Exlar Tritex II DC Series Manual

Curtiss-Wright | Tritex II DC Rev. J PN49220 2/8/2016
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Tritex II™DC Series Actuators
Models TDM/TDX 060 & 075, RDM/RDG 060, 075 & 090
48 VDC Linear and Rotary Actuator
Installation and Service Manual
Information furnished by Exlar Corporation is believed to be accurate and reliable.
However, no responsibility is assumed by Exlar Corporation for its use. Exlar reserves the
right to change the design and operation of the equipment described herein and any
associated motion products that may appear in this document. Information in this document
pertaining to equipment not furnished by Exlar should be confirmed by that equipment
manufacturer. Exlar assumes no responsibility for changes to information by other
manufacturers or errors in that information or the description of that information. Information
in this document is subject to change without notice.
This document does not contain any export controlled technical data.

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Warranty and Limitation of Liability
Products are warranted for two years from date of manufacture as determined by the
serial number on the product label. Labels are generated and applied to the product at the
time of shipment. The first and second digits are the year and the third and fourth digits
represent the manufacturing week. Product repairs are warranted for 90 days from the date
of the repair. The date of repair is recorded within Exlar’s database tracked by individual
product serial number.
Exlar Corporation warrants its product(s) to the original purchaser and in the case of
original equipment manufacturers, to their original customer to be free from defects in
material and workmanship and to be made only in accordance with Exlar's standard
published catalog specifications for the product(s) as published at the time of
purchase. Warranty or performance to any other specifications is not covered by this
warranty unless otherwise agreed to in writing by Exlar and documented as part of any and
all contracts, including but not limited to purchase orders, sales orders, order confirmations,
purchase contracts and purchase agreements. In no event shall Exlar be liable or have any
responsibility under such warranty if the product(s) has been improperly stored, installed,
used or maintained, or if Buyer has permitted any unauthorized modifications, adjustments
and/or repairs to such product(s). Seller's obligation hereunder is limited solely to repairing
or replacing (at its opinion), at the factory any product(s), or parts thereof, which prove to
Seller's satisfaction to be defective as a result of defective materials, or workmanship and
within the period of time, in accordance with the Seller's stated product warranty (see
Terms and Conditions above), provided, however, that written notice of claimed defects
shall have been given to Exlar within thirty (30) days from the date of any such defect is
first discovered. The product(s) claimed to be defective must be returned to Exlar,
transportation prepaid by Buyer, with written specification of the claimed defect. Evidence
acceptable to Exlar must be furnished that the claimed defects were not caused by misuse,
abuse, or neglect by anyone other than Exlar.
Components such as seals, wipers, bearings, brakes, bushings, gears, splines, and
roller screw parts are considered wear parts and must be inspected and serviced on a
regular basis. Any damage caused by failure to properly lubricate Exlar products and/or to
replace wear parts at appropriate times, is not covered by this warranty. Any damage due
to excessive loading is not covered by this warranty.
The use of products or components under load such that they reach the end of their
expected life is a normal characteristic of the application of mechanical products. Reaching
the end of a product’s expected life does not indicate any defect in material or workmanship
and is not covered by this warranty.
Costs for shipment of units returned to the factory for warranty repairs are the
responsibility of the owner of the product. Exlar will return ship all warranty repairs or
replacements via UPS Ground at no cost to the customer.
For international customers, Exlar will return ship warranty repairs or replacements via
UPS Expedited Service and cover the associated shipping costs. Any VAT or local country
taxes are the responsibility of the owner of the product.
The foregoing warranty is in lieu of all other warranties (except as Title), whether
expressed or implied, including without limitation, any warranty of merchantability, or of
fitness for any particular purpose, other than as expressly set forth and to the extent
specified herein, and is in lieu of all other obligations or liabilities on the part of Exlar.
Seller's maximum liability with respect to these terms and conditions and any resulting
sale, arising from any cause whatsoever, including without limitation, breach of contract or
negligence, shall not exceed the price specified herein of the product(s) giving rise to the
claim, and in no event shall Exlar be liable under this warranty otherwise for special,
incidental or consequential damages, whether similar or dissimilar, of any nature arising or
resulting from the purchase, installation, removal, repair, operation, use or breakdown of
the product(s) or any other cause whatsoever, including negligence.
The foregoing warranty shall also apply to products or parts which have been repaired
or replaced pursuant to such warranty, and within the period of time, in accordance with
Seller's stated warranty.
NO PERSON, INCLUDING ANY AGENT OR REPRESENTATIVE OF EXLAR, IS
AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY ON BEHALF OF
EXLAR CONCERNING ANY PRODUCTS MANUFACTURED BY EXLAR, EXCEPT TO
REFER PURCHASERS TO THIS WARRANTY.

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TABLE OF CONTENTS
SAFETY CONSIDERATIONS.............................................................................. 4
CSA Certified Product....................................................................................... 7
EU Declaration of Conformity for CE Mark ....................................................... 9
TRITEX™ PRODUCT OVERVIEW.................................................................... 11
System overview, shown with SIO / Ethernet Option Board ........................... 12
Tritex Configurations....................................................................................... 12
60mm frame, top exiting connections, shown with 90 deg, M23 connectors .. 13
General Specifications.................................................................................... 14
INSTALLATION................................................................................................. 15
Mechanical Installation.................................................................................... 15
Lubrication ........................................................................................15
Mounting Configurations.....................................................................15
Mounting and Operating Considerations...............................................15
Outdoor and Wash Down Installations............................................................ 16
Manual Drive Operating Instructions............................................................... 17
Electrical Installation....................................................................................... 24
Introduction .......................................................................................24
Main Power Supply Selection..............................................................24
Unregulated AC/DC Power Supplies....................................................25
Regulated AC/DC Power Supplies.......................................................25
Power from Battery Systems...............................................................27
Handling Regen Energy –Internal Shunt Resistor and Regulator ...........27
Handling Regen Energy –External Shunt Resistor and Regulator ..........28
Logic Power Supply ...........................................................................28
Shielding...........................................................................................31
NPT Connections...............................................................................31
Grounding.........................................................................................32
Power Supply Connections.................................................................33
Tritex Input and Output Wiring.............................................................35
Input/Output Connections ...................................................................36
CANopen..........................................................................................37
I/O Power Supply...............................................................................38
Two Power Supply Configuration.........................................................38
Single Power Supply Configuration......................................................38
Digital Inputs .....................................................................................39
Digital Outputs...................................................................................40
Actuator Brake Option ........................................................................41
Analog Input......................................................................................42
Analog Output ...................................................................................43
Communications................................................................................43
PC Communications...........................................................................44
IA4 Option board connections .............................................................46
AF Option, Absolute Feedback............................................................49
Ethernet Options, EIP,TCP or ProfiNet.................................................50
EMC Considerations ..........................................................................52

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TROUBLESHOOTING PROCEDURES............................................................. 54
MAINTENANCE................................................................................................. 55
Procedures for Roller Screw Re-Greasing...................................................... 55
Lubrication Maintenance.....................................................................56
Grease Renewal................................................................................56
Reassembly ......................................................................................57
Procedures for Complete Re-Greasing........................................................... 58
Disassembly......................................................................................58
Lubrication Maintenance.....................................................................59
Grease Renewal................................................................................59
Reassembly ......................................................................................60
ACCESSORIES ................................................................................................. 62
Cables............................................................................................................. 62
TTIOC-xxx I/O Cable..........................................................................62
TTIPC-xxx Power Cable .....................................................................63
TTICO-xxx Communications Cable......................................................63
Communication Converters....................................................................... 65
Power Supply.................................................................................................. 65
TTPS1048 Power Supply Introduction..................................................65
Shunt Regulator.............................................................................................. 67
TTSR1 Shunt Regulator Option...........................................................67
Power Distribution and Surge Filter ................................................................ 69
TDCESF1 Power Distribution and Surge Filter Accessory......................69
SAFETY CONSIDERATIONS
As with any electro-mechanical device, safety must be considered
during the installation and operation of your Tritex Series actuator.
Throughout this manual you will see paragraphs marked with CAUTION
and WARNING signs as shown below
“Warning” indicates the information following is essential
to avoiding a safety hazard.
“Caution” indicates the information following is necessary
for avoiding a risk of damage to the product or other
equipment.
General
Failure to follow safe installation guidelines can cause
death or serious injury. The voltages used in the product
_____________________________
WARNING
CAUTION
_____________________________
WARNING

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can cause severe electric shock and/or burns and could be lethal.
Extreme care is necessary at all times when working with or adjacent to
the product. The installation must comply with all relevant safety
legislation in the country of use. The forces created by actuator could be
lethal or cause severe injury if proper protection is not provided to keep
personnel away from moving components.
System Design and safety for personnel
The actuator is intended as a component for professional
incorporation into complete equipment or a system.
If installed incorrectly, the actuator may present a
safety hazard.
The actuator uses high voltages and currents, carries a high level of
stored electrical energy, and is used to control equipment which can
cause injury. Close attention is required to the electrical installation and
the system design to avoid hazards either in normal operation or in the
event of equipment malfunction. System design, installation,
commissioning, and maintenance must be carried out by personnel who
have the necessary training and experience. They must read this safety
information and this manual carefully.
None of the functions or features of the Tritex actuator may be
used to ensure safety of personnel, i.e. they must not be used for
safety-related functions. For example the actuators enable / disable,
brake, stop/start and forward/reverse functions are not sufficient for use
in safety-critical applications without additional independent channels of
protection. Careful consideration must be given to the functions of the
actuator which might result in a hazard, either through their intended
behavior or through incorrect operation due to a fault. In any application
where a malfunction of the actuator or its control system could lead to or
allow damage, loss or injury, a risk analysis must be carried out, and
where necessary, further measures taken to reduce the risk.- for
example a failsafe brake in case of loss of actuator braking power.
Never attempt to connect or disconnect the actuator
with power applied.
Dangerous voltages may be present. Damage to
equipment and injury to personnel can result. Many
amplifiers have voltage present for a considerable time period after
incoming power is removed. Take care to insure that the amplifier has
discharged all power.
WARNING
WARNING

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Supply isolation
The AC supply or high voltage DC supply must be
removed from the actuator using an approved isolation
device or disconnect before any servicing work is
performed, other than adjustments to the settings or parameters
specified in the manual. The actuator contains capacitors which remain
charged to a potentially lethal voltage after the supply has been
removed.
If connected by plug and socket
A special hazard may exist where the actuator is
incorporated into a system which is connected to the AC
supply by a plug and socket. When unplugged, the pins of
the plug may be connected to the drive input, which is only separated
from the charge stored in the bus capacitor. It is the responsibility of the
user to avoid any possibility of electric shock from the pins, if they are
accessible.
Grounding - High Leakage Current
In the event of a fault, this equipment has high earth
leakage current. You must comply with local safety
regulations with respect to minimum size and special
installation requirements on the protective earth conductor for high
leakage current equipment. The ground connections shown in this
manual must be followed.
Fuses and Branch circuit protection
“The Integral solid state short circuit protection does not
provide branch circuit protection. Branch circuit protection
must be provided in accordance with the National
Electrical Code and any additional local codes”, or equivalent. Fuses or
over-current protection must be provided at the input in accordance with
the instructions in the manual.
CAUTION –Hot Surface –Risk of Burn.
WARNING
WARNING
WARNING
WARNING
CAUTION

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CSA Certified Product
The Tritex II DC Linear and Rotary Actuators are marked
as shown after passing a rigorous set of design and testing
criteria developed by CSA International (C22.2 No. 139).
This label indicates that CSA certifies this product to be
safe when installed according to the installation guidelines and used with
the scope of the product specifications.
The conditions of acceptability required by CSA are:
The drive voltage rating range and maximum current operating rating:
Voltage
Current (Adc)
12-24 Vdc
18.0A max.
Installation Requirements
- Hazardous Location (Class I Division 2 Group A, B, C, D)
installations –½” rigid conduit with NPT connections must be used.
- For NPT connections the power wires must be UL approved copper
only wires, 12 AWG, 300 VAC minimum rating, and 105º C
minimum rating..
- For other non-hazardous installations:
•Use the above connection method, or
•Cable with connector assemblies, or
•Cables with cable glands are permitted.
- When an AC to DC power supply is used to supply main power then
the power supply must be agency approved and provided with its
own enclosure.
- If a customer requires an additional +24 VDC power supply to
provide power to the Digital I/O, 4-20 mA I/O, or the Analog Input
then it must be a recognized or listed Class 2 Power Supply.
- The full ratings are at 40C ambient temperature. Derate the input
current linearly above the 40°C ambient temperature to 14.0Adc at
maximum ambient temperature of 65°C.
- These conditions of acceptability only apply to units with a CSA
mark on the product label.
For additional information on cable installations or part numbers contact
Exlar.

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EU Declaration of Conformity for CE Mark

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TRITEX™ PRODUCT OVERVIEW
The Exlar Tritex Series of electric actuators combines an integrated
brushless servo motor, amplifier and motion controller. Optionally the
system can be configured for remote mounting of the amplifier and
motion control
Integrated actuator, servo motor, amplifier and motion control
*Note: 48V (Nominal) for full speed (except CSA certified installations).
24V and 12V (Nominal) will result in reduced speeds.
The Tritex actuators are available in linear and rotary versions with
integrated amplifier and motion control.
Frame
Size
Linear
Rotary
Motor
Rotary
Gearmotor
Std.
Capacity
High
Capacity
60 mm
TDM060
TDX060
RDM060
RDG060
75 mm
TDM075
TDX075
RDM075
RDG075
90 mm
NA
NA
RDM090
RDG090
All of the required power components and motion processor are
contained in the actuator housing.
12–48V* DC
Power Supply
I/O
Digital and Analog I/O
Connections
RS485
Communication
Port
Ethernet
Communication
Port
(Optional)

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System Overview, Shown with SIO / Ethernet Option Board
Tritex Configurations
The models TDM, TDX, RDM & RDG include the drive and motion
controller integrated into the rear of the actuator. Various power and I/O
connections are available. 60 mm frame sizes have top exiting 90 degree
M23 connectors (shown below), or embedded leads connection options.
75mm and 90mm frame sizes have rear exiting connectors and a top
access cover for field wiring. Connector option include straight M23
connectors (shown below), NPT or M20 threaded holes or embedded
leads. Customized connection options are also available. See ordering
section for model mask information.

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60 mm Frame, Top Exiting Connections, Shown with 90 Degree,
M23 Connectors
75 & 90 mm Frame, Rear Exiting Connectors, Shown with M23 Connectors
M23 I/O connector
Communications
Connector
Ethernet
(Optional)
M23 Power
connector
M23 Power
connector
Communications
Connector
Ethernet
(Optional)
M23 I/O
connector
Field wiring access

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General Specifications
Drive Specification for all Tritex II DC Models with embedded drives
Embedded Drive Specifications
Input Voltage,
Bus and Logic
12-24VDC nominal for CSA certified installation
12-48VDC nominal for general use
Internal logic remains active with Bus or Logic power at 9V min
I/O Power
Supply
12-24V nominal, 30V max, 9V min
Models with brakes require 24V +/- 10% for brake operation
SIO & Ethernet
Options
IA4 Option
Details
Digital Inputs,
8
4
Opto-isolated,
0-5V or 0-2mA OFF,
8-30V or >3mA ON,
programmable functions
Digital Outputs,
4
3
Opto-isolated,
1V max ON state voltage drop,
100mA max continuous load,
short circuit & overload protect,
programmable functions
Analog Input,
+/-10V,
differential
input 13 bit
resolution
Isolated 4-20 mA,
with >14 bit
resolution,
ext power, 12V
max drop @
22mA
Programmable as position,
velocity or torque command
Analog Output,
0-10V, 11 bit
resolution
Isolated 4-20 mA
12 bit resolution,
ext power, 8V lift-
off @ 21mA
Programmable functions
Serial Interface
RS485, Modbus RTU protocol, max baud rate 38.4k, Isolated
Commutation
Sinusoidal, 10kHz PWM
Resolution
(Std. Feedback)
0.001 revolution
Accuracy
(Std. Feedback)
+ / - 0.002 revolution
Output Current
Continuous and peak output current is dependent on actuator
Environmental
Ambient Temperature for rated output: 40°C
Maximum Operating Temperature Range:
0°-65°C with power de-rating
Humidity: 10-95% non-condensing
Altitude: 3000 m above sea level maximum

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INSTALLATION
Mechanical Installation
Lubrication
The TDM / TDX Series actuators are shipped from the factory fully
greased and ready for installation. Exlar recommends using Mobilith
SHC 220, a high performance, extreme-pressure grease. The unique
physical properties of the synthetic base oil provide outstanding
protection against wear, rust, corrosion and high or low-temperature
degradation. Mobilith SHC allows for very low starting and running torque
values. Its operating range is -40° C to 177° C (-40° F to 350° F).
However, in installation below 0° C is stiffer using some of the motors
available torque, for cold temperature operation contact Exlar Application
Engineer for lubrication options. See Maintenance section for detail on
disassembly for greasing.
Mounting Configurations
The standard configurations available are Rear Clevis, Side Mount,
Side Trunnion and Front Flange (See Model Mask and ordering guide
in Overview section). General drawings are shown in the product
section guide.
Mounting and Operating Considerations
Every effort should be made to minimize misalignment. Any
misalignment will decrease the life of the components within the actuator
and also may create problems within the application associated with
misalignment.
Excessive side load on the output rod of the actuator will
dramatically reduce the life of the actuator and should be
avoided completely. Side load can be caused from misalignment or
loading that is not in line with the actuator output rod.
Care should be taken not to exceed the physical travel
limits of TDM Series Actuators. Doing so will cause the
actuator to end-crash internally. End crashes can physically
damage the roller screw and the internal components of the
actuator.

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Outdoor and Wash Down Installations.
Tritex ratings: The TDM/X, RDM/G actuators have been tested to IP
66. Tritex actuators are not intended for applications where the actuator
could possibly be submerged.
1. Avoid rod/shaft up installations if possible; if not possible, make
external provisions to keep rod/shaft exposure to water to a
minimum. When new, the seals are effective to IP 66 or better.
However over time, depending on the amount of side load, they
can wear and eventually allow moisture to ingress. Contact Exlar
application engineering for special options.
2. With the NPT connection option use thread sealant or Teflon tape
on the connector/conduit threads.
3. If straight metric conduit connection is used verify the connector/
fitting IP rating and verify the connector O-ring is in place.
4. If cord-grip type cable glands are used, the type with soft rubber
glands are preferred (IP 68). The firmer rubber can cause the
cable to compress over time, compromising the seal between the
gland and the cable. Cable strain reliefs should also be considered
to assure tension, bending radius or flexing of the cable over time
does not compromise the seal. Careful consideration and testing is
required when these glands are used in outdoor applications.
5. If the I connector option is used verify the connector plugs are
properly sealed and have the desired
IP rating. During installation be sure to
screw the plug all the way on to the
receptacle for proper sealing.
6. Position conduit fittings or loop cable /
flexible conduit so water does not drain
towards the conduit fitting.
7. When the wire termination cover is re-
installed verify the gasket is in place
and the surfaces of the gasket as well as the cover are free from
debris so a good seal can be achieved. If the gasket is missing,
replace it with PN 51530.
8. When re-installing the termination cover, tighten all 4 screws
evenly to be sure the cover seats flat. Tighten the screws to assure
the cover is securely held against the gasket. Caution, over
tightening can strip the threads in the enclosure. If a screw is
missing replace it with Exlar PN 01185. (4-40 x ¼ Button Head
Cap Screw, Stainless Steel)

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Manual Drive Operating Instructions
Isolate all sources of energy to prevent safety hazard due
to unexpected motion. System design and operating
procedures must ensure that the drive will have no
unintended motion that can create a hazard to personnel when operating
the drive manually. This includes electrical energy turning the motor as
well as energy stored in a vertical load or spring.
There are two manual drive options available on the Tritex, Hand
Wheel (HW) and Side Drive (SD)
The hand wheel option includes an internal switch that is closed when
the hand-wheel drive is fully disengaged and opens when an attempt is
made to engage the hand wheel drive. This switch is in series with the
actuator overtemperature sensor to form a combined run permissive
signal. When manual drive is engaged, an Actuator Overtemperature
fault occurs. The fault action for this fault will disable the drive.
This function is not safety rated, so is not usually sufficient to ensure
safety. Power to the drive must be isolated before manually operation.
The Side Drive does not include and interlock switch so power must
be removed before use.
Important information to avoid damage to the manual drive
If manually driving with a brake engaged or high force is
necessary, please consult Exlar Application Engineering.
If a power tool is used to operate the manual side drive the
speed should be limited to 600 RPM
An impact driver should never be used to operate the manual
side drive.
Determine end of stroke of actuator or system and do not apply
force past it.
Refer to Table 1 for maximum torque specifications.
WARNING
CAUTION

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Push in to engage
Side Drive Instructions
1) Isolate all sources of energy from the drive
2) Press down on the hex until you feel you have bottomed out the
manual drive. Constant downward force is required to
maintain engagement during operation.
3) Give the hex a slight turn while observing if you are moving the
rod or not. It is possible that during engagement the gear teeth
have not completely engaged; this will prevent the gears from
meshing. If the rod is not moving continue to press down while
turning the manual drive slowly until it pushes farther down. When
this happens you have proper gear engagement.
4) After gear engagement is achieved, the manual drive can be
operated. The maximum torque input for the manual drive should
not exceed the values shown in Table 1.
5) When the manual drive movement is completed, cease the
downward force and the manual drive will disengage.
Table 1 - Maximum operating conditions
Model
Maximum Torque
in-lbs / (Nm)
T2M/X 090
30 / (3.4)
T2M/X 115
40 / (5.6)
Push in to
engage
Release to disengage

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Dimensions

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