Thomson PC-Series™ Precision Linear Actuator

Version History

Warranty

The Thomson PC-Series™ is warranted to be free from defects in materials and workmanship for a period of twelve (12) months from date of delivery. The application of this product is the responsibility of the buyer and Thomson makes no representation or warranty as to the suitability of the product for any particular use or purpose. For a copy of the entire warranty for this product that is contained in our standard terms and conditions of sale, please go to www.thomsonlinear.com/website/com/eng/support/terms_and_conditions.php.

Disclaimer

Technical changes to improve the performance of the equipment may be made without prior notice!

All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method) or processed, copied or distributed by electronic means without the written permission of Thomson.

1. General

1.1 About this manual

This manual describes how to install the Thomson PC-Series precision linear actuator mechanically and electrically. It also contains, among other things:

• Technical data
• Dimensional drawings
• Type designation key

It is important to carefully read this manual before installing the actuator and to have the correct qualifications needed to perform the installation.

1.2 Target group

This manual addresses qualified mechanical and electrical personnel.

1.3 Symbols used

⚠️ This symbol is shown to highlight a general warning, general instruction or as a warning for a mechanical hazard.

1.4 Transport and storage

The actuator may only be transported and stored in the original packaging supplied by Thomson. The temperature during transportation and storage must be between -40 to +85 °C (-40 to +185 °F). Avoid shocks to the package. If the package is damaged, check the actuator for visible damage and notify the carrier, and if appropriate also Thomson.

1.5 Disposal

Where required by law, used packaging and actuators are taken back by Thomson for professional disposal if the transportation cost is taken over by the sender. Please contact Thomson for information on where to ship it.

1.6 Support

In case you need technical support or any information related to this product, please contact the nearest Thomson Service Center. See the back of this manual. You can also visit www.thomsonlinear.com for information on this product and how to get in touch with us.

2. Safety

2.1 Safety notes

• Only properly qualified personnel are permitted to perform mechanical and electrical installation, service or maintenance on this product. Properly qualified personnel are familiar with mechanical or electrical installation work and have the appropriate qualifications for their jobs.
• Read this manual and any other available documentation before working on the equipment that the actuator is or shall be a part of.
• Keep strictly to the data in this manual and on the name plate on the actuator and never exceed the performance limits stated herein.
• Never work on the actuator or its installation with the power on.
• Never unplug any cables or connectors during operation or with power on.
• Immediately stop using the actuator if it seems faulty or broken in any way and notify an appropriate person so that corrective actions can be taken.
• Never try to open the actuator as that will compromise the sealing and the function of the actuator. There are no serviceable components inside.
• Grease may be present on the extension tube. Contact is non-hazardous. Film should not be removed.

3. Standards

3.1 EC Declaration of conformity

We, Tollo Linear AB, declare that this product corresponds with the directive 2006/42/EC annex 2.1.B, RoHS II directive 2011/65/EU, WEEE directive 2002/96/EC, low voltage directive 2006/95/EC (EN60204-1:2006+A1:2009) and also with the directive of electromagnetic compatibility 2004/108/EC (EN55014-1:2006+A1:2009, EN61000-6-3:2007, EN61000-3-2:2006+A2:2009, 61000-3-3:2008) and that the standard EN ISO 12100:2010, Safety of machinery, have been applied.

Product: Thomson Precision Linear Actuator

Description: PC

Can be used when the machine or the system, which it shall be a part of, is in accordance with the demands in the EEC Machinery Directive and/or other relevant regulations.

Kristianstad, 2014-04-14

Name: Anders Trygg, Title: Business Unit Manager

4. Installation

4.1 Name plate

The name plate can be found on the actuator cover tube. It will tell you which model of actuator you have and its basic performance data. Please study the name plate to see what type of actuator you have before starting any installation or service on the actuator. If you need any assistance from Thomson, please tell us the manufacturing date and the designation of the actuator(s) in question.

Example Name Plate:

T THOMSON™

Tollo Linear AB Sweden

DESIGNATION: PC32LX367B04-0100XM1

MAN DATE: 2014-03-14

PROT: IP65

PC32

MOVE/SHAFT/REV: 4MM

STROKE: 100mm

SERIAL No.: 14.5654

FOLLOW INSTRUCTIONS IN MANUAL. DO NOT DISASSEMBLE

ALWAYS USE END OF STROKE LIMIT SWITCHES. DO NOT RUN INTO ENDSTOP.

4.2 Terminology

The following diagrams illustrate the different styles of PC-Series actuators and their components:

A. Inline style PC-Series actuator without RediMount system

B. Inline style PC-Series actuator with RediMount system

C. Parallel style PC-Series actuator with belt gear and RediMount system

Components:

• 1. Input shaft
• 2. Motor flange plate
• 3. Grease port
• 4. Front plate
• 5. Front adaptor
• 6. RediMount system
• 7. Cover tube
• 8. Extension tube
• 9. Access plug for coupling clamping element
• 10. Belt gear with RediMount system

4.3 Operation environment

Temperature: Minimum -20°C, Maximum +70°C.

Protection: IP65 (Protection degree against the ingress of water and particles).

Operation temperature range is between -20 to +70° Celsius.

4.4 General mounting guidelines

The unit can be mounted in any direction, but do not mount the actuator such that the cover tube is subjected to any bending or twisting forces.

Ensure the actuator is mounted so that the maximum permissible load and load torques for the input shaft or the extension tube are never exceeded during standstill or operation. Refer to Table T6.1.1 for load and load torque data for each model.

Diagram illustrating forces: Frd (Drive shaft force), Fx, Fy, Fz (Linear forces), Mta (Drive shaft torque), Mz, My (Torques).

Make sure to install the actuator so that the extension tube never runs into the mechanical end stops. The distance between the mechanical end stops (Send) is the ordering stroke (Smax) plus 2.5 (± 0.5) mm of extra travel in both ends (Safe).

Diagram illustrating stroke: Shows 'Safe' zone, 'Send' (ordering stroke), 'Smax' (maximum stroke), and another 'Safe' zone.

• ⚠️ Warning! Do not hold the extension tube while the unit is energized.
• ⚠️ Warning! The extension tube is not self-holding. In a vertical application, a brake is required to hold the load at standstill. If it is removed, the extension tube may start moving, with the possible risk of injury to people or damage to the equipment.
• ⚠️ Warning! Never run into the mechanical ends of the unit.

4.5 Mounting of the unit using the mounting holes

All PC-Series actuators have mounting holes in the front plate. Parallel style actuators also have mounting holes in the rear plate on the belt gear. These holes can be used to attach the unit to the support or to mounting accessories (see point 4.7). Follow general mounting guidelines (see point 4.4) when using the mounting holes.

4.5.1 Mounting of the unit using the front plate mounting holes

The following diagrams and table show the hole pattern, size, and thread depth of the front mounting holes. Note that mounting holes on PC32 and PC40 have a 14 mm long unthreaded part before the thread starts.

Diagrams showing hole patterns for PC25, PC32, and PC40.

4.5.2 Mounting of the unit using the rear plate mounting holes on parallel style units

The following diagrams and table show the hole pattern, size, and thread depth of the rear mounting holes for parallel style units.

Diagrams showing hole patterns for PC25, PC32, and PC40.

4.6 Mounting of the unit using the extension tube rod end

The extension tube rod end is factory-equipped with either a male or a female threaded rod end. A spherical joint (see point 4.7.1) or a clevis (see point 4.7.2) can also be mounted to the male threaded rod end. The designation on the name plate and the ordering key (table T6.2.1) will help determine the rod end accessory. If a spherical joint or clevis is delivered separately, identify it by the part number on the packaging and follow the appropriate mounting instructions (see point 4.7.1 or 4.7.2).

1. Male threaded rod end

Diagram showing male threaded rod end with dimensions A and B.

2. Female threaded rod end

Diagram showing female threaded rod end with dimensions A and B.

The extension tube can handle some side load. To improve overall performance and life, it is good practice to follow these points:

• Make sure the extension tube travels in a straight line relative to the cover tube.
• Try to align the center of the load with the extension tube travel center.
• Avoid side loads altogether if possible.

4.7 Mounting of the unit using the mounting accessories

The unit can be shipped with mounting accessories pre-installed. The name plate designation and ordering key (table T6.2.1) will help identify the accessory. Some accessories can also be ordered separately. If in doubt, contact customer support.

4.7.1 Spherical joint

To mount a spherical joint, the extension tube must have a male threaded rod end. Screw the joint onto the rod end and secure it with the jam nut. Use a solid pin to connect the joint to the load. Any play between the pin and the joint may affect accuracy.

Diagram showing a spherical joint mounted on a male rod end.

* Assuming 2 mm gap from jam nut to shoulder.

4.7.2 Front clevis

To mount a separate front clevis, the extension tube must have a male threaded rod end. Screw the clevis onto the rod end and secure it with the jam nut.

Diagram showing a front clevis mounted on a male rod end.

* Assuming 2 mm gap from jam nut to shoulder.

4.7.3 Rear clevis - for PC25 parallel style models

The rear clevis is mounted to the rear plate of the belt gear housing. All necessary screws are included. Tighten all four screws according to table T6.3.1. Use a solid pin to connect the joint to the load. Any play between the pin and the joint may affect accuracy.

Diagram showing rear clevis for PC25 parallel style.

4.7.4 Rear clevis - for PC32 and PC40 parallel style models

The rear clevis is mounted to the rear plate of the belt gear housing. All necessary screws are included. Tighten all four screws according to table T6.3.1. Use a solid pin to connect the joint to the load. Any play between the pin and the joint may affect accuracy.

Diagram showing rear clevis for PC32 and PC40 parallel style.

4.7.5 Front mounting plate

The front mounting plate is mounted to the front plate of the cover tube. All necessary screws are included. Tighten all four screws according to table T6.3.1.

Diagram showing front mounting plate.

4.7.6 Foot mount for inline style models

The foot mount consists of a front and rear bracket. All necessary screws are included. Tighten all attachment screws according to table T6.3.1.

Diagram showing foot mount for inline style models.

4.7.7 Foot mount for parallel style models

The foot mount consists of a front and rear bracket. All necessary screws are included. Tighten all attachment screws according to table T6.3.1.

Diagram showing foot mount for parallel style models.

4.7.8 Fixed front trunnion

The fixed front trunnion consists of a plate with two shafts. All necessary screws are included. Tighten all attachment screws according to table T6.3.1. Contact your local bearing supplier for advice on suitable bearings between the trunnion pins and the support.

Diagram showing fixed front trunnion.

4.7.9 Fixed rear trunnion for parallel style models

The fixed rear trunnion consists of a plate with two shafts. All necessary screws are included. Tighten all attachment screws according to table T6.3.1. Contact your local bearing supplier for advice on suitable bearings between the trunnion pins and the support.

Diagram showing fixed rear trunnion for parallel style models.

4.7.10 Movable cover tube trunnion

The movable trunnion consists of two clamp units that are put around the profile of the unit at a desired position and joined and locked in place by the lock screws. Tighten the lock screws according to table T6.3.1. Contact your local bearing supplier for advice on suitable bearings between the trunnion pins and the support.

Diagram showing movable cover tube trunnion.

4.8 Mounting of sensor brackets

The bracket can be installed over the left or right corner of the cover tube surface where the sensor magnet travels. The correct surface is marked with a magnet sign sticker (1). The bracket (2) is secured using the worm drive clamp (3) around the cover tube and bracket. Ensure the clamp tightening screw is correctly positioned in the bracket's slot.

Diagram showing sensor bracket mounting, indicating magnet sticker (1), bracket (2), and clamp (3).

4.9 Mounting of sensors in the sensor brackets

The sensor is inserted into the slot of the sensor bracket and locked in position by the clamp screw (1).

Diagram showing a sensor being inserted into a bracket.

⚠️ If the sensor is mounted near magnetisable components, the sensor's switching characteristics may change.

4.10 Motor installation on inline style actuators without RediMount system

Motor installation on a PC-Series actuator without a RediMount flange requires a suitable bell housing flange and coupling, or a gearbox, between the motor and actuator. Flange dimensions for each actuator size are in the table below. Ensure maximum permissible drive shaft force and torque are not exceeded (see table T6.1.1) during standstill or operation.

Diagram showing space for motor installation on an inline actuator.

4.11 Motor installation on actuators with RediMount system

For PC-Series actuators with a RediMount flange, use a suitable motor for the specific RediMount flange type. Follow points 4.11.1 (inline style) or 4.11.2 (parallel style) for installation. Ensure maximum permissible drive shaft force and torque are not exceeded (see table T6.1.1) during standstill or operation. For motor removal, see point 4.11.3.

4.11.1 Motor installation on inline style models with RediMount system

1. Make sure the extension tube is fully retracted and then remove the sealing plug.
2. Press the motor shaft onto the coupling inside of the flange.
3. Bolt the motor to the flange using four screws. Tighten the screws according to table T6.3.1.
4. Use a hexagon key to tighten the coupling around the motor shaft. Correct tightening torque for PC25 models = 0.85 Nm and for PC32 and PC40 = 2.0 Nm.
5. Put the sealing plug back.

Images illustrating the steps for inline motor installation.

4.11.2 Motor installation on parallel style models with RediMount system

1. Make sure the extension tube is fully retracted and then remove the sealing plug.
2. Press the motor shaft onto the coupling inside of the belt gear flange.
3. Use a hexagon key to tighten the coupling around the motor shaft. Correct tightening torque for PC25 models = 0.85 Nm and for PC32 and PC40 = 2.0 Nm.
4. Bolt the motor to the flange using four screws. Tighten the screws according to table T6.3.1.
5. Put the sealing plug back.

Images illustrating the steps for parallel motor installation.

4.11.3 Removal of motor from a unit with RediMount system

If removing a motor from a unit with RediMount system, the extension tube must be fully extended to make it possible to loosen the coupling.

5. Service and maintenance

5.1 General

Regularly perform visual checks of the PC-Series unit and its installation. Service and repair if needed. If in doubt, please contact Thomson for advice.

5.2 Cleaning

The PC-Series actuators are designed to withstand water washdown. Clean gently and do not use tools that can mechanically damage the actuator. If detergents are used, it is recommended to stay within pH 3.5 – 8.5.

5.3 Lubrication

Lubrication is needed after 600 hours of operation or 6 months, whichever comes first. Perform lubrication as described below.

1. Make sure the extension tube is fully retracted to the mechanical end position. Retraction to the mechanical end position may only be done if the actuator is unloaded, and the retraction motion must not exceed the maximum torque and speed listed in table T5.3.1. Failing to do so may damage the actuator. Once in the mechanical end position, the retraction must be stopped immediately.

Table T5.3.1 - Max. retraction torque and speed

2. Lubricate via the grease port (1) with a grease gun (nipple type DIN3405 D1/A) using a grease of type Urethyn E/M1 (semi-synthetic, high temperature grease containing an organic thickener) with the amount listed in T5.3.2.

Diagram showing the grease port labeled '1'.

Table T5.3.2 - Grease amount and type

5.4 Replacement of coupling on inline models with RediMount flange

The coupling may break at overload and can be replaced per the instructions below. Ensure all other components are intact when replacing a broken coupling.

Exploded view diagram of the coupling components, with numbered parts.

1. Remove cover lid (12) and loosen screws on the coupling half (11) closest to the motor and remove it.
2. Remove screws (6) and remove the motor.
3. Make sure the extension tube on the unit (1) is fully retracted (this may not be changed until the screws (7) are tightened again).
4. Remove screws (7) and the flange plate (3), the sealings (4) and the bell house (2).
5. Loosen the lock screw on the coupling half closest to the unit (9) and remove it.
6. Push on the new coupling and make sure the parts of the new coupling (9, 10 and 11) are fully pressed together.
7. Make sure the coupling is at the correct LC distance as listed in table T5.4.1.
8. Tighten the lock screw on coupling half as listed in table T5.4.2.
9. Make sure the sealing (4) is correctly positioned against the bell house (2) and the flange plate (3) before tightening screws (7) according to table T6.3.1.
10. Mount the motor and tighten screws (6) according to table T5.4.2.
11. Tighten the lock screw on coupling half (11) according to table.
12. Check that the o-ring (12) is not damaged; if it is, replace it, and put back the cover lid (12).
13. Test run the unit without any load for 2 - 3 cycles to see that it runs smoothly and without any noise.

Table T5.4.1 - Distance LC

Table T5.4.2 - Coupling half lock screw tightening torque

5.5 Replacement of belt gear timing belt

The belt may break at overload and can be replaced per the instructions below. Ensure all other components are intact when replacing a broken belt.

Diagram showing exploded view of belt gear components, with numbered parts.

Table T5.5.1 - Screw size and tightening torque

Steps for belt replacement:

1. Remove cover lid (17) and loosen the lock screws on the coupling clamping unit (15).
2. Remove screws (21) and washers (22) and remove the motor (2).
3. Remove screws (18) and remove the plate (10).
4. Remove screws (19) and carefully remove the rear belt gear housing (9).
5. Check that the belt wheel (14) and its bearing (12) are attached to the front belt gear housing and loosen screw (20).
6. Pull out the PC-Series unit (1) 5 mm from the rear housing and replace the belt (6).
7. Push the unit (1) onto the housing again and tighten screw (20) according to table T5.5.1.
8. Put back the front housing (9) and make sure pin (13) and the belt wheel (14) with its bearing (12) get correctly positioned.
9. Mount screws (19) and tighten them according to table T5.5.1.
10. Mount plate (10) and tighten screws (18) according to table T5.5.1.
11. Mount the motor (2) and make sure it is correctly aligned to the coupling clamping unit (15) and its sleeve (23) before tightening screws (22).
12. Make sure the coupling clamping unit (15) is positioned correctly at distance A (see table T5.5.2) from the upper edge of the bearing and that the sleeve (23) is inside of the clamping unit (15).

Table T5.5.2 - Distance A

13. Pre-tighten the clamping unit lock screws (15) and then tighten them crosswise until all have the correct tightening torque according to table T5.5.3.

Table T5.5.3 - Coupling clamping unit screw tightening torque

14. Check that the o-ring (16) is not damaged; if it is, replace it, and put back the cover lid (17).

15. Test run the unit without any load for 2 - 3 cycles to see that it runs smoothly and without any noise.

6. Technical Specifications

6.1 Technical data

Table T6.1.1 - Technical Specifications

(1) Specifications are subject to change without notice. It is the responsibility of the product user to determine the suitability of this product for a specific application.

Definition of forces:

Diagram illustrating forces: Frd (Drive shaft force), Fx, Fy, Fz (Linear forces), Mta (Drive shaft torque), Mz, My (Torques).

6.2 Ordering key

Table T6.2.1 - Ordering Key

Key:

• 1. Actuator type: PC = PC-Series precision linear actuator
• 2. Size: 25 = profile size 34 x 34 mm, 32 = profile size 45 x 45 mm, 40 = profile size 55 x 55 mm
• 3. Transmission type: SX = inline style, directly coupled, no RediMount flange; LX = inline style, directly coupled, RediMount flange; PA = parallel style, 1:1 belt gear in standard position
• 4. RediMount motor ID: 000-999 = code for flange; XXX = code used when unit has no RediMount flange.
• 5. Screw type and lead: B03- = ball screw, 3 mm lead; B04- = ball screw, 4 mm lead; B05- = ball screw, 5 mm lead; B10- = ball screw, 10 mm lead; B20- = ball screw, 20 mm lead
• 6. Stroke length (S max): 0000-9999 = distance in mm
• 7. Cylinder mounting: R = rear trunnion (fixed, mounted on belt gear); C = rear clevis; F = feet kit; M = trunnion (movable); T = front trunnion (fixed, mounted on front housing); P = front mounting plate; X = without any cylinder mounting
• 8. Rod end: M = male thread (standard); F = female thread; J = spherical joint; C = front clevis
• 9. Environmental: 1 = IP65 rating (standard)

6.3 Screw tightening torque

Table T6.3.1 - Screw tightening torque