 P32 S32 42 B32 NEMA 34 42 2 82 0 111 TC5 P32 832 42 B32 NEMA 34 42 2 82 0 111 Le TC M Dimension C Series piers mm in TC2 H amp D only 6 73 0 265 TC3 H only 10 67 0 420 TC4 N A N A TC5 H4 amp B41 only 15 72 0 619 a TC M Dimension D Series ORIG mm in TC2 D H P22 S32 B23 NEMA 23 34 8 00 0 315 TC3 D H P32 532 B23 32 NEMA 23 34 7 62 0 300 ege TC4 H4 P32 S32 B32 NEMA 34 42 8 79 0 346 TC5 H4 P32 532 42 B32 41 NEMA 34 42 8 79 0 346 TC Electric Cylinder User s Manual Lubricating the Leadscrew In high load and or high duty cycle applications TC2 and TC3 cylinders with ACME screws should be re lubricated every 200 000 inches of travel All other TC cylinders should be re lubricated every 1 000 000 inches of travel TC2 and TC3 cylinders with ACME screws and all TC4 and TCS cylinders include a lube port and lube adapter nozzle for a standard lubrication dispenser grease gun Note Do not attempt to lubricate the leadscrew of a cylinder with
7. FE2 or FS2 rod ends MS1 Side End Angle Brackets Each mounting screw must be able to withstand a peak shear force of 4488 N TC2 8896 N TC3 15569 N TC4 26689 N TC5 MS2 Side Lugs Each mounting screw must be able to withstand a peak shear force of 4488 N TC2 8896 N TC3 15569 N TC4 26689 N TC5 MS6 Side Tapped Holes Each mounting screw must be able to withstand a peak shear force of 4488 N TC2 8896 N TC3 15569 N TC4 26689 N TC5 MT4 Trunnion Mount Use a flexible rod end or load attachment to compensate for system misalignment Mounting Rod Ends As with mounting styles different rod ends also require certain application considerations Find your rod end s in the table below and pay special attention to the corresponding Application Requirements column Rod End Style Application Requirements FC2 Clevis w MT1 Thread Clevis must be secured by its locknut when in desired position The mounting pin must be secured with a cotter pin after it is inserted into the double clevis holes FS2 Spherical Joint Not recommended if stiff or rigid load attachment is required FT1 Female Thread Any attachment to an FT1 rod end must be secured in place by a locknut MT1 Male Thread Any attachment to an MT1 rod end must be secured in place by a locknut TC Electric Cylinder User s Manual Attaching the Load to the Rod End 10 NNNNNNNNNNNNNNNNNNNNNNNNNNNNNN
8. revs able in same direction D Thrust Tube Expected linear travel distance not Possible Cause Incorrect screw pitch or drive ratio Possible Remedy Check screw pitch and drive ratio of the cylinder Enter correct pitch and ratio in the controller Expected stop position not repeat Incorrect scaling factor programmable controllers Load varies from cycle to cycle Enter correct scaling factor in the controller Change load to be more consis tent from cycle to cycle Erratic Motor Control operation Contact motor control vendor for more information Wobbles during extension Leadscrew or thrust tube is bent Send back to factory for evalua tion Excessive wear on leadscrew nut Send back to factory for evalua tion Improper mounting of cylinder Ensure cylinder travel is aligned with the travel of the load Excessive lateral endplay Deflects too much during extension Leadscrew nut or internal bearings are worn Send back to factory for evalua tion Excessive side loading Check side load rating Reduce side load Improper cylinder mounting Ensure that cylinder travel is in line with the travel of the load Bent thrust tube Load too great for cylinder Excessive side loading Improper cylinder mounting Send back to factory for evalua tion Rotates excessive radial play Internal guide flange is damaged Send back to factory fo
9. z z Description of Part see Exploded Parts Hardware Maximum Torque Maximum Torque E Size N m in Ibs Diagrams Screw Guide Cylinder 17 33 53 M5X 8 4 24 50 89 M6X1 9 9 87 62 M10X1 5 41 362 86 Screw Set 22 36 M4X 7 0 94 8 32 M6X1 4 3 38 06 Screw Set Coupling 4 58 10 24 UNC 2 83 25 05 1 4 20 UNC 4 53 40 09 Screw Motor Mounting 39 MAX 2 9 25 67 M5X 8 5 75 50 89 M6X1 9 9 87 62 Screw Cover Plate 18 MAX 2 9 25 67 M5X 8 5 75 50 89 M6X1 9 9 87 62 Lubricants and Adhesives When a specific lubricant or adhesive is required it will be specified within the applicable procedure 24 TC Electric Cylinder User s Manual Installing a Pulley Pinion Reverse Pinion or Coupling Refer to the applicable illustration and dimensions table on the following page for your pulley pinion reverse pinion or coupling placement 1 Di 8 Clean the motor shaft and bore free of any grease Apply Loctite 680 green to the motor shaft and the bore of the pulley pinion or coupling Slide pulley pinion reverse pinion or coupling onto the motor shaft with a rotating motion to evenly distribute the Loctite See Application Note 2 Position the pulley pinion reverse pinion or coupling according to the applicable drawing and table on the following page Ensure that one setscrew is positioned on a flat in a dimple over a key or keyway Apply Loctite 262 red to the setscrew s Tighten setsc
10. 31 5 1280 50 5 mm s in s Repeatability mm in 0 13 0 005 0 013 0 0005 Compatible Superior Elec D2200 SmartStep B8961 tric Controls D2300 D2400 D2500B Performance Curves See Latest Thomson Catalog or www linearactuators com Configurations and Options Available See Cylinder Configuration Guide for explanation of codes below 10 15 20 50 100 10L 04A 05B 16B 50 100 150 200 250 300 450 600 750 Custom lengths available in 1 mm increments MET MF2 MF3 MS1 MS2 MP2 MP3 MS6M MS6E MT4 Drive Ratio Screw Type Stroke Length mm Cylinder Mounting Rod End FT1M FT1E MT1M MT1E FC2 FS2 Options BS EMK L BM BS EMK BS EMK L BM BS L LR PB L LR PB LR PB LR PB TC3 Specifications Parameter TC3 H TC3 P32 TC3 B23 B32 Motor Type 160 VDC Brushed 1 8 amp Hybrid Stepper Brushless Servo Max Load Capacity N Ibs 7200 1620 Max No Load Speed mm s in s 930 36 5 800 31 5 1280 50 5 Repeatability mm in 0 025 0 001 0 013 0 0005 Compatible Superior Electric Controls SmartStep B8961 Performance Curves See Latest Thomson Catalog or www linearactuators com Configurations and Options Available See Cylinder Configuration Guide for explanation of codes 10 15 20 50 70 10L 04A 05B 10B 16B 50 100 150 200 250 300 450 600 750 1000 Custom lengths available i
11. B32 NEMA 34 Frame Brushless Servo Motor B41 A NEMA 42 Frame Brushless Servo Motor Customer Supplied Motor motor described in Options element of part number 10 1 0 1 Drive Belt Pulley 1 0 1 exact ratio 15 1 5 1 Drive Belt Pulley 1 5 1 exact ratio 20 2 0 1 Drive Belt Pulley 2 0 1 exact ratio 50 5 0 1 Drive Belt Pulley 5 0 1 ratio 70 7 0 1 Drive Belt Pulley 7 0 1 ratio 100 10 0 1 Helical Gear 10 1 exact ratio 10L 1 0 1 Inline Coupling Direct 1 1 coupling is the only ratio available for Inline Models TC3 only Screw Type 04A 4 mm rev ACME leadscrew 05B 5 mm rev ballscrew 10B 10 mm rev ballscrew 16B 16 mm rev ballscrew 25B 25 mm rev ballscrew 32B 32 mm rev ballscrew Stroke Length Specified in Millimeters Cylinder Configuration Guide TC Electric Cylinder User s Manual MF1 Front Rectangular Flange MF2 Rear Rectangular Flange i MF3 Front amp Rear Rectangular Flange rk i
12. EE 15 eek EL SE 16 DUTY CYCLE LIMITS re lad nasa ae TEATERET 16 ENVIRONMENTAL SPTCIFICATIONS ENE EE si hatiost vod ouansintusoaaedelehap taunt 17 PREVENTING EXPOSURE TO CONTAMINANTS cscsscssssssesesssceseseseescsesecsesssecsesssecsesssecsssececsesecaeseseeee 17 INSTALLING A VENT TUBE FITTING INCLUDED WITH ALL TC CYLINDERS ccccsccssccscscsececseeeceeseeeceenes 17 6 OPTIONAL EQUIPMENT SPTCIFICATIONS DIMENSIONS AND WIRING see 19 BRAKE ON LEADSCREW OPTION BS24 BS115 BS230 0 2 2 ececeececcceececceeeeeeeeteeeeeeneeaeeeeeeeeeeeess 19 BRAKE ON MOTOR OPTION BM24 BM115 BM230 rrrrrrrrnnrrrrnrrnnnrrrrrrrnarrrerrrnnnrrererrnernresrernnnn 20 ENCODER OPTION EMK EM scesscsssecsssessscssssesssessecssuesssessetssssssssssesssessnssssesssessetsssessetessessnseees 21 LINEAR POTENTIOMETER OPTION L seint heri pekende bd ba da d 22 7 FACTORY SERVICE AND ROUTINE FIELD MAINTENANCE rnnnnnnnnnnnnnnnnnnnnnnnnnnnnenenenennnnnennnnen 23 PERFORMING INSPTCTIONS AND ROUTINE MAINTENANCE cccccccsssscsesccscscsececsesececsesecesseseceeseeecseses 23 ROUTINE MAINTENANCE PROCEDURES sunmmsisinbaeirammminntdetnnsasisnedumnnidet vr nuveiddet dettan 24 PREVENT NJURY TO PERSONNEL sammsdasitagsdaamieainnsondinselhdnnkelamsnuerlatnksudvdadse ad 24 EDER ERE 24 LUBRICANTS AND ADHESIVES eegener 24 INSTALLING A PULLEY PINION REVERSE PINION OR COUPLING cccccsssscscsecscsesececsesececscsececseeeeeenes 25 SPACING REQUIREMENTS bie
13. Manual Exploded Parts Diagram TC4 TC5 Inline Motor Mounting De KE S Ee er w Bo P E 53 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Inline Motor Mounting P32 Motor D Z e d e e 18 x2 54 TC Electric Cylinder User s Manual Exploded Parts Diagram TC4 TC5 Inline Motor Mounting H4 Motor 55 TC Electric Cylinder User s Manual This page intentionally left blank 56 TC Electric Cylinder User s Manual 11 Warranty and Service Coverage Thomson warrants all TC Cylinders to be free of defects in material amp workmanship for a period of one year from the date of shipment to the user Products returned prepaid to the factory will be repaired or replaced at our option at no charge and returned prepaid to the user Products that fail due to improper use or misapplication are not subject to the terms of this warranty Technical Support Thomson offers technical support through its factory authorized and trained Distributors and through its factory based Applications Engineering and Inside Sales department If an application problem exists or if the product has failed contact your Distributor or Thomson for technical assistance Contact our factory at 1 800 544 8466 outside the U S at 704 588 5693 Factory Repair Service Product repairs are performed at our factory in Rohnert Park California Prior approval by Thomson is required before return
14. Norm Closed LED Color Green Red Green Red Yellow Red 2 shield 26 AWG 3 meters 3 shield 26 AWG 3 meters Leads wiring gt Voltage 8 120V AC or DC 5 12 or 24 VDC S Current 5 mA 12 VDC 10 mA 24 VDC 9 Power 0 24 W Leakage Current max 0 01 mA DC Maximum 120VDC 8 30VDC AC Maximum 120VAC 6 Current Max 40mA 100mA Power Max 5W 3W 48 to 158RF 20R to 70RC 48 to 176RF 20R to 80RC ITC Standard IP67 Operating Temp Storage Temp Environmental Rating Not compatible with Superior Electric s motion controllers Mounting Location Deceleration Distance The position sensor s location along the cylinder is associated with the beginning of a deceleration not the final stopping point Therefore position sensors must be mounted inward of the cylinder hard stops to provide a slowdown area to prevent jamming The faster the approach speed the longer it takes to stop the cylinder so deceleration distance varies with cylinder speed load and cylinder control type A small amount of adjustment may be necessary during initial setup Important Installation Notes 1 Position sensors may be mounted along either side of an TC cylinder Labels example shown indicate the sides of the cylinder where position sensors can be installed POSITION INDICATING MAGNET THIS SIDE 3 Using position sensors for end of travel protection reduces effect
15. 100 14 to 212 20 to 100 4 to 212 Storage Temp e CL F 20 to 80 4 to 176 30 to 110 22 to 230 25 to 100 13 to 212 Not an option Encoder is standard equipment on these motors Dimensions P32 532 542 B32 B23 and B41 Motors Encoder is enclosed within the standard motor housing no dimen sional changes Encoder Motors D H P22 P32 32 S42 Motors B23 B32 B41 Connections Signal Color Code Signal Color Code See Note A Red A Blue Blue Blue A Pink or Purple A Blue Black Yellow Blue White B Green B Green Yellow White Yellow B Blue B Green Black Red White Yellow White Z Yellow Z Violet Blue White Brown Z Orange Z Violet Black Black White Brown White 5 VDC White 5 VDC Red Red Red COM Black COM Black Black Black Note Due to different cable suppliers your encoder cable will contain one of three possible color codes Each column represents a color code for a different cable Find the color code that matches your cable and use that column only H Motor 30 48 d 1 2 17 79 8 3 14 v Encoder Cover D P22 Motor 25 4 1 00 54 1 2 13 gt Encoder Cover 21 TC Electric Cylinder User s Manual Linear Potentiometer Option L The Linear Potentiometer resides within the cylinder housing and is energized by an external DC po
16. NNNNNNNNNNNNNNNNNNNNNNNNN ND 00000000 Maximum Torque TC 5 A B Series N m ft lbs N m ft lbs TC2 68 50 27 20 TC3 88 65 41 30 TC4 163 120 68 50 TC5 163 120 68 50 Do Not Exceed A ft Ibs torque in the Clockwise CW direction Warning Do Not Exceed the Maximum Torque Limits on the Thrust Tube when attaching the load to the rod end Failure to heed this warning could cause irreparable damage to the internal guide flange Maximum torque limits are shown on the drawing below Hexagonal flats are provided at the end of the thrust tube to prevent rotation while the rod end attachment is being secured ZZ ZZZ ZZZ ZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ ZZZ Do Not Exceed B ft lbs torque in the Counter Clockwise CCW direction we Use wrench on flats to prevent rotation of thrust tube during load attachment WAARAAABRAARABRATA TC Electric Cylinder User s Manual Aligning the Electric Cylinder to the Load Load travel alignment is critical for the prevention of binding and premature wear of internal components The following alignment procedures and specifications have been developed for users who demand the highest level of precision and longest life from their Thomson electric cylinders Alignment Using MF1 MF2 MF3 MP2 MP3 or MT4 Cylinder Mounting Styles 1 Ensure that the mounting surface is within X millimeters from perpendicular to t
17. THOMSON INDUSTRIES TC Series Electric Cylinders User s Manual P N 61 0048 Version 1 0 2 THOMSON Table of Contents 1 PRODUGT OVERVIEW pen alen eege eege eeben 1 TO SERIES FEATURES eege 1 TC SERIES EIERE 1 TC ELTCTRIC CYLINDER CONSTRUCTION TYPICAL c csccscsssesecsesesecseseecsesesecseseecsesececsesaacsesesecsenees 2 2 CYLINDER PART NUMBERS IDENTIFYING A CYLINDER rernnnnnnnnnnnnnnnnnnnnnnnnnnnnenenennnnnnnnnnnnnnen 3 IDENTIFY YOUR TC CYLINDER USING THE CYLINDER CONFIGURATION GUIDE cccccccceceeseeeeeeseeeeseees 3 3 TC SERIES SPTCIFICATION AND CONFIGURATION REFERENCE ccccccccecceeeeeeeeeeseeeesenees 6 4 MOUNTING YOUR TG CYLINDER ic i3ssccccccsscdscvec ek ENEE EEN E tutes etesesebernssscstvestassseeeens 9 MOUNTING REQUIREMENTS si iscstoataatenatnictesmniidantcadntidetedicnancde a a naie 9 ATTACHING THE LOAD TO THE ROD END srdcseecatssaiantisaishacoxtssataesnssganigccnsachideasedzeabbiiohcateusdasbennacces 10 ALIGNING THE ELTCTRIC CYLINDER TO THE LOAD ccscscsssscscsesecsesesecsesesceseseseeseseseeseseseeseseseeaesens 11 INSTALLING POSITION SENSORS FOR OVERTRAVEL PROTTCTION rerrnrererrrverenrrverenrsvrvenernrvernnvenenennen 12 POSITION SENSOR DIMENSIONS AND MOUNTING LOCATIONS rrrrrrererarrerenrrverenrrnrvenernrvenesvenerenvenennnnen 13 5 APPLICATION CONSIDERATIONS rrnnvnvnvnnnnnnnnnnnnnunnnunnnnnnnnnnnnnnenennnnnnnnnnnnnnnnnnnnnnnnnnunnnunnnensvenennen 15 COLUMN LOAD L MIT
18. ated in an environment of solid contaminants connect the other end of the tubing to a non contaminated positive pressure source of 2 to 3 psi 2 Install white plastic vent tube fitting J TC2 TC3 TC4 TC5 TC4 and TC5 with Protective Boot PB Option TC Series Size Tubing Required Vent Tubing Sizes EET Eb i ee TC2 and TC3 1 4 inch inside diameter TC4 and TC5 3 8 inch inside diameter TC4 and TC5 with PB option 3 4 inch inside diameter TC Electric Cylinder User s Manual This page intentionally left blank TC Electric Cylinder User s Manual 6 Optional Equipment Specifications Dimensions and Wiring Brake on Leadscrew Option BS24 BS115 BS230 This brake option provides a spring set electrically released friction brake mounted to an extension of the leadscrew It prevents backdriving when the unit is at rest or in case of power failure The brake is engaged when power is not applied Applying power releases the brake allowing motion to occur Application Note This option is used only for in position holding it should not be used for stopping a moving load Specifications Dimensions Electrical Connections Specification Leadscrew Mounted Brake Configurations Parameters BS24 BS115 BS230 Voltage 24 VDC 115 VAC 230 VAC Power Watts TC2 12 5 TC3 7 TC4 5 15 Holding Torque N m in Ibs TC2 3 9 35 TC3 6 7 60 TC4 5 39 2 350 Cable Len
19. consider the following options 5 Contact Thomson Applications Engineering for a custom Column Load Limit 6 Use the Column Load Limit for the next shorter stroke length Example for an TC3 of 1100 mm with an 04A screw use 4650 N 15 TC Electric Cylinder User s Manual Critical Speed Limit All leadscrew systems have a critical speed at which harmonic vibrations begin to occur Sustained operation beyond this critical speed limit see tables below may cause the leadscrew to vibrate or whip violently eventually bending or warping the screw see illustration QI Maximum Speed per Cylinder Stroke Length Speed mm sec Observing the maximum speed limits in the tables below will help prevent damage to your TC cylinder OJ 50 200 mm 300 mm 450 mm 600 mm TC3 TC2 TC3 TC2 TC2 Note Shading indicates non applicability Important Note Thomson programmable controls have a max imum velocity parameter that can be config ured not to exceed the critical speed Duty Cycle Limits Duty cycle is the percentage of ON Time divided by Total Cycle Time for the worst case 10 minute period During operation duty cycle represents the maximum acceptable power dissipation of the motor and the frictional heat losses of the internal cylinder components primarily the leadscrew drivenut assembly In ge
20. cture on which the cylinder is mounted must be capable of holding three times 3X the cylinder load and be rigid enough to prevent undue deflection or distortion of the cylinder or its supporting members 3 The cylinder must be mounted parallel to the travel of the load to ensure proper alignment this is especially important with externally guided loads using rails bearings etc All mounting surfaces must be flat and clean to provide for secure and stable fittings Units with flat surface mounts MF1 MF2 MF3 MS1 MS6 must be rigidly mounted Cylinder Mounting Styles Each cylinder mounting style presents different application considerations Find your mounting style s in the table below and pay special attention to the corresponding Application Requirements column Cylinder Mounting Style Application Requirements MF 1 Front Flange Not recommended for use in horizontal applications with stroke lengths greater than 300 mm unless there is additional support in the rear of the cylinder MF2 Rear Flange Not recommended for use in horizontal applications with stroke lengths greater than 300 mm unless there is additional support in the front of the cylinder MF3 Front amp Rear Flange Do not allow the body of the cylinder to twist while aligning the front and rear mounting flanges to their mating surfaces MP2 Rear Clevis Use a flexible rod end or load attachment to compensate for system misalignment Example FC2
21. d Speed mm s in s 1330 52 5 Repeatability mm in 0 013 0 0005 Compatible Superior Electric Con trols SmartStep B8961 Performance Curves See Latest Thomson Catalog or www linearactuators com Configurations and Options Available See Cylinder Configuration Guide for explanation of codes Drive Ratio 10 15 20 50 100 10L Screw Type 10B 32B Stroke Length mm 50 100 150 200 250 300 450 600 750 1000 1500 Custom lengths available in 1 mm increments Cylinder Mounting MF1 MF2 MF3 MS2 MP2 MP3 MS6M MS6E MT4 Rod End FT1M FT1E MT1M MT1E FC2 FS2 Options BS EMK L PB BM BS L PB TC Electric Cylinder User s Manual 4 Mounting Your TC Cylinder A ZZ AE ZE AE AE ZE ZE ZE ZE ZZ ZE ZE AE ZE AE AE ZE AE AE ZE AE AE ZE AE AE ZE AE tt ttt tt tt tt tt tt tt th AE AE AE AE ft E V Warning Ensure that power to the electric cylinder is OFF before attempting any installa f d d y tion adjustment or modification of the cylinder mounting rod end attachment or the load IAA badaetdaessaetaitsasssaetsidagssastsassdatatsastsat atasasssssbsitstt a i a Mounting Requirements 1 CAUTION When using pivot mounting options MP2 MP3 or MT4 with a pivot rod end FS2 or FC2 it is recommended that the cylinder not be extended more than 95 of its full stroke This increases the system s rigidity and extends the life of the guide bearings and rod seal 2 The stru
22. e While we recommend factory service in most cases we recognize that it may occasionally be necessary to perform minor repairs or maintenance in the field Such cases include replacing worn or broken components i e belts rod ends or mounting hardware and lubrication of leadscrew or gears as required in extreme applications All routine maintenance procedures must be performed by qualified personnel using only Thomson supplied or Thomson recommended parts and supplies Improper routine maintenance which causes damage or premature wear will void the factory warranty The table below is provided as a quick reference to help users decide whether to return a unit to the factory or allow qualified personnel to perform routine maintenance in the field Factory Service Required Routine Maintenance Procedures Page Belt Pulley Ratio Conversion 1 1 1 5 1 2 1 Pulley and Pinion Installation 22 23 Helical Gear System Ratio Conversion 5 1 and 10 1 f Lubricating the Leadscrew excluding BS and L options 24 Motor Orientation Modification Lubricating Gears 26 Mounting or Rod End Modification Cylinder Option Modification BS and L Any Repair to Motor Pulley Drive Belt Gear Motor Pinion Intermediate Gear or Inline Coupling Sleeve This procedure was developed for users of Thomson motors but it may also be applicable to certain customer supplied motors Performing Inspections and Routine Maintenance Why Per
23. ew Motor Mounting 8 Bearing Leadscrew 40 Belt Timing 9 Bearing Housing 41 Washers Flat Motor Mounting 10 Washer Front Bearing 42 Spacer Motor 11 Leadscrew 43 Spacer Gear Motor Side 12 Bumper Rear 44 Bearing Idler 13 Drive Nut 45 Shaft Idler Gear 14 Bushing Leadscrew 46 Gear Idler 15t Stage 15 Drive Housing 47 Spring Wave 16 Gasket Drive Housing 48 Spacer Gear Non motor Side 17 Screw Guide Cylinder Upper Rear 49 Gear Idler 2 Stage 18 Screw Cover Plate 50 Label Thomson Serial Tag 19 Guide Flange Body 51 Plate Cover Main 20 Guide Flange Bushings 52 Label Thomson Decal 21 Magnet Limit Switch 53 Screw Guide Cylinder Lower Rear 22 Screw Set 54 Cover Motor shaft 23 Lube fitting 55 Screws Cover Motor shaft 24 Thrust Tube 56 Plate Cover Upper 25 Rod End 57 Quick Disconnect 26 Guide Cylinder 58 Coupling Drive 27 Breather 59 Sleeve Coupling 28 Plug Lube 60 Spacer Bumper 29 Bumper Front 61 Spacer Thrust Tube 30 Rod End Housing 62 Shield Pinion 31 Bearing Rod End 63 Spacer Quick Disconnect 32 Wiper Rod End 39 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Parallel Motor Mounting O 40 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Parallel Motor Mounting 41 TC Electric Cylinder User s Manual Exploded Parts Diagram TC2 TC3 Parallel Mounting B23 Motor 32 Motor 5 1 10 1 Drive Ratios 1 1 1 5 1 2 1
24. form Inspections and Routine Maintenance in the Field Periodic inspection and routine maintenance can extend the life of your cylinder especially under extreme operating conditions What are Extreme Operating Conditions Applications such as continuous high speed operation high speed stops starts or exposure to harsh environments When Should Routine Maintenance be Performed In such extreme applications it is recommended that the leadscrew and gears be re lubricated and an internal inspection be completed every 1 000 000 inches of cylinder travel Inspection re lubrication typically consists of partial disassembly followed by cleaning visual evaluation and lubrication TC2 and TC3 cylinders with ACME leadscrews operating in high load high duty cycle applications should be re lubricated every 200 000 inches of travel see page 24 23 TC Electric Cylinder User s Manual Routine Maintenance Procedures Routine maintenance procedures are provided in the remainder of this section Order parts and supplies from your local Thomson Distributor Prevent Injury to Personnel Do not attempt to perform any routine maintenance procedure while power is connected to the motor cylinder Hardware Torque Before attempting any routine maintenance procedure become familiar with the Torque Specification Table below Always refer to this table before applying torque to any of the listed parts Torque Specification Table Reference
25. g or grinding during operation B Cylinder Motion Possible Cause A Audible Noise Emitting from Cylinder Misalignment of internal components Possible Remedy Send back to factory for evalua tion Excessive Side loading Internal lubrication dried Check side load rating Reduce side load Remove old lubricant Re lubri cate the leadscrew and or gears Entry of foreign matter into cylinder body Send back to factory for evalua tion Stalls Binds Sticks during a move erratic motion Load too great for cylinder motor Check cylinder rating Reduce load Excessive thrust tube side loading Check side load rating Reduce side load Motor pulley gear pinion or coupling slipping Re install pulley gear or coupling onto the motor Erratic motor controller operation Ensure functionality of the control ler Replace motor Drive nut or internal bearing seizing locking up typically due to excessive duty cycle temperature or entry of foreign matter into cylinder Send back to factory for evalua tion Running rough not running smoothly Misalignment of internal components Send back to factory for evalua tion Excessive side loading Check side load ratings Reduce side load Internal lubrication dried Remove old lubricant Re lubri cate the leadscrew and or gear Entry of foreign matter into cylinder body Send back to fact
26. gth m ft 3 7 12 Holding Force with BS TC Configuration Screw Type Holding Force Brake Option TC2 16B Ball 16 mm rev 1550 N 350 Ibs 05B Ball 5 mm rev 3600 N 810 Ibs 04A ACME 4 mm rev 3600 N 810 Ibs TC3 16B Ball 16 mm rev 2660 N 600 Ibs 10B Ball 10 mm rev 4260 N 960 Ibs 05B Ball 5 mm rev 7200 N 1620 Ibs 04A ACME 4 mm rev 7200 N 1620 Ibs TC4 25B Ball 25 mm rev 9940 N 2230 Ibs 10B Ball 10 mm rev 12000 N 2700 Ibs TC5 32B Ball 32 mm rev 7770 N 1750 Ibs 10B Ball 10 mm rev 24800 N 5590 Ibs 23 Quick Disconnect Cable Bee Minimum Bend Radius f P ES SE zen H Brake Cover ech gD F L TC Series Dim D Dim H Dim L TC2 78 2 3 08 155 1 6 10 69 3 2 73 TC3 97 3 3 83 183 3 7 22 84 3 3 32 TC4 TC5 141 7 5 58 245 0 9 64 99 9 3 94 CE EE O 115 VAC BS115 8 A 230 VAC BS230 8 Brake CG Coil Z N 24 VDC BS24 19 TC Electric Cylinder User s Manual Brake on Motor Option BM24 BM115 BM230 The motor shaft mounted brake can be an advantage because brake torque is multiplied by the belt or gear reduction and does not interfere with certain rear cylinder mounting options A broken drive belt will render the motor mounted brake inoperable Note Th
27. h MP2 Rear Double Clevis Mount shown MP3 Rear Double Clevis Mount with Pivot Base ff SH Sa ay MS1 Side End Angles oT Oo 8 d o OI MS2 Side Lugs KE A MS6M Side Tapped Mounting Holes H MS6E i d y MT4 Trunnion Mount 2 i o o T Rod Ends Cylinder Options FC2 Clevis includes MT1M FS2 Spherical Joint includes FT1M FT1M Female Thread FT1E MT1M Male Thread MT1E F Note Rod End dimensions can be found in the latest Thomson Catalog or on our website www linearactuators com BM x Brake on Motor Insert one of the following codes for X BS x Brake on Leadscrew EMK Encoder on Motor 1000 line 24 24 VDC Brake 115 115 VAC Brake L Linear Potentiometer 230 230 VAC Brake LR Linear Rod Bearing TC2 only PB Protective Boot Motor Mod Codes for X Motors customer supplied also found in option part of Part Number TC Electric Cylinder User s Manual 3 TC Series Specification and Configuration Reference TC2 Specifications Parameter TC2 D TC2 H TC2 S32 P22 TC2 B23 Motor Type 24 VDC Brushed 160 VDC Brushed 1 88 Hybrid Stepper Brushless Servo Max Load Capacity N Ibs 3230 740 3600 810 Max No Load Speed 840 33 930 36 5 800
28. he drive belt onto the teeth of the drive pulley Refer to Checking Adjusting Drive Belt Tension in section 7 Gear Drive As you slide the motor and gear pinion through the mounting plate gently engage and mesh the pinion with the intermediate gear Refer to Aligning Motor Pinion in section 7 Inline Mounting As you slide the motor and coupling through the mounting plate rotate the motor coupling until it lines up the coupling sleeve inside the cylinder Continue to slide the motor shaft through the mounting plate until motor flange is flush with the motor mounting plate and the motor pilot is centered inside the mounting plate Secure the motor to the mounting plate using the motor mounting hardware previously removed 31 TC Electric Cylinder User s Manual This page intentionally left blank 32 9 Troubleshooting TC Electric Cylinder User s Manual This section offers assistance when troubleshooting basic electric cylinder problems related to mechanical operation When troubleshooting electric cylinder problems the cause may be related to the drive or motor used with the cylinder Refer to your drive control user s manual for additional assistance on troubleshooting your system The following categories are covered in this section A Audible Noise Emitting from Cylinder B Cylinder Motion C Positioning and Travel Length D Thrust Tube E Cylinder Parts and Options Category Symptom Knocking squealin
29. he travel of the guided load See illustrations below 2 Mount the cylinder loosely to the mounting surface i e all mounting screws are installed but they are loose enough to allow the cylinder to move in the mounting Attach the guided load system to the cylinder rod end Reduce as much weight as possible from the guided load system Run the cylinder for 5 to 10 cycles allowing the cylinder to align itself to the guided load system gare 2 Tighten the cylinder mounting screws according to the torque specifications for your specific hardware TG EE TT ee Series Se ER i load travel Tc2 0 03 001 ae i Mounting Surface TCa ong 0015 ee lex TC4 om 002 TC5 om 002 Mounting f gt Surface X 7 load travel Alignment Using MS1 MS2 or MS6 Cylinder Mounting Styles 1 Ensure that the mounting surface is within X millimeters from parallel to the travel of the guided load See table and illustration below 2 Mount the cylinder loosely to the mounting surface i e all mounting screws are installed but they are loose enough to allow the cylinder to move from side to side 3 Attach the guided load system to the cylinder rod end 4 Reduce as much weight as possible from the guided load system 5 Run the cylinder for 5 to 10 cycles allowing the cylinder to align itself to the guided load system 6 Tighten the cylinder mounting sc
30. ing a product for any reason All returned products must be accompanied by an Thomson supplied RMA Return Material Authorization number In Case of Failure 1 Get the Model and Serial Number of the defective unit and document the nature of the failure using the RMA Data Form to help us repair the unit 2 Contact your Thomson Distributor or Thomson at 1 800 544 8466 for an RMA 3 Prepare a purchase order for the repair cost in case the unit is out of warranty 4 Ship the unit prepaid with the RMA number and documentation to Danaher Motion 600 Martin Avenue Suite 103 Rohnert Park CA 94928 Attn RMA 57 TC Electric Cylinder User s Manual This page intentionally left blank 58 Index A adjustment drive belt 28 alignment cylinder load 11 motor pinion 30 position sensors 13 attachment load to rod end 10 B brakes on leadscrew 19 on motor shaft 20 C column load limits 15 coupling installation 25 critical speed limits 16 cross section of TC cylinder 2 customer supplied motors mounting 31 cylinder options how to specify 5 D drive belt tension checking and adjustment 28 drive ratios 4 E encoders specifications 21 environmental requirements 17 F factory service when required 23 G gear lubrication 29 l identifying the mechanical characteristics of an TC cyl inder 3 L leadscrew lubrication 27 TC Electric Cylinder User s Manual linear potentiometer specifica
31. ion back off or move the pinion gear away from the intermediate gear 0 076 to 0 203 mm 003 to 008 in See step 3 on the D H H4 Motor photo While maintaining proper position by hand tighten mounting alignment screws Install upper cover plate D H H4 Motors P22 P32 S32 S42 B23 B32 B41 Motor Mounting Alignment ka Screw 2 screws on D el amp H motors 4 screws on B and P Motors Motor TC Electric Cylinder User s Manual Mounting a Customer Supplied Motor This procedure is provided for the user who will be mounting a non Thomson motor on an TC Cylinder For this procedure it is assumed that the TC cylinder has been received without a motor l For parallel mounted motors only remove rear cover plate s from the gear housing TC2 cylinders have two covers all other TC cylinders have a one piece cover plate Remove motor mounting screws and washers from the cylinder motor mount Note If motor mounting screws and washers are not installed in the motor mount they can be found packaged in a separate bag Install the motor pulley gear pinion or inline coupling per the installation procedure in section 7 Using the following method appropriate to your application insert the motor shaft and motor pilot into the gear housing through the hole in the mounting plate Drive Belt As you slide the motor and pulley through the mounting plate lift t
32. is is a static brake intended only for in position holding It should not be used for routinely stopping a moving load Brake on Motor Specifications Parameter Brake Specifications per Cylinder Configuration Cylinder TC2 H TC3 H TC4 H TC2 B TC3 B TC4 B TC5 B Motor Type H H4 B23 B23 B32 B32 B32 B41 Brake Type BM24 BM115 BM230 BM24 BM24 BM24 Voltage 24 VDC 115 VAC 230 VAC 24 VDC 24 VDC 24 VDC Current Amps 0 25 0 05 0 03 0 21 0 52 0 88 Power Watts 6 5 12 48 21 12 Holding Torque N m in bs 1 1 10 1 1 10 6 7 60 27 240 Cable Length m ft 3 7 12 See Note Below Holding Force Consult the Factory Note Brake wiring included in B23 motor cable Motor cable available in 12 25 and 50 foot lengths Dimensions H Motor with Brake 3 7m 12 Brake Cable E 9 79 25 3 12 B23 Motor with Brake SQ 57 15 2 25 Electrical Connections 190 7 48 MAX ee 50 8 2 00 MAX L 201 9 7 95 MAX X Rectifier 115 VAC BM115 230 VAC BM230 20 H4 Motor with Brake 106 7 4 20 S EG X H 221 49 8 72 B32 Motor with Brake 63 5 2 50 MAX d E X SQ 84 07 3 31 L 260 1 10 24 MAX B41 Motor with Brake SQ 127 99 5 00 Note Observe polarity whe
33. ive travel distance Consult the factory 4 Superior Electric s D2200 D2300 and D2400 series controls use only PSR 1 and PSN 1 position sensors Distance between sensors should be 1 50 inches or more If sensors are located closer than 1 50 inches apart they could trigger at the same time A www ww VGA VGA VGA VGA VGA VGA VGA BE VGA VGA BE VGA VGA VGA VGA BE BE BE BE BE BE BE BE BE BE BE BE BE BE VG www wa CAUTION When installing a position sensor tighten the clamp screw to a maximum 7 0 oz in of torque Failure to heed this caution could cause irreparable damage to the sensor Tighten the clamp screw gently and only to the point where the sensor assembly feels secure and does not slide along the cylinder wall BBA BE EE EEE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EE EEE EE TC Electric Cylinder User s Manual Position Sensor Dimensions and Mounting Locations The illustrations below show sensor mounting locations when cylinder magnet and sensor are physically aligned These locations are recommended as a starting point when setting up a cylinder for the first time Depending on the speed and payload of the application sensors may be moved inward to prevent a hard stop crash when the load travels at full speed past a limit switch See Caution on previous page before Top View of TC Cylinder attempting to tighten the installation screws on a position sensor
34. n 1 mm increments MET MF2 MF3 MS1 MS2 MP2 MP3 MSGE MT4 FT1M FT1E MT1M MT1E FC2 and FS2 BM BS EMK L PB BS EMK L PB BM BS L PB Drive Ratio Screw Type Stroke Length Cylinder Mounting Rod End Options TC Electric Cylinder User s Manual TC4 Specifications Parameter TC4 H4 TC4 P32 TC4 B32 Motor Type 160 VDC Servo 1 8 Hybrid Stepper Brushless Servo Max Load Capacity N Ibs 12000 2700 Max No Load Speed mm s in s 1330 52 5 Repeatability mm in 0 025 0 001 0 013 0 0005 Compatible Thomson Controls H4301B NextStep B8001 H4321B SmartStep B8961 H4501 56002 B8962 S6961 S6962 Performance Curves See Latest Thomson Catalog or www linearactuators com Configurations and Options Available See Cylinder Configuration Guide for explanation of codes Drive Ratio 10 15 20 50 100 10L 10B 25B 50 100 150 200 250 300 450 600 750 1000 1500 Custom lengths available in 1 mm increments Cylinder Mounting MET MF2 MF3 MS2 MP2 MP3 MS6M MSGE MT4 Rod End FT1M FT1E MT1M MT1E FC2 FS2 Options BM BS EMK L PB BS EMK L PB BM BS L PB Screw Type Stroke Length TC5 Specifications Parameter TC5 S42 TC5 B32 B41 Motor Type 1 88 Hybrid Stepper Brushless Servo Max Load Capacity N lbs 25000 5620 Max No Loa
35. n using a BM24 Brake E SEH 71 12 2 80 MAX I ba 266 95 10 51 MAX _ with a B23 B32 or B41 Motor Encoder Option EMK EM The encoder option for TC applicable motors provides an incremental rotary encoder factory mounted directly to the rear of the D H P22 P32 S32 and S42 Thomson motors The EMK encoder is an industry standard 1000 line version and the EM is the 500 line version The digital pulse output is used to provide position feedback to external devices such as motor controllers counters or PLC s A 2000 line encoder is standard equipment on the B23 B32 and B41 motors Specifications per TC Applicable Thomson Motor TC Electric Cylinder User s Manual Parameter D H P22 32 542 Motors P32 Motor B23 B32 B41 Motors Pulses per Revolution EMK 1K line 4K post quad EM 500 line 2K post quad EMK 1K line 4K post quad EM 500 line 2K post quad 2000 line 8000 post quad Output Pulse Format Incremental Du al Square Wave Quadrature with Index Pulse Cable Length Type m ft 3 7 12 Leads 3 7 12 Leads 3 7 12 MS Connector Voltage 5 VDC 5 Current 120 mA 135 mA 200 mA Max Speed 6000 rpm 12000 rpm 6000 rpm Weight kg oz 0 17 6 0 057 2 0 0 25 8 8 Inertia kg m oz in sec 5 1 x 10 7 3 x 107 3 1 x 107 4 4 x 109 1 0 x 10 1 4 x 104 Operating Temp C F 10 to 70 14 to 158 10 to
36. neral ballscrew cylinders are rated for 100 duty cycle and ACME screws are rated for a maximum of 60 Your motor may also have duty cycle limitations Consult your Thomson Catalog or www linearactuators com for more information on duty cycles Exceeding the recommended duty cycle will damage the motor or internal cylinder components 16 f0 Table continued Maximum Speed per Cylinder Stroke Speed mm sec Screw Type 750 mm 1000 mm 1250 mm 1500 mm TC2 TC3 TC4 TC5 TC3 TC4 TC5 TC4 TC5 TC4 TCS 04A 48 61 33 05B 71 84 48 10B 212 185 254 96 119 156 63 99 53 72 16B 230 216 127 25B 462 298 171 131 32B 814 499 316 229 TC Electric Cylinder User s Manual Environmental Specifications The following environmental specifications must be observed for optimal cylinder performance Temperature Rating The operational temperature range for all TC cylinders is 308 to 708 C 228 to 1588 F When operating below 28 C 358 F a vent tube must be installed see below Preventing Exposure to Contaminants Liquids Standard TC cylinders are water resistant for environments with a slight mist on the cylinder body but not on the thrust tube If liquid or moisture contaminates internal components damage may occur Standard TC cylinders are IP54 rated The IP65 rated Protective Boot option PB is available to protect the thrust tube wipe
37. ng operated below the speed thrust curve Decrease the load Limited by critical speed oscillation of screw Check the critical speed limits Reduce the speed Incorrect screw pitch or drive ratio Enter the correct screw pitch or drive ratio the controller ing torque on motor C Positioning and Travel Length Cylinder backdriving without hold Backdriving force generated by load is greater than the static holding capacity of the cylinder Check the rated backdriving force for the cylinder Reduce backdriv ing force Excessive external vibration Mounting requires modification to isolate or reduce vibration torque on the motor Cylinder backdriving with holding Backdriving force generated by load is greater than the holding capacity of the screw nut of the cylinder and the holding torque of the motor Loss of motor holding torque servo and steppers Reduce backdriving force Recycle power to the motor and controller Not enough travel Position Sensors reducing actual travel Adjust sensors to increase cylin der travel without allowing cylinder to hit its internal hard stop bumper Excessive side loading Check side load rating for the cyl inder Reduce side load Customer mounting is physically limiting travel Re design mounting 34 TC Electric Cylinder User s Manual Category Symptom corresponding to number of motor
38. ory for evalua tion Brake wired incorrectly Check wiring and make correc tions or repairs 36 TC Electric Cylinder User s Manual Category Symptom Encoder reading improperly Possible Cause Encoder damaged Possible Remedy Send back to factory for evalua tion Encoder wired incorrectly Check wiring and make correc tions or repairs Incorrect supply voltage to encoder Check encoder voltage rating to the encoder Ensure correct voltage is supplied 37 TC Electric Cylinder User s Manual This page intentionally left blank 38 TC Electric Cylinder User s Manual 10 Parts List and Exploded Parts Diagrams Parts can be ordered through your local Thomson distributor Kits include all essential parts and instructions Item numbers below correspond with numbered items on the Exploded Parts Diagrams see following pages Reference on Reference on Exploded Parts Description of Part Exploded Parts Description of Part Diagram Diagram Nut Jam Rear 33 Screw Guide Cylinder Front 2 Washer 34 Motor 3 Key Pulley Gear or Coupling 35 Key Motor Pulley Gear or Coupling 4 Pulley Gear or Coupling 36 Drive Pulley or Gear Pinion 5 Washer Rear Bearing 37 Gasket Motor 6 Plate Motor Mounting 38 Washers Lock Motor Mounting 7 Gasket Bearing Housing 39 Scr
39. ory for evalua tion Extends when it should retract and visa versa Motor polarity reversed Reverse motor polarity at the con trol 33 TC Electric Cylinder User s Manual Category Symptom Vibrates during motion Possible Cause Motor Unstable servo gains stepper resonance Possible Remedy Reduce motor gain for servo motors Increase step resolution for step motors Cylinder being operated at critical speed Misalignment of internal components Check critical speed limit Reduce speed to less than critical speed Send back to factory for evalua tion No motor movement when commanded to move Motor not connected or is damaged Load too great for cylinder motor Reconnect the motor Replace the motor Check the load limit Reduce the load Problem with drive control Check output of drive controller Does not move or is erratic although motor is rotating Not running at rated speed Gear pinion pulley or coupling not secured to motor shaft Secure gear pinion pulley or cou pling to the motor shaft Belt is loose or damaged Adjust belt tension Replace belt Bad gear alignment Stripped teeth on gear Adjust gear pinion placement Send back to factory for evalua tion Threads are stripped on the drive nut ACME Load is too great for desired speed Send back to factory for evalua tion Ensure cylinder is bei
40. r Pinion 30 l D Ensure power to the motor is OFF and the load is removed from the thrust tube Remove rear cover plate s as necessary for inspection For cover plate removal refer to steps I and 2 in Lubricating Gears earlier in this section Reinstall cover plate s Aligning Motor Pinion on D and H Motors shown below L Loosen two 2 mounting alignment screws just enough to allow the motor to move Both screws are in slots which allow up down movement of the motor to align the motor pinion Move the motor pinion into the fully meshed or seated position against the intermediate gear i e pinion will not move any farther See 2 in photo below From the fully meshed position back off or move the pinion gear away from the intermediate gear 0 076 to 0 203 mm 003 to 008 in See 3 in photo below While maintaining proper position by hand tighten mounting alignment screws Install upper cover plate Aligning Motor Pinion on P22 P32 532 542 B23 B32 and B41 Motors 1 003 to 008 gap between pinion and intermediate gears Loosen four 4 mounting adjusting screws just enough to allow the motor to move All screws are in clearance holes which allow just enough up down movement to adjust the motor pinion Move the motor pinion into the fully meshed or seated position against the intermediate gear i e pinion will not move any farther See step 2 on the D H H4 Motor photo From the fully meshed posit
41. r evalua tion Thrust tube not fully engaged in the internal guide flange Rotate thrust tube clockwise until it stops turning The maximum torque exerted on the thrust tube in ft lbs is TC2 50 TC3 65 TC4 5 120 position Stuck in fully extended or retracted Drive nut physically jammed into end of travel Load too great for cylinder motor Remove rear cover s and rotate the leadscrew gear pulley or coupling until the leadscrew turns freely If jammed in extend rotate CW If jammed in retract rotate CCW Check cylinder load rating Reduce load Excessive side loading Pulley gear or coupling slipping Check side load rating Reduce side load Re install pulley gear or coupling onto the motor Erratic motor drive operation Contact motor drive vendor for more information 35 TC Electric Cylinder User s Manual Category Symptom Excessive axial endplay system backlash Possible Cause Leadscrew nut is worn Possible Remedy Send back to factory for evalua tion Gears worn Send back to factory for evalua tion Belt stretching Re tension belt E Cylinder Parts and Options Drive belt breaking or gears stripping Motor torque is too great Reduce Accel and Decel Reduce load Motor accel decel too great for given load Reduce Accel or Decel Load is too great for cylinder Check load rating of cylinder Red
42. r interface The standard TC cylinder provides a seal between the motor and cylinder body but does not protect the motor itself For applications where exposure is unavoidable with a corrosive liquid or a pressurized liquid an external protective enclosure is recommended Consult the factory for assistance Solid Particles Rod type cylinders are generally well protected against particle contaminants For environments with exposure to fine or abrasive particles the standard TC cylinder provides added resistance to entry by sealing mating surfaces with gaskets during assembly The Protective Boot PB option is recommended when the thrust tube sleeve bearing interface is exposed to abrasive particles or water spray Installing a Vent Tube Fitting included with all TC cylinders A Vent Tube is required when Any TC cylinder is equipped with the PB option 3 Connect tubing customer supplied to the vent Operating any TC cylinder below 28 C 35BF tube fitting See table for size of tubing required Operating anynon PB equipped TC cylinder inan 4 If the cylinder has the PB option and or is being environment of solid contaminants i e dust operated below 28 C 358 F connect the other paper or wood particles end of the tubing to a non contaminated air source of 0 psi Installation 1 Remove breather plug from all cylinders except If the cylinder does not have the PB option and TC4 and TCS with PB option is being oper
43. rew s Refer to the motor mounting procedure on page 28 Application Notes 1 WARNING The combination of pulley placement and operating torque may exceed motor shaft load capacity It is the user s responsibility to verify adequate shaft load capacity If a supplemental mounting plate or adapter is used it must be installed before measuring pulley pinion reverse pinion or coupling spacing All spacing dimensions for pulleys pinions reverse pinions or couplings have a tolerance of 0 13 mm 005 inches 25 TC Electric Cylinder User s Manual Spacing Requirements Pulley Spacing Pulley spacing A must be mea sured from the inner face of the pulley to the face of the mount ing plate see App Note 2 Pinion Spacing B B must be measured from the inner edge of the pinion to the face of the mounting plate see App Note 2 Reverse Pinion Spacing C C must be measured from the inner edge of the pinion to the face of the mounting plate see App Note 2 Coupling Spacing inline motors D gt Coupling spacing D must be measured from the inner face of the coupling to the face of the mounting plate see Application Note 26
44. rews according to the torque specifications for your specific hardware Cyl Length X mm in mm in vi eeng n 50 2 0 04 002 z ii 100 4 0 06 002 4 i 150 6 0 08 003 i 8 200 8 0 10 004 eene a poss 250 10 0 12 005 ii i i i TT load travel 300 12 0 14 006 X SS G 450 18 0 20 008 E 600 24 0 26 010 Mounting Surface 750 30 0 32 013 1000 40 0 42 017 1250 50 0 52 020 1500 60 0 62 024 TC Electric Cylinder User s Manual Installing Position Sensors for Overtravel Protection Although an elastomeric spring inside the cylinder is designed to prevent cylinder jams position sensors aka limit switches are required to prevent such potentially damaging jam conditions If the motor is accidentally commanded to move toward a hard stop position sensors can signal a stop before a collision occurs To work properly position sensors must be positioned inward from the hard stop and wired correctly to the motor controller Note Using the physical limits of the cylinder hard stops will reduce cylinder life and can cause premature component failure Position Sensor Specifications for Sensors Used on TC Electric Cylinders Sensor Series PSR 1 PSR 2 PSN 1 PSN 2 PSP 1 PSP 2 Sensor Type Mechanical Reed Hall Effect Output Type Contact Closure Sinking Open Collector NPN Sourcing PNP Connection Norm Open Norm Closed Norm Open Norm Closed Norm Open
45. ric cylinders Following are several features that make the TC the cylinder of choice for the most demanding applications Robust design for highest loads and longest life possible Precision rolled ballscrews for smoothness and accuracy Environmentally sealed All standard versions of TC cylinders are IP54 rated An IP65 rated Protective Boot PB option is available on all TC cylinders This optional thrust tube boot prevents moisture and dry contaminants from bypassing the thrust tube wiper seal Metric dimensions in accordance with IS06431 Meets the needs of customers who manufacture for the international marketplace Both English and Metric versions of threaded mounting options are standard ACME screws available on the TC2 and TC3 versions TC Series Specifications Specifications vary for the four basic TC configurations TC2 TC3 TC4 TCS Please refer to Section 3 TC Series Specification and Configuration Reference for specification parameters and configurations TC Electric Cylinder User s Manual TC Electric Cylinder Construction Typical This cross section of an TC4 cylinder with parallel motor mounting is provided to illustrate the typical components of an Thomson electric cylinder Refer to Section 10 Parts List and Exploded Parts Diagrams for a more detailed breakdown of TC cylinders 2 11 10 DDT TTT TT TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
46. t Pulley BS Brake on Screw Option 05B 5 mm Lead Ballscrew L Linear Potentiometer Option 50 50 inch stroke Identify Your TC Cylinder Using the Cylinder Configuration Guide This fill in the box section is provided for users who want to identify an existing TC cylinder or perhaps order a new TC cylinder To identify the mechanical characteristics of an existing TC cylinder photocopy this page and transcribe the model number from the factory label to boxes 2 through 8 To reconfigure or order a new TC fill in boxes 2 8 with codes for the new cylinder Refer to the Cylinder Configuration Guide on the following pages for boxes 2 8 See Thomson s latest catalog or website www linearactuators com for more information Base Model Number Stroke Cylinder Rod om Rod Type Motor Drive Screw Length Mounting End Cylinder Type Ratio Pitch Type Geer a TC Electric Cylinder User s Manual Cylinder Configuration Guide Motor Type D 24VDC 4 5 Amp Permanent Magnet Motor Insert one of the following H 160VDC 2 Amp Permanent Magnet Motor codes for X H4 160VDC 5 Amp Permanent Magnet Motor N 8 leads windings can be wired in Series or Parallel ESCH NEMA 23 Frame Step Motor 3Stask Pre wired in Series P32 x NEMA 34 Frame Step Motor 2 Stack V Pre wired in Parallel 32 x NEMA 34 Frame Step Motor 2 Stack B23 S42 x NEMA 42 Frame Step Motor 2 Stack NEMA 23 Frame Brushless Servo Motor
47. t gereegelt Eege 26 LUBRICATING THE EE 27 CHTCKING ADJUSTING DRIVE BELT TENSION ccccccccsesececsesecsesesecsesesecsesesassesesacsesaacsesasacsesacecsenees 28 LUBRICATING JE EE EN 29 ALIGNING MOTOR PINION EE 30 8 MOUNTING A CUSTOMER SUPPLIED MOTOR nnnnnnnunnnnnnnnnnnnnnennnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenenevenenr 31 9 TROUBLESHOOTING TE 33 10 PARTS LIST AND EXPLODED PARTS DIAGRAMS rnnnnnnnnnnnnnnvnnonnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 39 EXPLODED PARTS DIAGRAM TC2 TC3 PARALLEL MOTOR MOUNTING cccsscecsscscsessescseeeeeeees 40 43 EXPLODED PARTS DIAGRAM TC2 TC3 INLINE MOTOR MOUNTING rrnrererrrvrenrrvevenrsnrvenrsnrvenennen 44 47 EXPLODED PARTS DIAGRAM TC4 TC5 PARALLEL MOTOR MOUNTING cccsscsssscseseecseseeeceeees 48 51 EXPLODED PARTS DIAGRAM TC4 TC5 INLINE MOTOR MOUNTING rrnrererrrverenrrvrverrrnrvenernrvenennen 52 55 11 WARRANTY AND SERVICE COVERAGE nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonenennnnnnnnnnnnnnnnnnnnnnnnnnnnunnnenevevenner 57 INDEX PE EN EE NN ee 59 TC Electric Cylinder User s Manual 1 Product Overview Thomson s TC Series Electric Cylinders are designed for use in a wide variety of industrial scientific and commercial applications requiring precise control of linear thrust speed or position This manual will help you install operate and maintain your TC Series Cylinder TC Series Features From the TC2 to the TC5 the TC series is Thomson s highest performance line of elect
48. the L Linear Potentiometer Option This procedure must be done at the factory Recommended Lubricants Type of Leadscrew Type of Lubricant Ballscrews with 05B 10B 16B 25B and 32B Screws NLGI Grade 2 Synthetic Base Lithium Grease ACME Screws with Bronze ACME Nut 04A Screws NLGI Grade 2 Synthetic Base Grease with PTFE Additive Lubricating TC2 TC3 Ballscrews 1 Remove upper rear cover plate from the gear housing 5 Move the drive nut attached to thrust tube to the far end TC2 only by removing two 2 SHCS of the leadscrew 2 Remove main rear cover plate by removing four 4 6 Remove as much of the old grease from the leadscrew as SHCS possible 7 With most of the leadscrew exposed apply no more than 0 8 mm 03 of the recommended lubricant over the length of the screw Run the drivenut over the screw length to spread the grease evenly Wipe off any excess grease expelled from the leadscrew by the drivenut 3 Loosen two 2 SHCS inside gear housing that secure the upper part of the guide housing These screws must be loosened in consecutive increments i e 2 turns on one screw then 2 turns on the other repeating until each is loose Note these are captive screws and cannot be removed as shown in the illustration below 8 Reassemble Unit 4 Remove guide housing by sliding it away from the thrust Note After lubricating the leadscrew check belt tension tube on belt driven cylinders next page
49. tions 22 load alignment 11 lubrication ACME screws 27 ballscrews 27 gears 29 motor pinion alignment 30 motor types how to specify 4 mounting requirements 9 mounting styles how to specify 5 P part numbering scheme 3 parts list 39 pinion installation 25 position sensors mounting 13 specifications 12 pulley installation 25 R reverse pinion installation 25 rod end attachment maximum torque 10 rod ends how to specify 5 routine maintenance hardware torque 24 lubricants and adhesives 24 perfoming inspections 23 procedures 23 S screw types how to specify 4 specifications TC2 TC3 6 TC4 TCS 7 stroke length how to specify 4 T troubleshooting the cylinder cylinder noise 33 motion problems 33 parts and options 36 position and travel length 34 thrust tube 35 59 TC Electric Cylinder User s Manual This page intentionally left blank 60 Thomson Industries 13500 J South Point Blvd Charlotte NC 28273 TEL 800 544 8466 FAX 704 588 5695 OUTSIDE THE U S CALL 704 588 5693 E mail sales2 danahermotion com Web Site www linearactuators com ZS THOMSON
50. troller Hall Effect 5 input 5 Sensor 9 Black S lt PSP sensor is not compatible with Thomson con D Blue COM A a gt On Shield Sensor Hall Effect 13 TC Electric Cylinder User s Manual This page intentionally left blank TC Electric Cylinder User s Manual 5 Application Considerations Certain conditions can limit cylinder performance and should be addressed prior to installation and operation Adherence to the following application guidelines will ensure a successful application Column Load Limit Exceeding the Column Load Limit will cause the leadscrew to buckle and become permanently damaged The Load Limit Table below contains Column Load Limits per stroke length and screw type Thrust Load EE OJ Compression column Load Load Limit Table for Standard Stroke Lengths TC Cylinder i Column Load Limit N per TC Series Stroke Length with Applicable Thomson Screw Type in Parentheses TC2 TC3 TC4 TC5 50 600 mm 750 mm 2500 04A 4900 16B 1000 mm 2780 16B 4650 04A 5340 10B 6530 05B 1250 mm 10300 10B 1500 mm 7400 10B 8600 25B Shaded areas indicate NO Column Loading Restriction for example Column Load Limits do not apply to any length of TC5 cylinder or to 32B Screws Column Load Limits for Custom Stroke Lengths Ifyou require a Column Load Limit for a custom stroke length between 750 and 1500 mm
51. uce load Excessive shock loading running into physical hardstop rapid change in direction Reduce Accel Decel of cylinder Stop motion just before the hard stop Position Sensors not being acti vated by internal magnet Linear Potentiometer LP not reading properly Misalignment of internal components Send back to factory for evalua tion Weak or missing internal magnet Send back to factory for evalua tion Switch sensor is damaged or miswired Check correct switch wiring Send back to factory for evalua tion Cylinder speed too fast LPO wiper lifting off track misalign ment or LP bending due to excessive load Reduce cylinder speed Ensure cylinder travel is in line with travel of the load Reduce load Damaged contaminated LP by liquid particle Send back to factory for evalua tion Motor overheating Duty cycle too high Check duty cycle rating Reduce duty cycle High ambient temperature Use an external fan to cool the motor Incorrect current setting on drive Check the control drive user s manual for correct current set tings Reset the control drive with correct current setting Brake not holding load Brake not coupled to motor or lead screw properly Send back to factory for evalua tion Load exceeds holding capacity of cyl inder brake Check brake load rating Reduce the load Brake damaged Send back to fact
52. wer supply The potentiometer wiper moves in conjunction with the cylinder thrust tube providing an analog voltage feedback signal which is proportional to the linear displacement Example Using a 5 volt supply OVDC 0 Stroke 2 5 VDC 50 Stroke and 5 VDC 100 Stroke Application Notes 1 This option is not recommended for high vibration environments 2 This option is required when the TC is used with Thomson D2500 H3500 H4500 and B8500 series controls Specifications Stroke mm Resistance ohms Max Non Linearity 3000 20 1 6000 20 1 9000 20 1 9000 30 1 9000 30 1 7000 30 1 5 to 95 of function 7000 30 1 5 to 95 of function 7000 30 1 5 to 95 of function 1 18 30 0 0 50 7 12 7 BE Dimensions i A Linear Pot top mounted eA on TC cylinder L oroe Cable JR 0 17 4 3 RO 51 13 0 Minimum Bend Radius TC DIM A DIM B Cylinder Model mm in mm in TC2 37 3 1 47 28 5 1 12 TC3 43 7 1 72 34 8 1 37 TC4 54 5 2 15 46 1 1 82 TC5 54 5 2 15 46 1 1 82 Electrical SIRE Brown Connections T Wiper Feedback Black f i GJE GND Blue Shield 22 TC Electric Cylinder User s Manual 7 Factory Service and Routine Field Maintenanc

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