Thomson Electrak® GX Electric Linear Actuator Installation Manual

1. General Information

This manual guides the mechanical and electrical installation of the Thomson Electrak® GX electric linear actuator. It includes technical data, installation data, and type designation numbers. Ensure the installer is qualified and has read this manual before installation.

1.1 Manual Information

This manual covers:

• Technical data
• Installation data
• Type designation number

1.2 Target Audience

This manual is intended for qualified mechanical and electrical personnel.

1.3 Symbols Used

The following symbol is used to highlight general warnings, general instructions, or warnings about mechanical hazards: !

1.4 Transport and Storage

Transport and store the actuator in its original packaging. The temperature range for transport and storage is -25°C to +65°C (-15°F to +150°F). Avoid impacts to the packaging. If the packaging is damaged, visually inspect the actuator for damage and contact the carrier and Thomson.

1.5 Packaging

Packaging consists of a cardboard box containing the actuator and this manual. Bulk packaging may be provided for large orders, with terms and contents subject to agreement.

1.6 Disposal

Upon request, and where legally required, packaging materials and actuators will be collected by Thomson for professional disposal at the shipper's expense. Contact Thomson for shipping information.

1.7 Support

For technical support or information during product use, contact the nearest Thomson service center. More information and contact details are available at www.thomsonlinear.com.

2. Safety

2.1 Safety Precautions

• Only qualified personnel with appropriate qualifications should perform mechanical and electrical installation. Qualified personnel are those familiar with mechanical and electrical installation work and suitable for the task.
• Read this manual and other documentation carefully before operating equipment that includes this actuator.
• Strictly adhere to the information in this manual and on the product label attached to the actuator. Do not exceed the performance limits specified in this manual.
• Do not operate or install the actuator while it is energized.
• Do not disconnect cables or connectors while the actuator is operating or energized.
• If the actuator appears to be faulty or damaged in any way, cease use immediately and notify the appropriate personnel for corrective action.
• Do not open the actuator, as this will damage the seal and function. There are no user-serviceable parts inside.
• Grease may be present on the extension tube. Grease is not hazardous if it comes into contact with skin. Do not remove the film.

3. Standards

3.1 EC Declaration of Conformity for Partially Completed Machinery

Thomson Linear declares that this product corresponds with Directive 2006/42/EC, RoHSIII Directive 2015/863, WEEE Directive 2012/19/EU, Low Voltage Directive 2014/35/UE, and the Directive of Electromagnetic Compatibility 2014/30/UE. Standard EN ISO 12100:2010, Safety of machinery, has been applied.

Product: Thomson Electrak® GX

Description: Linear Actuator

This product can be used in machines or systems that comply with the EEC Machinery Directive and other relevant regulations.

Date: 2021-11-08

Location: Kristianstad

Signatories: Håkan Persson (Business Unit Manager)

4. Installation

4.1 Product Identification and Product Label

4.1.1 Devices Without Product Label

Devices without a CE mark have the manufacturing date and actuator designation engraved on the housing. Refer to this manual for actuator performance data. Check the performance data before installation or maintenance. Contact Thomson with the manufacturing date and actuator designation for support.

4.1.2 Devices With Product Label

These devices have a product label on the cover tube, showing the actuator model, basic performance data, CE mark status, and country of origin. Verify the actuator type and performance data before installation or maintenance. Contact Thomson with the manufacturing date and actuator designation for support.

Product Label Information:

CE Mark

Instructions: FOLLOW INSTRUCTIONS IN MANUAL. DO NOT TUBE MOUNT. DO NOT DISASSEMBLE. NO SERVICEABLE PARTS INSIDE. INSTALL FUSE BETWEEN POWER SUPPLY AND MOTOR.

Website: WWW.THOMSONLINEAR.COM

4.2 Terminology

• a. Front adapter
• b. Extension tube
• c. Cover tube
• d. Housing (standard)
• e. Rear adapter
• f. Housing (with potentiometer option)
• g. Connector
• h. Electrical wiring
• i. Electrical wiring
• j. Manual operation input
• k. Cable (with potentiometer option)

4.3 Operating Environment

• Operating Temperature: -25°C to +65°C (-15°F to +150°F)
• Ingress Protection: Vdc units: IP66 or IP66/IP69K (refer to product label). Vac units: IP45.
• Relative Humidity: 10-90% non-condensing.

4.4 Mechanical Installation

4.4.1 General Installation Precautions

• Do not install the actuator while the power is on!
• Do not grasp the extension tube while power is supplied to the unit.
• The actuator's failure mode is designed to prevent damage.

4.4.2 Basic Installation Considerations

1. Mount the actuator exclusively using the holes in the front and rear adapters. Confirm the actuator model and refer to the Ordering Key (Section 6) to configure the adapter type. Refer to the diagrams and tables for precise dimensions.
2. Mount the actuator such that connectors or cables are accessible for connection or disconnection.
3. If the actuator has a manual override option, ensure sufficient clearance for operating the manual override input (Section 4.4.6).

Dimensions: (Diagram showing mounting dimensions with various measurements in mm and inches)

• E: Ø 12.8 ±0.1 [0.50 ±0.004]
• K: Ø 10.2 ±0.1 [0.40 ±0.004]
• M: Ø 12.2 ±0.1 [0.48 ±0.004]
• F: Ø 12.8 ±0.1 [0.50 ±0.004] SW *8.2 [0.323]
• N: Ø 12.2 ±0.1 [0.48 ±0.004] SW* 8.2 [0.323]
• SW: Slot width
• Flat: Flat dimension
• G: 1/2-20 UNF 2B
• P: M12

4.4.3 Mounting Position and Forces

• The actuator can be mounted in any orientation and can handle push and pull loads.
• Always install the actuator so that the force of the load acts on the center of the extension tube and the rear adapter.
• Mount the actuator only in the mounting holes of the rear and front adapters.
• Use rigid mounting pins and support both ends securely.
• Mounting pins must be parallel in both radial and axial directions.

Diagrams: (Illustrations showing correct 'YES' and incorrect 'NO' mounting orientations)

4.4.4 Torque Limit

The front and rear adapters must be secured to withstand a torque of 11.3 Nm (100 lbf-in) for the Electrak GX. If both ends are not secured, the extension tube (or actuator) will rotate instead of moving.

Torque Specification: 11.3 Nm (100 lbf-in)

4.4.5 Slip Clutch

The actuator is protected by a mechanical load-limiting clutch that prevents the motor from stopping at the end of the actuator's stroke. This clutch slips at a point in the stroke if the load limit (1.2 to 1.5 x dynamic load rating) is exceeded. If the clutch operates, immediately stop the motor and, if it operates mid-stroke, determine the cause.

4.4.6 Manual Operation Mounting and Operation Considerations (Optional)

1. When mounting the actuator, ensure there is sufficient space between the rear adapter and the object behind it to perform manual operation.
2. To perform manual operation, remove the cover plug located above the manual operation input.
3. Use a 6 mm hex key to turn the hex socket on the manual operation input to move the extension tube.
4. The maximum torque required to move the extension tube using manual operation at the actuator's maximum rated load is typically 1.5 to 2.5 Nm (13 to 22 in-lb), depending on the model.

Diagram: (Shows manual override hex socket and dimensions)

• Always turn off the actuator power before performing manual operation.
• Do not apply more than 5 Nm (44 in-lbs) of torque to the manual operation input.
• If the slip clutch operates (see Section 4.4.5), immediately stop the operation of the extension tube.
• Do not use drills or power tools for manual operation.

4.5 Electrical Installation

4.5.1 General

• Connect the motor using lead wires and cables capable of handling the motor's maximum current.
• Emergency stops are recommended to reduce the risk of pinching accidents.
• Do not attempt to service or wire the actuator while it is energized.

4.5.2 Fuse

Protect the actuator and wiring with a slow-blow fuse between the actuator and the power supply. The fuse size depends on the actuator's current consumption and local installation regulations and must be determined on a case-by-case basis.

4.5.3 Power Lead Wire Cross-Section

To prevent malfunction due to voltage drop, the cross-section of the power lead wire between the actuator and the power supply must be sufficient. Sufficient size is determined by supply voltage, current consumption, cable length, ambient temperature, and local regulations. The table below provides Thomson's recommended minimum specifications for various lead wire lengths. However, the installer is always responsible for ensuring compliance with local regulations.

Recommended Power Lead Wire Cross-Section:

* Ambient temperature below 30°C (86°F)

4.6.3 DC Input Voltage Actuator Installation

Connect the red lead wire to +Vdc and the black (or yellow) lead wire to -Vdc to extend the actuator. Reverse polarity to retract the actuator.

The internal slip clutch will engage at the mechanical stroke end in either direction, stopping the extension tube from moving further. This clutch may also engage mid-stroke under overload conditions (see Section 4.4.5). If the clutch engages, disconnect power to the motor as soon as possible, regardless of the reason.

Electrical Specifications (DC):

* If the device lacks a product label, check the designation engraved on the actuator housing and refer to Section 6 (Ordering Code) and Section 5 (Technical Specifications) for values.

Components:

• F: Fuse
• S1: DPDT (Double Pole Double Throw) switch
• M: Actuator motor

Wiring Diagram: (Shows DC actuator wiring with S1 switch, fuse F, and motor M)

4.6.4 Single-Phase AC Input Voltage Actuator Installation

Lead wires may be color-coded or numbered. Connect the white lead wire (1) to L1 and the red lead wire (2) between the black (or yellow) lead wire and the capacitor. A 35 µF capacitor is required for 115 Vac actuators, and a 10 µF capacitor for 230 Vac actuators.

Connecting the black lead wire (1) to L1 and the white lead wire (3) to N (neutral) will retract the actuator. Connecting L1 to the black lead wire (1) and then to the red lead wire (2) will extend the actuator.

The anti-coast brake must be disengaged during operation, which can be achieved by connecting the orange lead wire (4) to L1.

The internal slip clutch will engage at the mechanical stroke end in either direction, stopping the extension tube from moving further. This clutch may also engage mid-stroke under overload conditions (see Section 4.4.5). If the clutch engages, disconnect power to the motor as soon as possible, regardless of the reason.

Electrical Specifications (AC):

* If the device lacks a product label, check the designation engraved on the actuator housing and refer to Section 6 (Ordering Code) and Section 5 (Technical Specifications) for values.

Components:

• F: Fuse
• S1: DPDT (Double Pole Double Throw) switch
• M: Actuator motor
• Capacitor: Connect between black (1) and red (2) leads.
• Anti-coast brake: Connect orange (4) to L1.

Wiring Diagram: (Shows AC actuator wiring with S1 switch, fuse F, motor M, capacitor, and anti-coast brake connection)

4.6.5 Three-Phase AC Input Voltage Actuator Installation

Lead wires may be color-coded or numbered. Connect the white lead wire (1) to L1, the red lead wire (2) to L2, and the black lead wire (3) to L3 to extend the actuator. Swap the positions of the white lead wire (2) and the black lead wire (3) to retract the actuator. The anti-coast brake must be disengaged during operation, which can be achieved by connecting the orange lead wire (4) to the neutral (N).

The internal clutch will engage at the mechanical stroke end in either direction, stopping the extension tube from moving further. This clutch may also engage mid-stroke under overload conditions (see Section 4.4.5). If the clutch engages, disconnect power to the motor as soon as possible, regardless of the reason.

Electrical Specifications (3-Phase AC):

* If the device lacks a product label, check the designation engraved on the actuator housing and refer to Section 6 (Ordering Code) and Section 5 (Technical Specifications) for values.

Components:

• F: Fuse
• K1: Relay / Contactor Extension
• K2: Relay / Contactor Retraction
• M: Actuator motor
• Wiring Diagram: (Shows 3-phase AC actuator wiring with fuse F, K1, K2, M, and PE connection)

4.6.6 Feedback Potentiometer Installation (Optional)

When the actuator is fully extended, the potentiometer output between the gray lead and the yellow lead is 0 Ohm.

Potentiometer Specifications:

Wiring: Gray lead, Yellow lead, Green lead

5. Technical Specifications

5.1 General Specifications

5.2 DC Input Voltage Unit Weight

Weight:

5.3 AC Input Voltage Unit Weight

Weight:

5.5 DC Input Voltage Unit Technical Data

5.6 AC Input Voltage Unit Technical Data

* Actuator requires a 35 µF capacitor (p/n 9200-448-002) for operation.

** Actuator requires a 10 µF capacitor (p/n 9200-448-003) for operation.

Operating Temperature Limit: -25-65°C (-15–150°F)

Max Duty Cycle at 25°C (77°F): 25 [%]

End Play, Max: 1.0 (0.04) [mm (in)]

Torque Limit: 11.3 (100) [Nm lbf-in)]

Ingress Protection Rating: IP45

6. Ordering Keys

6.1 DC Voltage Model Ordering Key

Ordering Key Structure:

Key Descriptions:

1. Model, Input Voltage, and CE Compliance:
• D12C = Electrak GX, 12 Vdc, CE compliant
• D24C = Electrak GX, 24 Vdc, CE compliant
• D36C = Electrak GX, 36 Vdc, CE compliant
• D48C = Electrak GX, 48 Vdc, CE compliant
• D12N = Electrak GX, 12 Vdc, not CE compliant
• D24N = Electrak GX, 24 Vdc, not CE compliant
• D36N = Electrak GX, 36 Vdc, not CE compliant
• D48N = Electrak GX, 48 Vdc, not CE compliant
• D90N = Electrak GX, 90 Vdc, not CE compliant
2. Dynamic Load Capacity, Screw Type, and Maximum Speed:
• 05A5 = 1100 N, acme, 54 mm/s
• 10A5 = 2250 N, acme, 30 mm/s
• 20A5 = 2250 N, acme, 15 mm/s
• 05B5 = 2250 N, ball, 61 mm/s
• 10B5 = 4500 N, ball, 30 mm/s
• 20B5 = 4500 N, ball, 15 mm/s
• 21B5 = 6800 N, ball, 15 mm/s
• 2KB5 = 9000 N, ball, 9 mm/s
3. Ordering Stroke Length:
• 02 = 2 inch (50.8 mm)
• 04 = 4 inch (101.6 mm)
• 06 = 6 inch (152.4 mm)
• 08 = 8 inch (203.2 mm)
• 10 = 10 inch (254.0 mm)
• 12 = 12 inch (304.8 mm)
• 14 = 14 inch (355.6 mm)
• 16 = 16 inch (406.4 mm)
• 18 = 18 inch (457.2 mm)
• 20 = 20 inch (508.0 mm)
• 22 = 22 inch (558.8 mm)
• 24 = 24 inch (609.6 mm)
4. Rear Adapter Hole Orientation:
• M0 = adapter at 0° (standard)
• M3 = adapter at 90°
5. Ingress Protection Rating:
• N = IP66
• K = IP66 and IP69K
6. Options:
• N = no option
• P = potentiometer feedback
• H = manual override
7. Connector Option:
• -A = AMP terminal 42098-2, house 180908-5
• -B = Packard Electric 56 Series
• -D = no connector (flying leads)
8. Front Adapter Option:
• E = cross hole for 0.5 inch pin
• F = forked cross hole for 0.5 inch pin
• G = 1/2-20 UNF 2B female thread
• K = cross hole for 10 mm pin
• M = cross hole for 12 mm pin
• N = forked cross hole for 12 mm pin
• P = M12 female thread
9. Rear Adapter Option:
• E = cross hole for 0.5 inch pin
• K = cross hole for 10 mm pin
• M = cross hole for 12 mm pin

Dimensions for Manual Override Option: (Diagram showing dimensions)

Notes:

• (1) 21B5 not available for strokes 20 inches and longer.
• (2) 2KB5 not available for strokes 12 inches and longer.
• (3) Manual override option not available.

6.2 AC Voltage Model Ordering Key

Ordering Key Structure:

Key Descriptions:

1. Model, Input Voltage, Dynamic Load Capacity, Screw Type, Maximum Speed:
• A12C05A5- = Electrak GX, 1 × 115 Vac, 1100 N, acme, 54 mm/s
• A12C10A5- = Electrak GX, 1 × 115 Vac, 2250 N, acme, 30 mm/s
• A12C20A5- = Electrak GX, 1 × 115 Vac, 2250 N, acme, 15 mm/s
• A12C05B5- = Electrak GX, 1 × 115 Vac, 2250 N, ball, 61 mm/s
• A12C10B5- = Electrak GX, 1 × 115 Vac, 4500 N, ball, 30 mm/s
• A12C20B5- = Electrak GX, 1 × 115 Vac, 4500 N, ball, 15 mm/s
• A12C21B5- = Electrak GX, 1 × 115 Vac, 6800 N, ball, 15 mm/s
• A12C2KB5- = Electrak GX, 1 × 115 Vac, 9000 N, ball, 10 mm/s
• A22C05A5- = Electrak GX, 1 × 230 Vac, 1100 N, acme, 54 mm/s
• A22C10A5- = Electrak GX, 1 × 230 Vac, 2250 N, acme, 30 mm/s
• A22C20A5- = Electrak GX, 1 × 230 Vac, 2250 N, acme, 15 mm/s
• A22C05B5- = Electrak GX, 1 × 230 Vac, 2250 N, ball, 61 mm/s
• A22C10B5- = Electrak GX, 1 × 230 Vac, 4500 N, ball, 30 mm/s
• A22C20B5- = Electrak GX, 1 × 230 Vac, 4500 N, ball, 15 mm/s
• A22C21B5- = Electrak GX, 1 × 230 Vac, 6800 N, ball, 15 mm/s
• A22C2KB5- = Electrak GX, 1 × 230 Vac, 9000 N, ball, 10 mm/s
• A42C10A5- = Electrak GX, 3 × 400 Vac, 1100 N, acme, 30 mm/s
• A42C20A5- = Electrak GX, 3 × 400 Vac, 1100 N, acme, 15 mm/s
• A42C05B5- = Electrak GX, 3 × 400 Vac, 1100 N, ball, 61 mm/s
• A42C10B5- = Electrak GX, 3 × 400 Vac, 2250 N, ball, 30 mm/s
• A42C20B5- = Electrak GX, 3 × 400 Vac, 2250 N, ball, 15 mm/s
2. Ordering Stroke Length:
• 06 = 6 inch (152.4 mm)
• 08 = 8 inch (203.2 mm)
• 10 = 10 inch (254.0 mm)
• 12 = 12 inch (304.8 mm)
• 14 = 14 inch (355.6 mm)
• 16 = 16 inch (406.4 mm)
• 18 = 18 inch (457.2 mm)
• 20 = 20 inch (508.0 mm)
• 22 = 22 inch (558.8 mm)
• 24 = 24 inch (609.6 mm)
3. Rear Adapter Hole Orientation:
• M0 = adapter at 0° (standard)
• M3 = adapter at 90°
4. Ingress Protection Rating:
• B = IP45
5. Options:
• N = no option
• P = potentiometer feedback
• H = manual override
6. Connector Option:
• -D = no connector (flying leads)
7. Front Adapter Option:
• E = cross hole for 0.5 inch pin
• F = forked cross hole for 0.5 inch pin
• G = 1/2-20 UNF 2B female thread
• K = cross hole for 10 mm pin
• M = cross hole for 12 mm pin
• N = forked cross hole for 12 mm pin
• P = M12 female thread
8. Rear Adapter Option:
• E = cross hole for 0.5 inch pin
• K = cross hole for 10 mm pin
• M = cross hole for 12 mm pin

Dimensions for Manual Override Option: (Diagram showing dimensions)

Notes:

• (1) 21B5 not available for strokes 20 inches and longer.
• (2) 2KB5 not available for strokes 12 inches and longer.
• (3) Manual override option not available.

Contact Information

USA, CANADA and MEXICO

Thomson
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Radford, VA 24141, USA
Phone: 1-540-633-3549
Fax: 1-540-633-0294
E-mail: thomson@regalrexnord.com
Literature: literature.thomsonlinear.com

EUROPE

United Kingdom
Thomson
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Caddsdown Business Park
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Phone: +44 1271 334 500
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ASIA

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India
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India Private Limited
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Baner Road, Pune, 411045
Maharashtra
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SOUTH AMERICA

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Phone: +55 11 4615 6300
E-mail:thomson.brasil@regalrexnord.com

Website: www.thomsonlinear.com

Disclaimer: Specifications are subject to change without notice. It is the responsibility of the product user to determine the suitability of this product for a particular application. All trademarks are the property of their respective owners. ©2025 Thomson Industries, Inc.

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